Miller PHOENIX 456 Owner's manual

Miller
Brand
Miller
Model
PHOENIX 456
Category
Welding System
Type
Owner's manual

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Processes
OM-186 989C
October 1998
Processes
MIG (GMAW) and Pulsed MIG
(GMAW-P) Welding
Flux Cored (FCAW) Welding
Phoenix 456 CC/CV:
Multiprocess Welding
Description
Invision 456P:
Invision 456P:
Phoenix 456 CC/CV:
Invision 456P and
Phoenix 456 CC/CV
(575 Volt Models)
The following terms are
used interchangeably
throughout this manual:
TIG = GTAW
Stick = SMAW
TABLE OF CONTENTS
SECTION 1 -- SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance 3. . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 -- CONSIGNES DE SECURITE -- LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 -- INSTALLATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Duty Cycle and Overheating 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Volt-Ampere Curves 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dimensions And Weight 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Selecting a Location 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Weld Output Terminals and Selecting Cable Sizes 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Remote 14 Receptacle Information 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. 115 Volts AC Duplex Receptacle And Circuit Breakers 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Electrical Service Guide 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. Connecting Input Power 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 -- OPERATION 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Front Panel Controls For Invision 456P 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Mode and Voltage Control For Invision 456P 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Meter Functions For Invision 456P 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Front Panel Controls For Phoenix 456 CC/CV 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Meter Functions For Phoenix 456 CC/CV 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Mode Switch Settings For Phoenix 456 CC/CV 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Lift-Arc TIG Procedure For Phoenix 456 CC/CV 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 -- MAINTENANCE AND TROUBLESHOOTING 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Routine Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Blowing Out Inside of Unit 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Removing Case and Measuring Input Capacitor Voltage 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Voltmeter/Ammeter Help Displays 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Troubleshooting 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 -- ELECTRICAL DIAGRAM 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 -- PARTS LIST 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
OM-186 989
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OM-186 989 Page 1
SECTION 1 -- SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_5/97
1-1. Symbol Usage
Means Warning! Watch Out! There are possible haz-
ards with this procedure! The possible hazards are
shown in the adjoining symbols.
YY Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible ELEC-
TRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Con-
sult symbols and related instructions below for necessary actions to
avoid the hazards.
1-2. Arc Welding Hazards
YY The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
seethesymbol, watch out,andfollow therelatedinstructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-4. Read and
follow all Safety Standards.
YY Only qualified persons should install, operate, maintain, and
repair this unit.
YY During operation,keepeverybody, especially children,away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal
shocks or severe burns. The electrode and work
circuit is electrically live whenever the output is on.
The input power circuit and machine internal
circuits are also live when power is on. In semiautomatic or
automatic wire welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire areelectricallylive.Incorrectly
installed or improperly grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the
work or ground.
D Donotuse AC outputin dampareas,if movementisconfined, orif
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or servic-
ing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its Own-
er’s Manual and national, state, and local codes.
D Always verify the supply ground -- check and be sure that input
power cord ground wire is properly connected to ground terminal
in disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding con-
ductor first -- double-check connections.
D Frequently inspect input power cord for damage or bare wiring --
replace cord immediately if damaged -- bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable -- do not use work clamp or work cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Useonlywell-maintained equipment.Repairor replacedamaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable withgood metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when notconnected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D TurnOffinverter, disconnect input power, and discharge input ca-
pacitors according to instructions in Maintenance Section before
touching any parts.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use exhaust at the arc to re-
move welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Workinaconfinedspaceonlyifitiswellventilated,orwhilewear-
ingan air-suppliedrespirator.Alwayshave atrainedwatchperson
nearby. Welding fumes and gases can displace air and lower the
oxygen level causing injury or death. Be sure the breathing air is
safe.
D Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or cad-
mium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing
an air-supplied respirator. The coatings and any metals contain-
ing these elements can give off toxic fumes if welded.
OM-186 989 Page 2
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
ARC RAYS can burn eyes and skin.
