Miller Electric OM-180 800 User's Manual
Contents
1. 1 NOT canines 1185629 peer rouen eer A MUR 1 OB IV pres 134 327 LABEL warning general precautionary 1 zug CR1 059 266 RELAY 120VAC DPDT 1 AQ se VR1 181 430 VARISTOR w lugs 442022 1 N 1 ER 186 100 CABLE POWER Lice eee Gay cual een 1 139 042 BUSHING strain 1 a uu PC2 134560 CIRCUIT CARD filter 1 14 RC2 076 624 CONNECTOR circ 4pin 1 235 us Ts ces 186 104 TRANSFORMER control 115 115 24 1 16 RC1 089 646 CONNECTOR Circ 10pin 1 Tes dI ass 038 783 BLOCK term 20 12 1 134 201 STAND OFF SUPPORT card 4 A9 os seras 019 663 MOUNT nprn hah n 4 mn 186 016 NAMEPLATE ovis eec beer er ER PIG CA m RP RC RE ER La 1 idee weg 046 432 HOLDER fuse mintr 1 x22 cin ds F1 012 658 FUSE mintr gl slo blo 2A 250V 1 Sw ers PL2 5074 188 LIGHT ina red ici e EIL Nem ae 1 PL1 163562 LIGHT ind wh2. 1 Touch Sensor Rear Panel 2 Receptacle RC1 3 Robotic Interface Il Rear Panel 4 Receptacle RC33 Connect supplied interconnecting cable between RC1 on Touch Sensor and RC33 on Robotic Interface 10 Ref ST 801 886 Ref ST 801 853 OM 186 360 A Do not connect voltage sense cord to Robotic Inter face Il when using touch sensing function 1 Robotic Interface Il Rear Panel 2 4 Receptacle Disconnect plug on end of voltage sensing cord from 4 pin receptacle 3 Touch Sensor Rear Panel 4 Voltage Sensing Receptacle Connect voltage sensing plug to receptacle on Touch Sensor rear panel 1 115 VAC Cord Plug 2 115 VAC Grounded Receptacle Connect input power plug to weld ing power source or other 115 volts ac receptacle OM 186 360 ST 800 962 A Ref ST 801 886 ST 801 884 11 4 Operation ST 801 884 SB 186 016 1 Input Power Pilot Light Pilot light goes on when the unit is connected to a proper 115 vac power supply The Robotic Interface 11 sends a 115 vac signal to the Touch Sensor to close the contactor before welding begins The contactor remains closed until the welding current drops below 15 amperes which is sensed by reed switch CR2 When no weld current is detected the contactor deenergizes 2 Touch Sensor Pilot Light Pilot light goes on when 170 vdc is present on voltage sense leads The Touch Sensor receives a signal fr
3. 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 walved the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be avallable but may vary from province to province miller warr 3 97 Owner s Record Please complete and retain with your personal records Model Name Serlal Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Tip Resources Available Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables To locate distributor nearest you call Options and Accessories 800 4 A Miller EN Personal Safety Equipment Service and Repair Miller Electric Mfg Co An Illinois Tool Works Company Replacement Parts 1635 West Spencer Street a 2 Appleton WI 54914 USA Training Schools Videos Books USA Phone 414 734 9821 Owner s Manuals USA amp Canada FAX 414 735 4134 Technical Manuals Servicing Information and Parts European Headquarters
4. source during touch sensing operation It also operates during the weld cycle by closing before welding begins and remains closed during the welding operation by sensing weld current When no weld current is detected the contactor deenergizes Table of Contents 1 Safety Precautions mm 1 Consignes de s curit seine 2 Introduction 3 Installation 4 Operation Viet d acia CA E ate DR E 5 Maintenance and Troubleshooting 6 Electrical Diagram va 7 Parts List Sud da uana a aa Warranty Features m 115 VAC 2 A 60 Hz input Power 170 VDC 5 mA Touch Sense Output Touch Sensor And Input Power Pilot Lights External Connections For Cords And Cables Product features and specifications are subject to change without notice Processes Sf Automatic Welding Miller offers a Technical Manual 9 which provides more detailed service and parts information for your unit To obtain a Technical 9 Manual contact your local distributor Your distributor can also 12 supply you with Welding Process Manuals such as SMAW GTAW 12 GMAW and GMAW P For practical information on welding 14 process applications and Miller products visit our website at 16 www millerwelds com 1 Safety Precautions Read Before Using Means Warning Watch Out There are possible hazards with this proced
5. Engines outside North America Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 6 Months Batteries 5 90 Days Parts and Labor MIG Guns TIG Torches APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Miller s True Blue Limited Warranty shall not apply to 1 Items fumished by Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s warranty If any 2 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 3 Equipment that has been modified by any party other than Miller or equipment that has been improperly Installed Improperty 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 repalr or 2 replacemen
6. United Kingdom Circuit Diagrams Phone 44 0 1625 525556 FAX 44 0 1625 537553 Welding Process Handbooks Contact the Delivering Carrier for File a claim for loss or damage during ship ment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s TransportationDepartment Miller The Power of Blue PRINTED IN USA 1997 Miller Electric Mfg Co
7. d incendie ettenir un extincteur proxi mit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t e Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit e Brancherle c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lec trocution et d incendie e Ne pas utiliser le poste de soudage pour d geler des conduites ge l es e En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fi la pointe de contact e Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes Lesoudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles etdes particules m talliques volan tes Pendant ta p riode de refroidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un c
