Miller Electric 452 Owner's Manual

OM-203 860COctober 2002Visit our website atwww.MillerWelds.comProcessesDescriptionGas Metal Arc (MIG) WeldingArc Welding Power SourceAuto Deltaweld452

OM-203 860 Page 6Le rayonnement de l’arc génère des rayons visibles etinvisibles intenses (ultraviolets et infrarouges) suscep-tibles de causer des br

OM-203 860 Page 71-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien del’appareil.Risque D’INCENDIE OU D’EXPLO-SIOND Ne

OM-203 860 Page 81-4. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,de l’American Welding Society,

OM-203 860 Page 9SECTION 2 – INSTALLATION2-1. SpecificationsRatedAmperes Input at Rated Load Output, 50 or 60 Hz,Three-PhaseModelWeldingOutputVoltageR

OM-203 860 Page 102-3. Volt-Ampere CurvesVolt-ampere curves show minimumand maximum voltage and amper-age output capabilities of unit.Curves of other

OM-203 860 Page 112-5. Dimensions And WeightsDimensionsAA 30 in (762 mm) Including lift eyeB 23 in (584 mm)BCC38 in (965 mm) Including strainreliefD 3

OM-203 860 Page 122-7. 115 VAC Receptacle And Circuit BreakersRef. 800 166-DY Turn Off power before con-necting to receptacle.1 115 V 15 A AC Receptac

OM-203 860 Page 132-9. Weld Output Terminals And Selecting Cable SizesY Turn off power beforeTotal Cable (Copper) Length In Weld Circuit Not Exceeding

OM-203 860 Page 142-10. Electrical Service Guide60 Hertz Models 450 Amp ModelInput Voltage 200 230 460 575Input Amperes At Rated Output 72 63 32 25Max

OM-203 860 Page 152-11. Placing Jumper LinksRef. ST-800 103-AY Disconnect and lockout/tag-out input power beforeinstalling or moving jumperlinks.Check

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-203 860 Page 162-12. Connecting Input Power ST-800 103-B / Ref. ST-801 116Y Disconnect and lockout/tagout in-put power before connecting inputcondu

OM-203 860 Page 171 Receptacle2 Keyway3 4-Pin Receptacle (Optional ExternalVoltage Sensing Connection)To connect interconnecting cord to recep-tacle,

OM-203 860 Page 182-14. Peripheral Receptacle FunctionsFunction Socket Socket InformationC* Circuit common.PurgeD Contact closure to C completes 24 vo

OM-203 860 Page 19SECTION 3 – OPERATION3-1. Upper Front Panel Controls1 Jog Forward Push ButtonAdvances wire out of the gun.2 Wirefeed Indicator LEDLE

OM-203 860 Page 201 Front Panel Control Buttons2 Power Switch On Front Panel. All three buttons must be helddown for 3 seconds after unit isenergized.

OM-203 860 Page 214-2. Blowing Out Inside Of UnitY Do not remove case whenblowing out inside of unit.To blow out unit, direct airflowthrough front and

OM-203 860 Page 221 Memory CRC Error DisplayCorrupted program data has been detectedor loaded. The “X” value indicates the pro-gram number.May be caus

OM-203 860 Page 231 Weld Interface Board PC12Diagnostic LED’s are visible insideunit, located on PC12 (see illustrationfor board location).Refer to Se

OM-203 860 Page 244-7. Diagnostic LED’s On Weld Interface Board PC12LED Status Diagnosis1 On Indicates auxiliary output relay is not energized.Off Ind

OM-203 860 Page 251 Customer Interface Board PC14Diagnostic LED’s are visible insideunit, located on PC14 (see illustrationfor board location).Refer t

The following terms areused interchangeablythroughout this manual:Mig = GMAWTABLE OF CONTENTS1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . .

OM-203 860 Page 264-9. Diagnostic LED’s On Customer Interface Board PC14LED Status DiagnosisOn Indicates –15 volts dc RA supply is present on customer

OM-203 860 Page 27LED DiagnosisStatus23 On Input signal On from peripheral for jog advance.Off Input signal Off from peripheral for no jog advance.24

OM-203 860 Page 281 Motor Board PC13Diagnostic LED’s are visible insideunit, located on PC13 (see illustrationfor board location).Refer to Section 4-1

OM-203 860 Page 294-11. Diagnostic LED’s On Motor Board PC13LED Status Diagnosis1 On Indicates motor reverse relay is energized.Off Indicates motor r

OM-203 860 Page 304-12. TroubleshootingTrouble RemedyNo weld output; unit completelyinoperative.Place line disconnect switch in On position (see Secti

OM-203 860 Page 31SECTION 5 – ELECTRICAL DIAGRAM207 810-B. For Primary Circuit Diagram Portion, refer to Circuit Diagramlocated inside wrapper of weld

OM-203 860 Page 32Figure 5-2. Circuit Diagram For Interface Module

OM-203 860 Page 33207 811-A

OM-203 860 Page 34Figure 5-3. Circuit Diagram For Control Board PC1 (Part 1 Of 2)