D Weara weldinghelmetfitted witha propershadeof filtertoprotect
your face and eyes when welding or watching (see ANSI Z49.1
and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your hel-
met.
D Useprotective screensor barriersto protectothersfrom flashand
glare; warn others not to watch the arc.
D Wearprotectiveclothingmade from durable, flame-resistant ma-
terial (leather and wool) and foot protection.
Welding on closed containers, such as tanks,
drums,orpipes, can causethemto blow up.Sparks
can fly off from the welding arc. The flying sparks,
hot workpiece, and hot equipment can cause fires
and burns. Accidental contact of electrode to metal objects can
cause sparks, explosion, overheating, or fire. Check and be surethe
area is safe before doing any welding.
WELDING can cause fire or explosion.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, orpipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut offweldingwireatcon-
tact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding,chipping, wirebrushing,and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use ap-
proved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETICFIELDScan affect pacemakers.
D Pacemaker wearers keep away.
D Wearersshould consult theirdoctor beforego-
ing near arc welding, gouging, or spot welding
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode.
Since gascylindersarenormally part of the welding
process, be sure to treat them carefully.
CYLINDERS can explode if damaged.
D Protectcompressed gascylindersfrom excessiveheat,mechan-
ical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electricalcircuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder -- explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keepprotectivecap in placeovervalveexcept when cylinder is in
use or connected for use.
D Readandfollow instructions oncompressedgas cylinders, asso-
ciated equipment, and CGA publication P-1 listed in Safety
Standards.
OM-186 989 Page 3
1-3. Additional Symbols for Installation, Operation, and Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring -- be sure power supply system
is properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Useequipmentofadequate capacity to lift and
support unit.
D If using lift forks to moveunit, be sure forks are
longenough toextend beyondopposite sideof
unit.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE han-
dling boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
MOVING PARTS can cause injury.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with elec-
tronic equipment perform this installation.
D The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
D If notified by the FCC about interference, stop using the equip-
ment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut,
keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
ARC WELDING can cause interference.
D Electromagnetic energy can interfere with
sensitive electronic equipment such as com-
puters and computer-driven equipment such
as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D Besurethiswelding machine is installed and groundedaccord-
ing to this manual.
D If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have HeldHazardous Substances, Ameri-
can Welding Society Standard AWS F4.1, from American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
CanadianStandardsAssociation,StandardsSales,178 RexdaleBou-
levard, Rexdale, Ontario, Canada M9W 1R3.
SafePractices ForOccupationAndEducationalEyeAndFaceProtec-
tion, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-186 989 Page 4
1-5. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables,will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National Re-
search Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure topower-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to beex-
amined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following proce-
dures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as pos-
sible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If clearedbyyourdoctor,
then following the above procedures is recommended.
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OM-186 989 Page 8
1-4. Principales normes de sécurité
Safety in Welding and Cutting, normeANSI Z49.1, de l’American Wel-
ding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe PracticeforthePreparation for Welding andCut-
ting of Containers That Have Held Hazardous Substances, norme
AWSF4.1, de l’American Welding Society,550 N.W.LejeuneRd,Mia-
mi FL 33126
National Electrical Code, NFPA Standard 70, de la National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-1, de la Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, nor-
meCSAW117.2,del’Association canadiennede normalisation,vente
de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W
1R3.
SafePractices ForOccupationAndEducationalEyeAndFaceProtec-
tion, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, dela National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
L’extraitsuivant est tirédesconclusions générales dudocumentintitu-
lé Biological Effects of Power Frequency Electric & Magnetic Fields --
Background Paper, OTA--BP--E--53 (Washington DC : U.S. Govern-
ment Printing Office, mai 1989), publié par le Office of Technology
Assessment du Congrès américain : «... il existe maintenant d’abon-
dantes données scientifiques compilées à la suite d’expériences sur
la cellule ou d’études sur des animaux et des humains, qui montrent
clairementque leschampsélectromagnétiques bassefréquencepeu-
vent avoir des effets sur l’organisme et même y produire des
transformations. Même s’il s’agit de travaux de trèsgrandequalité,les
résultats sont complexes. Cette démarche scientifique ne nous per-
met pas d’établir un tableau d’ensemble cohérent. Pire encore, elle ne
nous permet pas de tirer des conclusions finales concernant les ris-
ques éventuels, ni d’offrir des conseils sur les mesuresà prendre pour
réduire sinon éliminer les risques éventuels». (Traduction libre)
Afin de réduire les champsélectromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1 Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
2 Mettre tous les câbles du côté opposé de l’opérateur.
3 Ne pas courber pas et ne pas entourer pas les câbles autour de
vous.