8. de s curit installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es Fixer l cable de retour de fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure gt gt Au cours de l utilisation tenir toute personne l cart et plus par ticuli rement les enfants e Rangeretisoler correctement la pince de masse apr s utilisation pour viter le contact avec des objets reli s la masse Il y a DU COURANT CONTINU IMPORTANT dans les convertisseurs apr s la suppression de l alimenta tion lectrique Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entra nement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie entretien avant de toucher les pi ces Ne jamais toucher
9. et sur les effets pour l organisme des champs magn tiques basse fr quence L extrait suivant esttir des conclusions g n rales du document intitu l Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 53 Washington DC U S Govern ment Printing Office mai 1989 publi par le Office of Technology Assessment du Congr s am ricain il existe maintenant d abon dantes donn es scientifiques compil es la suite d exp riences sur la cellule ou d tudes sur des animaux et des humains qui montrent clairement que les champs lectromagn tiques basse fr quence peu vent avoir des effets sur l organisme et m me y produire des transformations M me s il s agit de travaux de tr s grande qualit les r sultats sont complexes Cette d marche scientifique ne nous per met pas d tablir un tableau d ensemble coh rent Pire encore elle ne nous permet pas de tirer des conclusions finales concernant les ris ques ventuels ni d offrir des conseils sur les mesures prendre pour r duire sinon liminer les risques ventuels Traduction libre Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour
10. l appareil A e Pr voir une p riode de refroidissement respec ter le cycle op ratoire nominal R duirele courant oule cycle op ratoire avant de recommancer le soudage e Ne pas obstruer les passages d air du poste e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces Utiliser des pochettes et des boites antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes provoquer des blessures Ne pas s approcher des organes mobiles Ne pas s approcher des points de coincement tels que des rouleaux de commande Ne pas appuyer sur la gachette avant d en avoir re u l instruction Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en engageant le fil de soudage e Rester l cart des organes mobiles comme le ventilateur e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection Le e Lerayonnementhaute frequence peut provoquer des interf rences avec les quipements de ra dio navigation et de communication les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricion qualifi les interf rences r sultant de l installation S
11. 0M 180 360 April 1997 m Eff w Style Number KH17 Miller Automatic Welding The Power of Blue Description Automatic Welding System OWNER S MANUAL 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 build and sell Miller products continue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products 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 IS 0001 With Miller you can count on years of reliable service with proper maintenance And if for REGISTERED f some reason the unit needs repair there s a Troubleshooting section that will help you Miller is the first welding figure out what the problem is The parts list equipment manufacturer in will then h
12. ading welding wire e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e If notified by the FCC about interference stop using the equipment at once e Have the installation regularly checked and maintained e 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 e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e Toreduce possible interference keep weld cables as short as possible close together and down low such as on the floor e Locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e if interference still occurs the user must take extra measures such as moving the welding machine using shiel
13. an cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Protect yourself and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby e Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Donotweld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e 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 e Do not use welder to thaw frozen pipes e Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wearoil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap Remove any combustibles such as a butane lighter or matches from your person before doing any welding e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool
14. arranted 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 date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an Intemational distributor 1 5 Years Parts 3 Years Labor Original main power rectifiers inverters input and output rectifiers only 2 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Robots Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 1 Year Parts and Labor Motor Driven Guns Process Controllers Positloners and Controllers Automatic Motion Devices Orbital Weld Heads IHPS Power Sources Water Coolant Systems HF Units Grids Spot Welders Load Banks SDX Transformers Miller Cyclomatic Equipment Running Gear Trailers Plasma Cutt ng Torches except APT ZIPCUT amp PLAZCUT Models Deutz