OM-203 860 Page 35208 198-1 (1 0f 2)

OM-203 860 Page 36Figure 5-4. Circuit Diagram For Control Board PC1 (Part 2 Of 2)208 198-2 (2 of 2)

OM-203 860 Page 37Notes

OM-203 860 Page 38Figure 5-5. Circuit Diagram For Microprocessor Board PC11

OM-203 860 Page 39191 838

OM-203 860 Page 40Figure 5-6. Circuit Diagram For Motor Board PC13

OM-203 860 Page 41209 749

OM-203 860 Page 42Figure 5-7. Circuit Diagram For Interface Board PC12 (Part 1 of 2)

OM-203 860 Page 43191 843-A (Part 1 of 2)

OM-203 860 Page 44Figure 5-8. Circuit Diagram For Interface Board PC12 (Part 2 of 2)

OM-203 860 Page 45191 843-A (Part 2 of 2)

OM-203 860 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_7/021-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswi

OM-203 860 Page 46Figure 5-9. Circuit Diagram For Customer Interface Board PC14 (Part 1 of 3)+35V+22VDC+22VDCTP4R692212R651012C8.1uF50V12C64330pF100V1

OM-203 860 Page 47Pensar 86147 (Part 1 of 3)PRELOADTL431RD_GNDRD_GNDRA+15V+24RDRD_GNDRA–15VRD_GNDRAGNDRAGNDRA–15VRA+15V+22VDCRD_GNDRAGNDRAGND–20V_UNRE

OM-203 860 Page 48Figure 5-10. Circuit Diagram For Customer Interface Board PC14 (Part 2 of 3)WFS_CMDTRIM_CMDAGNDAGNDRA–15VAGNDRA+15V+15VRA+15V+15VAGN

OM-203 860 Page 49Pensar 86147 (Part 2 of 3)K1_COMMONRA+15VRA+15VRAGNDRAGNDRA–15VRAGNDRA+15VRA+15VRD_GNDRAGNDRAGNDRAGNDRA–15VRA+15VRAGNDRA+15VRAGNDRAG

OM-203 860 Page 50Figure 5-11. Circuit Diagram For Customer Interface Board PC14 (Part 3 of 3)A5AIN1A6A7A4AIN4AIN4AIN5AIN5AIN6AIN7BIN_SINK0BIN_SINK1BI

OM-203 860 Page 51Pensar 86147 (Part 3 of 3)AIN0AIN3AIN1AIN2AIN7NOB_READYNOB_READYCOMM_STUCKRELAY_COMCOM_READYNCB_ARCNOA_FLOWNOA_SPARENCB_SPARENOA_REA

OM-203 860 Page 52Figure 5-12. Circuit Diagram For Touch Sensor Board PC18174 578-B

OM-203 860 Page 53Figure 5-13. Circuit Diagram For Power Distribution Board PC20191 531

OM-203 860 Page 54SECTION 6 – PARTS LIST. Hardware is common and notavailable unless listed.802 994-B12345678910111213141617151819 (Fig.6–4)2021233424

OM-203 860 Page 55DescriptionPartNo.Dia.Mkgs.ItemNo.QuantityFigure 6-1 Main Assembly1 +179 432 PANEL, side 2. . . . . . . . . . . . . . . . . . . .

OM-203 860 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sp

OM-203 860 Page 56DescriptionPartNo.Dia.Mkgs.ItemNo.QuantityFigure 6-1 Main Assembly (Continued)30 161 294 BRACKET, mtg rectifier 2. . . . . . . . .

OM-203 860 Page 57. Hardware is common and notavailable unless listed.802 997-A12346 7 6 7871011121523171318192021222425162627282930313214Figure 6-2.

OM-203 860 Page 58Figure 6-2 Panel, Front w/Components (Fig 6-1 Item 31)DescriptionPartNo.Dia.Mkgs.ItemNo.Quantity1 203 630 ELECTRONICS BOX 1. . . .

OM-203 860 Page 59. Hardware is common and notavailable unless listed.Figure 6-3. Rectifier, SCR Main SR1802 351123456DescriptionPartNo.Dia.Mkgs.SR1It

OM-203 860 Page 60DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 6-4 Panel, Rear w/Components (Fig 6-1 Item 19)Quantity1 173 283 CHAMBER, plenum 14 in 1. .

OM-203 860 Page 61802 686-AFigure 6-5. Blocking DiodeDescriptionPartNo.ItemNo.Figure 6-5. Blocking Diode (Fig 6-4 Item 11)Quantity1 200 355 Bracket, M

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/02Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2002 Miller Electric Mfg. Co. 8/02Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-203 860 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over,

OM-203 860 Page 41-4. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from American Welding Society, 5

OM-203 860 Page 5SECTION 1 – CONSIGNES DE SÉCURITÉ – À LIRE AVANTUTILISATIONsom _nd_fre 7/021-1. Signification des symbolesSignifie « Mise en garde. F