4 Garder le poste de soudage et les câbles le plus loin possible
de vous.
5 Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Lesconsignes mentionnéesprécédemment fontpartie decelles desti-
nées aux personnes ayant recours à un stimulateur cardiaque.
Veuillez consulter votre médecin pour obtenir plus de détails.
OM-186 989 Page 9
SECTION 2 – INSTALLATION
Unless otherwise noted, the Invision 456P is shown throughout this manual.
NOTE
2-1. Specifications
Input
Power
Rated Welding
Out
p
ut
Amperage
Range
(Phoenix
456 CC/
Voltage
Ran
g
e
Maximum
Open-Circuit
Voltage DC
Amperes Input At Rated
Load Output 60 Hz,
Three-Phase
Power
O
u
tp
u
t
456 CC/
CV Only)
Range
Voltage DC
575 V KVA KW
Three
Phase
450 A @ 38 Volts DC, 100%
Duty Cycle;
565 A @ 43 Volts DC,
60% Duty Cycle
5 – 600 10 – 38 95
24.4
(0.12*)
24.3
(0.12*)
19.0
(0.07*)
*While idling
2-2. Duty Cycle and Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void war-
ranty.
Overheating
0
15
A/V
OR
Reduce Duty Cycle
Minutes
duty1 4/95 – SA-181 560
Continuous Welding
100% Duty Cycle At 450 Amperes 60% Duty Cycle At 565 Amperes
6 Minutes Welding 4 Minutes Resting
OM-186 989 Page 10
2-3. Volt-Ampere Curves
Volt-ampere curves show mini-
mum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall
between curves shown.
va_curve1 4/95 – SA-181 561 / SA-181 562
Phoenix 456 (CC Only)
Invision 456P and Phoenix 456 (CV Only)
OM-186 989 Page 11
2-4. Dimensions And Weight
Hole Layout Dimensions
A
F
A 14-21/64 in (363.9 mm)
A
B 20-3/4 in (527.1 mm)
28 in
C 23-27/64 in (594.9 mm)
28
in
(711 mm)
D 24-31/32 in (634.2 mm)
18 in
(457 mm)
C
D
E 12-3/8 in (314.3 mm)
B
C
D
F 9/32 in (7.1 mm) Dia.
/i
Weight
15-1/2 in
(394 mm)
118 lb (53.5 kg)
E
2-5. Selecting a Location
loc_2 3/96 - ST-800 611 / Ref. ST-801 718
1 Lifting Forks
Use lifting forks to move unit.
Extend forks beyond opposite side
of unit.
2 Lifting Handles
Use handles to lift unit.
3 Hand Cart
Use cart or similar device to move
unit.
4 Rating Label
Use rating label to determine input
power needs.
5 Line Disconnect Device
Locate unit near correct input pow-
er supply.
Y Special installation may be
required where gasoline or
volatile liquids are present –
see NEC Article 511 or CEC
Section 20.
Movement
2
3
Location
5
18 in
(460 mm)
18 in
(460 mm)
4
Y Do not move or operate
unit where it could tip.
Tipping
1
OR
OM-186 989 Page 12
2-6. Weld Output Terminals and Selecting Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Weld Output
Terminals
Welding
Amperes
10 – 60%
Duty Cycle
60 – 100%
Duty Cycle
10 – 100% Duty Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
Positive
(
+
)
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
(+)
Negative
(–)
500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
()
600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0
Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007-D
2-7. Remote 14 Receptacle Information
Socket* Socket Information
24 VOLTS AC
A 24 volts ac. Protected by circuit breaker CB2.