15. d condition Turn face away from valve outlet when opening cylinder valve e Keep protective cap in place over valve except when cylinder is in use or connected for use e Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards OM 186 360 e Do not install or place unit on over or near combustible surfaces e Donotinstall unit near flammables e Donotoverload building wiring be sure power supply system is properly sized rated and protected to handle this unit i nba ak Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories Use equipment of adequate capacity to lift and support unit e Ifusinglift forks to move unit be sure forks are long enough to extend beyond opposite side of unit P T t i rn nn mn m nn mn e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit z x HEAR SERRES Put on grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards IN e Keep away from moving parts e Keep away from pinch points such as drive rolls e Do not press gun trigger until instructed to do so e Do not point gun toward any part of the body other people or any metal when thre
16. de vous 4 Garderle poste de soudage et les c bles le plus loin possible de vous 5 Relier la pince de masse le plus pr s possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les consignes mentionn es pr c demment font partie de celles desti n es aux personnes ayant recours un stimulateur cardiaque Veuillez consulter votre m decin pour obtenir plus de d tails OM 186 360 2 Introduction Overall Dimensions Length 15 1 2 in 394 Input Power Touch Sense Voltage Input Power Cord Weight mm 800 A At 10096 Width 12 5 8 in Duty Cycle 115 VAC 2 A 60 Hz 170 VDC 5 mA 10 ft 2 5 m 321 mm 15 1 2 Ib 7 kg Height 4 1 2 in 114 mm Duty cycle is percentage of 10 minutes that unit can operate at rated load without overheating A Exceeding duty cycle can Continuous Welding damage unit and void warranty 3 Installation X Means switch position is factory set E Means switch position can be changed Welding Power Source Selection Invision 456 Phoenix Maxtron 450 Tools Needed C B Non conductive CF 1 4 in OM 186 360 9 1 Weld Terminal On Rear Of Unit Connect weld cable from welding power source to weld terminal on rear of unit 2 Terminal On Front Of Unit Connect weld cable from wire drive assembly to weld terminal on front of unit ST 801 88 Tools Needed 22 3 4in
17. ded cables using line filters or shielding the work area Safety in Welding and Cutting ANSI Standard 249 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 Held Hazardous Substances American 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 Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protection ANSI Standard 287 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 186 360 Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation
18. e bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille e Ne jamais souder une bouteille pressuris e risque d explosion e Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat e Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Lireetsuivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m r es dans les normes de s curit OM 186 360 No pas placer l appareil sur au dessus ou proximit de surfaces infllammables Nepasinstaller l appareil proximit de produits inflammables Nepassurcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn et prot g avant de mettre l appareil en service Esset dh Utiliser l anneau de levage uniquement pour sou lever l appareil NON PAS les chariot les bouteil les de gaz ou tout autre accessoire Utiliser un engin d une capacit appropri e pour soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de
19. elp you to decide which exact part ing ele cay cae you may need to fix the problem Warranty and System Standard service information for your particular model are also provided Working as hard as youdo every power source from Miller is backed by the most hassle free warranty In the business Miller Electric manufactures a full line of welders and welding related equipment For information on other quality Miller products contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets To locate your nearest distributor call 1 800 4 A Miller Miller The Power of Blue Call 1 800 4 A MILLER for your local Miller distributor Your distributor 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 Description The Touch Sensor is designed to provide touch sensing capability using the welding wire and voltage sense leads The robot controller sends a signal to the Touch Sensor to begin touch sensing operation A signal is sent from the Touch Sensor to the robot controller when the welding wire touches the weldment The contactor in the Touch Sensor prevents any low impedance path through the welding power
20. evel causing injury or death Be sure the breathing air is safe e 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 Do not weld on coated metals such as galvanized lead or cadmium 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 containing these elements can give off toxic fumes if welded OM 186 360 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 e Weara welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI 249 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Useprotective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant material leather and wool and foot protection Welding on closed containers such as tanks drums or pipes can cause them to 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 c
