Miller Electric 400P, 500 X manual Your distributor also gives, Service, Support

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miller_warr 2007−01

Warranty Questions?

Effective January 1, 2007 (Equipment with a serial number preface of “LH” or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

guarantees or warranties expressed or implied.

Call

1-800-4-A-MILLER for your local Miller distributor.

Your distributor also gives

you ...

Service

You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? Contact your distributor.

The expertise of the distributor and Miller is there to help you, every step of the way.

LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the delivery date of the equipment to the original end-user purchaser, and not to exceed one year after the equipment is shipped to a North American distributor or eighteen months after the equipment is shipped to an International distributor.

1.5 Years Parts — 3 Years Labor

*Original main power rectifiers

2.3 Years — Parts and Labor

*Transformer/Rectifier Power Sources

*Plasma Arc Cutting Power Sources

*Process Controllers

*Semi-Automatic and Automatic Wire Feeders

*Inverter Power Sources (Unless Otherwise Stated)

*Water Coolant Systems (Integrated)

*Intellitig

*Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

3.1 Year — Parts and Labor Unless Specified

*Motor Driven Guns (w/exception of Spoolmate Spoolguns)

*Positioners and Controllers

*Automatic Motion Devices

*RFCS Foot Controls

*Induction Heating Power Sources, Coolers, and Electronic

Controls/Recorders

*Water Coolant Systems (Non-Integrated)

*Flowgauge and Flowmeter Regulators (No Labor)

*HF Units

*Grids

*Spot Welders

*Load Banks

*Arc Stud Power Sources & Arc Stud Guns

*Racks

*Running Gear/Trailers

*Plasma Cutting Torches (except APT & SAF Models)

*Field Options

(NOTE: Field options are covered under True Bluefor the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

*Bernard-Branded Mig Guns (No Labor)

*Weldcraft-Branded TIG Torches (No Labor)

*Subarc Wire Drive Assemblies

4.6 Months — Batteries

5.90 Days — Parts

*MIG Guns/TIG Torches and Subarc (SAW) Guns

*Induction Heating Coils and Blankets, Cables, and Non-Electronic Controls

*APT & SAF Model Plasma Cutting Torches

*Remote Controls

*Accessory (Kits)

*Replacement Parts (No labor)

*Spoolmate Spoolguns

*Canvas Covers

Miller’s True BlueLimited Warranty shall not apply to:

1.Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. (Exception: brushes, slip rings, and relays are covered on Bobcat, Trailblazer, and Legend models.)

2.Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

3.Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,

INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

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Contents File Engine Drive OM-4421215 075QProcesses DescriptionFrom Miller to You Table of Contents − Maintenance & Troubleshooting Decrot1/07 DirectivesStandards Decrotsound6/05 Manufacturer European Contact Notified BodyHOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinCompressed Air Hazards Engine HazardsFalling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazardRadiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF InformationIndique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux LE Soudage peut provoquer un in cendie ou une explosionDES Organes Mobiles peuvent pro voquer des blessures ’EXPLOSION DE LA Batterie peuRisque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessuresEn ce qui concerne les implants médicaux Proposition californienne 65 AvertissementsPrincipales normes de sécurité Information EMFStd − Definitions− 50 h Std Manufacturer’s Rating Labels Some symbols are found only on export products Symbols And DefinitionsDimensions, Weights, And Operating Angles − SpecificationsWeld, Power, And Engine Specifications Volt-Ampere Curves For CC Models Volt-Ampere Curves For CC/CV Models Stick ModeMIG Mode TIG Mode100% Duty Cycle At 400 Amperes Fuel ConsumptionDuty Cycle And Overheating 15 kVA/kW Three-Phase AC Output No Weld Load AC Generator Power CurveOptional Three-Phase Generator Curves 12 kVA/kW Single-Phase AC Output No Weld LoadGrounding1 − InstallationInstalling Welding Generator Location/Airflow ClearanceUsing Lifting Eye Mounting Welding Generator Stop engine and let cool Installing Exhaust PipeConnecting The Battery Activating The Dry Charge Battery If ApplicableEngine Prestart Checks Coolant Recovery TankStop engine Connecting To Weld Output TerminalsStick and TIG Welding MIG and Fcaw Welding350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Connecting to WeldSelecting Weld Cable Sizes 150 ft 200 ft 250 ftSocket Connecting To Remote 14 Receptacle RC14 On CC/CV ModelsOM-4421 Front Panel Controls For CC Models See Section − Operating Welding Generator − CC ModelsWeld Controls Engine Starting ControlsTo Start Engine Gauges And MetersExample Combination Remote Amperage Control Stick Remote Amperage Control On CC Models OptionalWeld Control/Arc Condition Information Label OM-4421 Front Panel Controls For CC/CV Models See Section − Operating Welding Generator − CC/CV Models14 AC/DC Voltmeter Optional Voltage/Amperage Adjust Switch And Remote 14 ReceptacleElectric shock can kill Process/Contactor Switch Settings Process/Contactor Switch On CC/CV ModelsExample Combination Remote Amperage Control TIG Remote Voltage/Amperage Control On CC/CV Models OptionalIf a Supplementary − Operating Auxiliary EquipmentVolt And 240 Volt Receptacles At least once a month, run enClose panel opening if no connections are made to generator Three-Phase Power ConnectionRear Of Panel Supplementary Protector CB2 Supplementary Protector CB3 Optional Generator Power Receptacles240 V 15 a AC South African Receptacle RC1 Maintenance Label − Maintenance & TroubleshootingRoutine Maintenance Checking Generator Brushes To clean air filter Servicing Air CleanerInspecting And Cleaning Optional Spark Arrestor Muffler Standard Model Idle Speed Ad- justment Adjusting Engine SpeedWeld/Power Speed Adjustment Engine Speed No LoadWhile draining fuel tank Servicing Fuel And Lubrication SystemsTo change oil and filter To replace primary fuel filterOverload Protection Welding − CC Models TroubleshootingWelding − CC/CV Models Optional Three-Phase Generator Power CC/CV Models Only Standard Generator PowerEngine Welding Symbols Circuit Diagram For CC Welding Generator − Electrical Diagrams223 522-B Circuit Diagram For CC/CV Welding Generator 223 523-B Welding Generator − RUN-IN ProcedureWetstacking From flammables Run-In Procedure Using Load BankKeep exhaust and pipe away Manual Run-In Procedure Using Resistance GridSpecifications section in this Just generator A/V control soElectrically Bond Generator − Generator Power GuidelinesSelecting Equipment Grounding Generator To Truck Or Trailer FrameAmperes x Volts = Watts Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated in electrical codesFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Parts List 128 93 −6 105 104 100 101 102 103 Main Assembly 010 Figures 13-2 Figures 13-4 Control Box Assembly − CC Models 087 Control Box Assembly − CC/CV Models -1Item Control Box Assembly − CC/CV ModelsTD1 214 3634 Panel, Front w/Components − CC ModelsPanel, Front w/Components − CC Models -1Item 40 39 Panel, Front w/Components − CC/CV ModelsPanel, Front w/Components − CC/CV Models -1Item 170 34 36 27 26 Hardware is common Not available unless listed602 SCREW, .312−18x .75 hexwhd.66d stl pld slffmg tap−rw 601 Main Rectifier Assembly Wiring Harnesses PLG4 Harness, receptacle auxiliary power export models includesPage Support ServiceYour distributor also gives Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact