Miller Electric STR 450, Owner'S Manual

Page 1: ...Processes STR 450 CE OM 236 031D 2011 01 Description Arc Welding Power Source Stick SMAW Welding www MillerWelds com TIG GTAW Welding ...

Page 2: ...ducts Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Miller you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The par...

Page 3: ...er And Rating Label Location 8 3 3 Specifications 8 3 4 Duty Cycle and Overheating 9 3 5 Volt Ampere Curves 10 3 6 Selecting A Location 10 3 7 Tipping 11 3 8 Weld Output Terminals and Selecting Cable Sizes 11 3 9 Remote Receptacle Information 12 3 10 Typical Connections For Stick SMAW Welding 13 3 11 Typical Connections For TIG GTAW Welding 13 3 12 Positioning Jumper Links 14 3 13 Electrical Servi...

Page 4: ...08 EC Electromagnetic Compatibility Standards IEC 60974 1 Arc Welding Equipment Welding Power Sources edition 3 2005 07 IEC 60974 10 Arc Welding Equipment Electromagnetic Compatibility Requirements edition 2 0 2007 08 EN 50445 2008 Product family standard to demonstrate compliance of equipment for resistance welding arc welding and allied processes with the basic restrictions related to human expo...

Page 5: ...eling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work a...

Page 6: ...ee Safety Standards Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline 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 sparks and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off wel...

Page 7: ...ls covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS Read and follow all labels and the Owner s Manual carefully before installing operating or servicing unit Read th...

Page 8: ... web site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office...

Page 9: ...1 Keep your head out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from welding Do not weld near flammables 3 2 Welding sparks can cause fires Have a fire extinguisher nearby and have a watchperson ready to use it 3 3 Do not weld on drums or any closed contai...

Page 10: ... procedures 3 Move jumper links as shown on inside label to match voltage at job site 4 Having a loop of extra length connect grounding conductor first 5 Connect line input conductors as shown on inside label double check all connections jumper link positions and input voltage before applying power 1 96 2 2 WEEE Label For Products Sold Within The EU Do not discard product where ap plicable with ge...

Page 11: ...olts Shielded Metal Arc Welding SMAW Input Remote Constant Current CC X Duty Cycle I1 Rated Supply Current I2 Rated Welding Current U0 Rated No Load Voltage Average U1 Rated Supply Voltage U2 Load voltage Line Connection Scratch Start TIG Adjust X Duty Cycle Three Phase Transformer Rectifier Fuse IP Internal Protection Rating S1 KVA Current Increase Scale Current Increase Decrease ...

Page 12: ...f the welding circuit for additional EMF exposure information The EMF assessment on this equipment was conducted at 0 5 meter At a distance of 1 meter the EMF exposure values were less than 20 of the permissible values 3 2 Serial Number And Rating Label Location The serial number and rating information for this product is located on the back Use rating label to determine input power requirements a...

Page 13: ...es for unit to cool Reduce amperage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty 3 5 Minutes Welding 6 5 Minutes Resting Overheating 0 15 A or V OR Reduce Duty Cycle Minutes 35 Duty Cycle At 450 A 200 250 300 400 450 350 500 150 Weld Amperes 0 10 20 30 40 50 60 70 80 90 100 Duty Cycle 6 Minutes Welding 4 Minutes Resting 60 Duty Cycle At 350 A 100 Duty ...

Page 14: ...360 400 440 480 3 6 Selecting A Location 1 Lifting Eye 2 Lifting Forks Use lifting eye or lifting forks to move unit If using lifting forks extend forks beyond opposite side of unit 3 Line Disconnect Device Locate unit near correct input pow er supply Special installation may be required where gasoline or volatile liquids are present see NEC Article 511 or CEC Section 20 3 18 in 460 mm 18 in 460 m...

Page 15: ...erminal 956142737_5 5_B 100 20 4 20 4 20 4 30 3 35 2 50 1 60 1 0 60 1 0 150 30 3 30 3 35 2 50 1 60 1 0 70 2 0 95 3 0 95 3 0 200 30 3 35 2 50 1 60 1 0 70 2 0 95 3 0 120 4 0 120 4 0 250 35 2 50 1 60 1 0 70 2 0 95 3 0 120 4 0 2x70 2 ea 2 0 2x70 2 ea 2 0 300 50 1 60 1 0 70 2 0 95 3 0 120 4 0 2x70 2 ea 2 0 2x95 2 ea 3 0 2x95 2 ea 3 0 350 60 1 0 70 2 0 95 3 0 120 4 0 2x70 2 ea 2 0 2x95 2 ea 3 0 2x95 2 e...

Page 16: ...act closure to B completes 24 volts AC con tactor control circuit B Contact closure to A completes 24 volts AC con tactor control circuit C Output to remote control 10 volts DC D Remote control circuit common E 0 to 10 volts DC input command signal from re mote control The remaining sockets are not used Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this m...