21. from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 53 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to in terpret the evidence in a single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science based advice on strategies to minimize or avoid potential risks NES To reduce magnetic fields in the workplace use the following procedures 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 the 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 possible About Pacemakers The above procedures are also recommended for pacemaker wearers Consult your doctor for complete information OM 186 360 1 C
22. ile FCC signale des interf rences arr ter imm diatement l appa reil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les inter f rences ventuelles e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit com patible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipement lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail Porteurs de stimulateur cardiaque restez dis tance Les porteurs d un st mulateur cardiaque doi
23. ite 1 n 185 628 PANEL front bottom sideS 1 120 357 CABLE interconnecting 25ft 1 When ordering a component originally displaying a precautionary label the label should also be ordered Recommended Spare Parts 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 OM 186 360 17 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Miller The Power of Blu Effective January 1 1997 Equipment with a serial number preface of KH or newer This limited warranty supersedes all previous Miller warranties and Is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the tarms 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 MERCHANTABILITY AND FITNESS Within the warranty periods listed below Miller will repair or replace any w
24. le Donottouch electrode if you are in contact with the work ground or another electrode from a different machine Useonly well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual e Wear a safety harness if working above floor level e Keep all panels and covers securely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts Welding produces fumes and gases Breathing ineno tumes and gases can be hazardous to your ealth e Keep your head out of the fumes Do not breathe the fumes e If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen l
25. les pi ces lectriques sous tension Porter des gants et des v tements de protection secs ne comportant pas de trous S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact phy sigue ventuel avec la pi ce ou la terre Ne pas se servir de source lectrique courant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande Si l utilisation d une source lectrique courant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip Couper l alimentation ou arr terle moteur avant de proc der l instal lation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit Installeret mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux Toujours v rifier la terre du cordon d alimentation V rifier et s assu rer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et con
26. n d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun danger e Nepas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n cessaire en portant un respirateur alimenta tion d air Los rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage Le rayonnement de l arc du proc d de soudage n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage Porteruncasque de soudage muni d un cran de filtre appropri pour prot ger votre visage et vos yeux pendant le soudage ou pour regar der voir ANSI 249 1 et 287 1 num r dans les normes de s curit e Porter des protections approuv s pour les oreilles
27. om the robot controller to begin the touch sensing operation The contactor deenergizes to prevent any low impedance path through the welding power source The Touch Sensor provides 170 vdc to the voltage sense leads When less than 1 5k ohms of resistance is detected a signal is sent to the robot controller indicating a touch by the welding wire Touch Sensor Sensor w Contactor WER ELECTRO wre CO APPLETON w UBA 3 Months Replace damaged or Clean and tighten weld unreadable labels ji terminals vit Y Repair or replace cracked cables and cords Es 6 Months Blow out or vacuum inside 12 OM 186 360 F1 protects unit from overload If F1 opens the unit shuts down To check or change F1 proceed as follows 1 Fuse Holder Cover 2 Fuse F1 See Parts List For Rating Insert new fuse into cover and in stall fuse with cover by pressing and turning cover clockwise cm E Ref ST 801 886 Ref ST 800 185 A 1 Push l Turn Pull Out y Replace F1 Push And Turn Trouble Unit does not work and pilot light PL1 does not turn on Touch sensor function inoperative and pilot light PL2 does not turn off Contactor W does not close before beginning welding operation Contactor W does not open after welding operation ends Remedy Be sure input power cord is plugged into energized receptacle on welder or wall see Section 3 5 Check protective fuse