Ref. ST-801 718
24
VOLTS
AC
B Contact closure to A completes 24 volts ac con-
tactor control circuit.
AJ
B
K
I
115 VOLTS AC
I 115 volts ac. Protected by circuit breaker CB1.
B
C
L
NH
D
M
G
115
VOLTS
AC
J Contact closure to I completes 115 volts ac con-
tactor control circuit.
DG
E
F
C Output to remote control; +10 volts dc in MIG
mode. For Phoenix 456 only: 0 to +10 volts dc in
other modes.
REMOTE
D Remote control circuit common.
REMOTE
CONTROL
E 0 to +10 volts dc input command signal from re-
mote control.
M Mode select.
N Remote inductance control.
A/V
AMPERAGE
F Current feedback; +1 volt dc per 100 amperes.
AMPERAGE
VOLTAGE
H Voltage feedback; +1 volt dc per 10 arc volts.
GND
G Circuit common for 24 and 115 volts ac circuits.
GND
K Chassis common.
*The remaining sockets are not used.
OM-186 989 Page 13
2-8. 115 Volts AC Duplex Receptacle And Circuit Breakers
ST-801 524-B
1 115 V 10 A AC Receptacle
Power is shared between duplex
receptacle and Remote 14 recep-
tacle (see Section 2-7).
2 Circuit Breaker CB1
3 Circuit Breaker CB2
CB1 protects duplex receptacle
and 115 volts ac portion of Remote
14 receptacle from overload.
CB2 protects 24 volts ac portion of
Remote 14 receptacle from over-
load.
Press button to reset breaker.
2 3
1
2-9. Electrical Service Guide
Three-Phase
Input Voltage 575
Input Amperes At Rated Output 24.4
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 35
Min Input Conductor Size In AWG/Kcmil 10
Max Recommended Input Conductor Length In Feet (Meters) 371 (113)
Min Grounding Conductor Size In AWG/Kcmil 10
Reference: 1993 National Electrical Code (NEC). S-0092J
OM-186 989 Page 14
2-10. Connecting Input Power
ST-801 535-B / ST-801 822
Y Turn Off welding power
source, and check voltage
on input capacitors accord-
ing to Section 4-3 before
proceeding.
1 Strain Relief Connector
Clamp
Obtain and install proper connec-
tor.
2 Input And Grounding
Conductors
Select size and length using Sec-
tion 2-9. Connect as shown in il-
lustration.
3 Line Disconnect Device
See Section 2-9.
Reinstall right side panel.
Tools Needed:
5/16 in
Contactor W1
L1 L2 L3
= GND/PE
Y Always connect grounding
conductor first.
L1
3
L2
L3
2
Connections For
Standard Model
1
OM-186 989 Page 15
SECTION 3 – OPERATION
3-1. Front Panel Controls For Invision 456P
1 Power Switch
.
The fan motor is thermostatically con-
trolled and only runs when cooling is
needed.
2 Voltmeter (see Section 3-3)
3 Ammeter (see Section 3-3)
4 Voltage Adjustment Control
5 Inductance Control
Inductance determines the “wetness” of the
weld puddle. When set higher, “wetness”
(puddle fluidity) increases.
23 4
5
ST-180 306-C
1
3-2. Mode and Voltage Control For Invision 456P
1 Remote 14 Receptacle
Mode Control
The unit defaults to standard MIG
mode. When a suitable external
pulsing control is attached to the
Remote 14 receptacle, the remote
pendant controls whether the unit
is in standard MIG or pulsed MIG
mode. When the pulsing control is
disconnected, the unit returns to
standard MIG operation.
Voltage Control
The unit defaults to Panel control of
output voltage. When a suitable re-
mote voltage control or pulsing
control is attached to the Remote
14 receptacle, the remote device
assumes control of output voltage.
To return to Panel control of volt-
age, disconnect or disable any re-
mote devices that send an input to
pin E.
ST-801 192
1
OM-186 989 Page 16
3-3. Meter Functions For Invision 456P
The meters display the actual weld output values for approximately three seconds
after the arc is broken.