Page 17: ...For TIG GTAW Welding Remote output is always On in TIG mode See Section 4 3 for scratch start TIG information Hot Start function for Stick weld ing is disabled in TIG mode This unit automatically uses the remote control if connected to the remote receptacle see Section 3 9 1 Remote Hand Control 2 Remote Foot Control 1 2 ...

Page 18: ... 60 Min Input Conductor Size In mm2 AWG 4 10 8 6 10 Max Recommended Input Conductor Length In Meters Feet 33 107 67 219 Min Grounding Conductor Size In mm2 AWG 4 10 8 6 10 Power cord supplied with the unit is sized for 230V operation Larger power cord may be required for cable lengths greater than 3 meters Consult national and local regulations Reference 2008 National Electrical Code NEC including...

Page 19: ...nt see NEC Article 511 or CEC Section 20 See rating label on unit and check input voltage available at site 1 Disconnect Device switch shown in OFF position 2 Disconnect Device Supply Grounding Terminal Connect green or green yellow groundingconductor to disconnect device grounding terminal first 3 Disconnect Device Line Terminals Connect input conductors L1 U L2 V And L3 W to disconnect device li...

Page 20: ...election Switch Remote output is always On in TIG mode Hot Start function for Stick welding is disabled in TIG mode 5 TIG GTAW Welding Indicator Light 6 Power On Pilot Light 7 Welding Current Indicator 8 High Temperature Indicator 9 Weld Current Control 10 Remote Control Receptacle See Section 3 9 11 Positive Weld Terminal 1 3 4 5 6 7 8 9 10 11 2 ...

Page 21: ...electrode sticks to workpiece use a quick twist to free it 1 2 3 4 3 Scratch Start TIG Ref WM Marketing This starting method is not accept able for critical applications since small tungsten particles may be come embedded in the workpiece and contaminate the weld Turn gas on Quickly drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out el...

Page 22: ...se If any of these displays are shown check input power con nections If trouble continues contact a Factory Authorized Service Agent 1 2 3 AL1 AL2 AL3 5 3 Troubleshooting Trouble Remedy No weld output fan does not run Be sure Power switch is On see Section 4 1 Be sure line disconnect switch is in On position Check and replace line fuses if open Reset breakers if necessary Fan does not run weld out...

Page 23: ...Use dry properly stored electrodes Low weld output with no control Check position of Amperage Control see Section 4 1 Limited output and low open circuit voltage Check incoming power for correct voltage Replace line fuse if open see Section 3 14 Check for proper input and output connections see Sections 3 8 and or 3 14 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beg...

Page 24: ...OM 236 031 Page 20 SECTION 6 ELECTRICAL DIAGRAMS Figure 6 1 Circuit Diagram For STR 450 ...

Page 25: ...OM 236 031 Page 21 956142738 A ...

Page 26: ...Retaining Wheel 2 8 156009127 Washer Round hooking For Handle 2 9 056020071 Knob for hose 25 mm dia 2 10 156002047 Handle 2 11 156018114 Nut Locking 2 12 156009128 Washer flat 10x30 6 13 156012132 Handle Fixing Pin 2 14 156122086 Panel LH 1 15 156110001 Foot 2 16 156012133 Axle Wheels 25x605 mm 1 17 000176254 Label General Precautionary 1 18 000207291 Label Warning Electric Shock Input 1 And 3Phas...

Page 27: ... Clamp Cable D 16 23 1 2 556070017 Link Primary Terminal 9 3 756069030 Board Primary Voltage Terminal 1 4 156005130 Support Voltage Change Board 1 5 L1 057098017 Choke 80x62x240 Al 1 6 T1 058021143 Transformer 230 400V 60x100 Al 1 7 TP1 056159026 Thermostat 100c 10 A 1 8 SR1 056050155 Rectifier 1 9 HD1 057028116 Probe Kit 1 10 056020069 Knob Pointer D 40 1 11 058040016 Control Panel Effective w MA...

Page 28: ... 1 30 S1 056067210 Switch 32 A 1 31 956142611 Nameplate Rear 115VAC 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Hardware is common and not available unless listed 956142737_4 5_C 6 5 1 2 3 4 Figure 7 3 Front Panel Part No Description Item No Figu...

Page 29: ...Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 30: ...Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 31: ...Systems Hydramate 1 and 2 Water Coolant Systems USA Models Non Integrated Work Stations Weld Tables No Labor 5 6 Months Parts Batteries 6 90 Days Parts Accessory Kits Canvas Covers Induction Heating Coils and Blankets MIG Guns Remote Controls Replacement Parts No Labor Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting no...

Page 32: ...Country Zip Postal Code Please complete and retain with your personal records Owner s Record Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Service and Repair Replacement Parts Owner s Manuals Contact the Delivering Carrier to For Service File a claim for loss or damage during shipment For ...