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OM-221 677C 2006 −07
Effective with serial number 222 842
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Description
Arc Welding Power Source
Blu-Fab 3500
and 4500 Series
OWNER’S MANUAL
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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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 Instal
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Declaration of Conformity for European Community (CE) Products This information is provided for units with CE certification (see rating label on unit). NOTE Manufacturer: European Contact: ITW Welding Products Italy S.r.l. Mr. Danilo Fedolfi, Via Privata Iseo 6/E Managing Director 20098 San Giuliano ITW Welding Products Italy S.r.l. Milanese, Italy Via Privata Iseo 6/E Phone: 39(02)98290-1 20098 San Giuliano Milanese, Italy Phone: 39(02)98290-1 Fax: 39(02)98290203 European Contact Signature: D
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING eng_som_woPPS_3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below fo
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching HOT PART
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. READ INSTRUCTIONS. Do not install or place unit on, over, or near Read Owner’s Manual before using or servic- combustible surfaces. ing unit. Do not install unit near flammables. Use only genuine Miller/Hobart replacement parts. 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. Use liftin
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1-4. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800 −463 −6727 or in Toronto 416 −747 −4044, website: www.csa −in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American Na
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SECTION 2 − DEFINITIONS Warning! Watch Out! There are possible 2.1 Keep your head out of the fumes. 4 Arc rays can burn eyes and injure hazards as shown by the symbols. skin. 2.2 Use forced ventilation or local exhaust to remove the fumes. 1 Electric shock can kill. 4.1 Wear hat and safety glasses. Use 2.3 Use ventilating fan to remove fumes. 1.1 Wear dry insulating gloves. Do not ear protection and button shirt collar. touch electrode with bare hand. Do 3 Welding sparks can cause explosion Use
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Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Read the Owner’s Manual before working on this machine. 1 Consult rating label for input power requirements, and check power available at the job site − they must match. 2 Read Owner’s Manual and inside labels for connection points and procedures. 3 Move jumper links as shown on inside label to match voltage at job site. 4 Having a
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SECTION 3 − INTRODUCTION 3-1. Included with Your Unit 1 1 Power Source 2 Power Cord (4m) 2 3 Work Cable and Clamp (4m) 4 Running Gear 3 4 3-2. Specifications Rated Output at 45% Duty Welding Cycle Range Max. OVC Input Rating KVA Dimensions Net Weight Blu-Fab 3500 350 A 32 V 16-32 38 400 −18A 11.8 KVA Length: 1040mm 146 kg Height: 760mm Width: 435mm Blu-Fab 4500 450 A 37 V 14-37 47 400-27A 17.7 KVA Length: 1040mm 156 kg Height: 760mm Width: 435mm 3-3. Duty Cycle Chart 800 700 Blu-Fab 3500: 45% Du
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SECTION 4 − INSTALLATION 4-1. Selecting a Location Position unit so air can circulate. 500 mm 500 mm 500 mm 4-2. Typical MIG Connections 5 1 Power source 2 Work clamp (connect to receptacle as shown) 4 6 3 Cylinder (chain to running gear) 4 Cylinder valve Open valve slightly so gas flow blows dirt from valve. Close valve. 5 Regulator/Flow gauge Install so face is vertical. 6 Flow adjust 7 Gas supply line 7 8 Wire feeder 9 MIG torch 3 8 1 9 2 OM-221 677 Page 8
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4-3. Electrical Service Guide Blu-Fab 3500 Blu-Fab 4500 Input Voltage 400 400 Input amperes at rated output 21A 30A Fuse or circuit breaker rating (max. rec) 21A 30A 2 2 Input conductor size 6 mm 6 mm 2 2 Grounding conductor size** 6 mm 6 mm ** Larger power cord may be required for cable length greater than 3 meters. Consult national or local regulations. 4-4. Connecting Input Power GND/PE Have only qualified persons make this installation. Special installation may be required where gasolin
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4-6. Connecting Welding Gun And Weld Cable 1 Gun Securing Knob 2 Gun Block 3 Gun Outlet Wire Guide Loosen knob, insert gun into block. Position outlet wire guide as close as possible to drive rolls without touching. Tighten knob. 1 4 Gun Trigger Plug 5 Gun Trigger Receptacle 3 2 Euro Torch 6 Weld Cable Terminal 7 Weld Cable From Welding Power Source US Torch 5 7 4 6 4-7. Installing Wire Guide And Drive Roll 1 Inlet Wire Guide 1 −2 2 Intermediate Wire Guide Install and secure inlet wire guide, an
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SECTION 5 − OPERATION 5-1. Controls 1 Power Switch 1 2 3 4 5 6 The power switch is a selector knob which permits selection of operation on either of the two available ranges (I and II) and the center position is off. 2 Indicator Lamp This lights up when the power switch is placed in the ON position. 3 Protection Fuse Fuse F protects the control circuit. Should it become necesary to re- place any fuse in the welding power source, be sure to substitute with one of the same size and rating. 4 Use t
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5-2. Panel Controls 1 Voltage Control 2 Purge Control 1 2 3 4 5 3 Jog 42T −4T Switch 5 Power ON-OFF 6 Torch Connection 7 Circuit Breaker 8 Gas In Connector 7 9 Control Cable Connection 10 Weld Cable Connection 8 9 10 6 5-3. Run-In Control and Burnback Control Run-In Control 6 Use control to set wire feed speed 4 before arc initiation After arc initiation, wire feed speed is controlled by the wire feed speed control on the front control panel. 2 8 Burnback Control Control adjusts the time welding
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SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 6-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld Repair or replace cracked gas cable. hose. Replace o-ring in Electrode/Gas Output receptacle if cracked. 6 Months Blow out or vacuum inside. OR 6-2. Troubleshooting Trouble Remedy No weld output; fan does not run. Place line disconnect switch
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Notes OM-221 677 Page 14
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SECTION 7 - ELECTRICAL DIAGRAM 956142300_9 −10 −04 OM-221 677 Page 15 R1 S2 T3 1 2 34 56 7 8 9101112 B B 1 X X X MT 2 X X X Z 3 X X X 28 30 X X PRI. 4 X 5 X X X X B 6 X X SR1 31 X 7 X X B 8 X X X 9 X X X Vc 10 X XX B SEC. B SHUNT 29 2 1 2 121 + 1234 567 8 9101112 25 S2 C1 C2 C3 26 S3 12 RR R 3 4 W 12 1 2 7 5 6 R 24 Vac 3 6 W 19 S 24 5 4 W 8 T GND F 11 S3 230V 400V 10 9 FM RC3 AT 20 24V 115V PL OPTIONAL IN RECT.TP OL RC2 CR 13 RC1 R 14 CR CR w 22 20 23 21 115 BG AKI RC1 POSIZIONI RL 1 SL 2 TL 3 R
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SECTION 8 - PARTS LIST 8-1. Main Assembly 1 2 36 10 26 27 25 28 3 31 30 29 4 24 5 23 6 22 47 4 32 11 7 40 * 9 46 * 34 10 20 33 42 44 45 39 43 19 18 35 41 * 21 14 48 12 13 15 37 17 38 16 9/13/04 OM-221 677 Page 16