NOTE
Mode Meter Reading At Idle Meter Reading While Welding
MIG
Preset Volts Blank
VA
24.5
Actual Volts Actual Amps
VA
24.5 250
Pulsed
MIG
Pulse Display Pulse Display
VA
PPP PPP
Actual Volts Actual Amps
VA
24.5 250
3-4. Front Panel Controls For Phoenix 456 CC/CV
1 Power Switch
.
The fan motor is thermostatically con-
trolled and only runs when cooling is
needed.
2 Voltmeter (see Section 3-5)
3 Ammeter (see Section 3-5)
4 V/A (Voltage/Amperage) Adjust Control
5 Voltage/Amperage Control Switch
For front panel control, place switch in Panel
position and use the V/A Adjust control.
For remote control, make connections to Re-
mote 14 receptacle, and place switch in Re-
mote position. In most modes, remote control
is a percent of the V/A Adjust control setting.
Value selected on V/A Adjust is maximum
available on remote. In the MIG mode, remote
control provides full range of unit output re-
gardless of V/A Adjust control setting.
6 Mode Switch
The Mode switch setting determines both the
process and output On/Off control (see Sec-
tion 3-6). Source of control (panel or remote)
for the amount of output is selected on the V/A
Control switch.
For Air Carbon Arc (CAC-A) cutting and goug-
ing, place switch in the Stick position. For best
results, place Inductance/Dig control in the
maximum position.
7 Inductance/Dig Control
Control adjusts Dig when the Stick or CC
mode is selected on the Mode switch. When
set towards minimum, short-circuit amperage
at low arc voltage is the same as normal weld-
ing amperage.
When set towards maximum, short-circuit am-
perage is increased at low arc voltage to assist
with arc starts as well as reduce sticking while
welding (see volt-ampere curves in Section
2-3).
Select setting best suited for application.
Control adjusts inductance when MIG position
is selected on the Mode switch. Inductance
determines the “wetness” of the weld puddle.
When set towards maximum, “wetness”
(puddle fluidity) increases.
When Pulsed MIG, or one of the TIG modes is
selected, this control is not functional.
7
ST-179 842-B
2
31
4
65
OM-186 989 Page 17
3-5. Meter Functions For Phoenix 456 CC/CV
The meters display the actual weld output values for approximately three seconds
after the arc is broken.
NOTE
Mode Meter Reading At Idle Meter Reading While Welding
Lift-Arc TIG
Actual Volts Preset Amps
VA
7.0 85
Actual Volts Actual Amps
VA
10.3 85
TIG
Blank Preset Amps
VA
85
Actual Volts Actual Amps
VA
10.3 85
MIG
Preset Volts Blank
VA
24.5
Actual Volts Actual Amps
VA
24.5 250
Pulsed
MIG
Pulse Display Pulse Display
VA
PPP PPP
Actual Volts Actual Amps
VA
24.5 250
CC
Blank Preset Amps
VA
85
Actual Volts Actual Amps
VA
24.5 85
Stick
Actual Volts (OCV) Preset Amps
VA
80.0 85
Actual Volts Actual Amps
VA
24.5 85
3-6. Mode Switch Settings For Phoenix 456 CC/CV
The Stick and CC modes provide the
Adaptive Hot Start
feature, which
automatically increases the output amperage at the start of a weld should the start
require it. This eliminates electrode sticking at arc start.
NOTE
Mode Switch Setting
Process
O tp t On/Off Control
Mode Switch Setting Process Output On/Off Control
Lift-Arc TIG GTAW – See Section 3-7 Electrode Hot
TIG
GTAW With HF Unit, Pulsing Device,
Or Remote Control
At Remote 14
MIG GMAW At Remote 14
Pulsed MIG GMAW-P (Requires an external pulsing device.) At Remote 14
CC Stick (SMAW) With Remote On/Off At Remote 14
Stick SMAW Electrode Hot
OM-186 989 Page 18
3-7. Lift-Arc TIG Procedure For Phoenix 456 CC/CV
With Mode switch in the Lift-Arc
TIG position, start an arc as fol-
lows:
1 TIG Electrode
2 Workpiece
Touch tungsten electrode to work-
piece at weld start point, hold elec-
trode to workpiece for 1-2 sec-
onds, and slowly lift electrode. An
arc will form when electrode is
lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present be-
tween electrode and workpiece.
The solid-state output contactor
does not energize until after elec-
trode is touching workpiece. This
allows electrode to touch work-
piece without overheating, stick-
ing, or getting contaminated.
1
1 – 2
Seconds
“Touch”
Do NOT Strike Like A Match!
2
Ref. S-156 279
SECTION 4 – MAINTENANCE AND TROUBLESHOOTING
Y Disconnect power
before maintaining.
.
Maintain more often
during severe conditions.
4-1. Routine Maintenance
3 Months
Replace
damaged or
unreadable
label.
Repair or
replace
cracked
cables.
Replace
cracked
torch body.
Repair or
replace cracked
cables and cords.
6 Months
Clean and
tighten weld
terminals.
Blow out
inside.
OM-186 989 Page 19
4-2. Blowing Out Inside of Unit
Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
Ref. ST-801 718
OM-186 989 Page 20
4-3. Removing Case and Measuring Input Capacitor Voltage
Turn Off welding power source,
and disconnect input power.
1 Right Side Panel
To remove panel, remove screws
securing panel to unit.
2 Interconnect Board PC2
3 Voltmeter
Measure the dc voltage across the
screw terminals on PC2 as shown
until voltage drops to near 0 (zero)
volts.
Proceed with job inside unit. Rein-
stall cover when finished.
Tools Needed:
5/16 in
Ref. ST-801 718 / Ref. ST-801 536-A
Y Significant DC voltage can remain on capacitors
after unit is Off. Always check the voltage as shown
to be sure the input capacitors have discharged be-
fore working on unit.
2
3
+ lead to lower right
terminal, – lead to
upper right terminal
1
OM-186 989 Page 21
4-4. Voltmeter/Ammeter Help Displays
.
All directions are in reference
to the front of the unit. All cir-
cuitry referred to is located in-
side the unit.
1 Help 1 Display
Indicates a malfunction in the pri-
mary power circuit. If this display is
shown, contact a Factory Autho-
rized Service Agent.
2 Help 2 Display
Indicates a malfunction in the ther-
mal protection circuitry located on
the left side of the unit. If this dis-
play is shown, contact a Factory
Authorized Service Agent.
3 Help 3 Display
Indicates the left side of the unit
has overheated. The unit has shut
down to allow the fan to cool it (see
Section 2-2). Operation will contin-
ue when the unit has cooled.
4 Help 4 Display
Indicates a malfunction in the ther-
mal protection circuitry located on
the right side of the unit. If this dis-
play is shown, contact a Factory
Authorized Service Agent.
5 Help 5 Display
Indicates the right side of the unit
has overheated. The unit has shut
down to allow the fan to cool it (see
Section 2-2). Operation will contin-
ue when the unit has cooled.
6 Help 6 Display
Indicates that the input voltage is
too low and the unit has automati-
cally shut down. Operation will
continue when the voltage is within
±15% of the operating range. If this
display is shown, have an electri-
cian check the input voltage.
7 Help 7 Display
Indicates that the input voltage is
too high and the unit has automati-
cally shut down. Operation will
continue when the voltage is within
±15% of the operating range. If this
display is shown, have an electri-
cian check the input voltage.
8 Help 8 Display
Indicates a malfunction in the sec-
ondary power circuit of the unit. If
this display is shown, contact a
Factory Authorized Service Agent.
1
AV
2
AV
3
AV
HE.L P–1
HE.L P–2
HE.L P–3
4
AV
HE.L P–4
5
AV
HE.L P–5
6
AV
HE.L P–6
7
AV
HE.L P–7
8
AV
HE.L P–8
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Miller PHOENIX 456 Owner's manual

Miller
Brand
Miller
Model
PHOENIX 456
Category
Welding System
Type
Owner's manual
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