28. onsignes de s curit lire avant utilisation CAN RANCE PRE 86 360 4 97 safety som fre 3 97 NAN rl Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS LECTRIQUES aux PI CES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles etauxdirectives ci dessous afin de connaitre les mesures prendre pour viter tout danger Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives identifie un message de s curit particulier gt Signifie NOTA n est pas relatif la s curit Les symboles pr sent s ci apr s sont utilis s tout au long du e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le pr sent manuel pour attirer votre attention et identifier les champ les pi ces endommag es Entretenir l appareil conform ment risques de danger Lorsque vous voyez un symbole soyez T i h gt Hariri ce manuel vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font e Porter un hamais de s curit quand on travaille en hauteur que r sumer l information contenue dans les normes de s curit RENE num r es la section 1 5 Veuillez lire et respecter toutes ces e Maintenir solidement en place tous les panneaux et capots normes
29. ran facial e Fermer l alimentation du gaz protecteur en cas de non utilisation Veillertoujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche e Porteursdestimulateurcardiaque restez distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points Le bruit des processus et des quipements peut affecter l oute e Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Des bouteilles de gaz protectour contiennent du gaz sous haute pression Si une bouteille est endomma e elle peut exploser Du fait que tes bouteilles de gaz ont normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tin celles et des arcs e Placerles bouteilles debout en les fixant dans un support station naire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser e Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques e Ne jamais placer une torche de soudage sur un
30. s or circuit breaker and replace or reset if necessary Check fuse F1 and replace if necessary see Section 5 2 Check connection of voltage sense leads Have Factory Authorized Service Agent check touch sensing circuit Have Factory Authorized Service Agent check relay CR1 and contactor W and replace if necessary Have Factory Authorized Service Agent check reed relay CR2 and contactor W and replace if necessary OM 186 360 13 6 Electrical Diagram SB 186 072 TO ROBOT NTERFACE INTERFACE REMOTE VOLTAGE SENSE 14 OM 186 360 Notes 5 0 0 10 OM 186 360 7 Parts List ST 801 887 Hardware is common and not available unless listed OM 186 360 16 Item Dia Part No Mkgs No Description Quantity x osea cte 182 665 TERMINAL pwr output neutral 2 REN 186 098 BUS BAR contactor to output 1 a PORN PC1 174573 CIRCUIT CARD touch sensor 1 nad d oes PLG1 162382 CONNECTOR 8 SOCKETS 1 T PLG2 115094 CONNECTOR 8 SOCKETS 1 4 CR2 186 102 SWITCH reed nee ERTL Soe 1 SE ce Ba Di 184 193 DIODE w terminals 1 gt gt ERS RER Wo 185 846 CONTACTOR 24VDC SPST 600
31. si le niveau sondre est trop lev Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de blouissement demander aux autres personnes de ne pas re garder l arc Porterdes v tements de protection constitu dans une mati re dura ble r sistant au feu cuir ou laine et une protection des pieds Le soudage e ur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquerleur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincel les des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e D placertoutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections homologu s e Des tincelles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures Survellortoyt d clenchement
32. t 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 retum 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
33. they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator e Donottouch hot parts bare handed e Allow cooling period before working on gun or torch NUM e Pacemaker wearers keep away e Wearers should consult their doctor before going near arc welding gouging or spot welding operations Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high LAB vedere nent Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully e Protect compressed gas cylinders from excessive heat mechanical shocks slag open flames sparks and arcs e Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fittings designed for the specific application maintain them and associated parts in goo
34. tre v rifier les connexions V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement s il est endommag un cable d nud peut provoquer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s Ne pas enrouler les c bles autour du corps Sila pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour Ne pas toucher l lectrode quand on est en contact avec la piece la terre ou une lectrode provenant d une autre machine OM 186 360 uvent Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser un chappement au ni veau de l arc pour l vacuation des fum es et des gaz de soudage e Si la ventilation est insuffisante utiliser un respirateur alimenta tion d air homologu e Lirelessp cifications de s curit des mat riaux MSDSs et les ins tructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentatio
35. ts e Wear dry hole free insulating gloves and body protection e insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Donotuse ACoutputin damp areas if movementis confined or if there is a danger of falling Use AC output ONLY if required for the welding process e If AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e 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 e When making input connections attach proper grounding conductor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill e Turn off all equipment when not in use Do notuse worn damaged undersized or poorly spliced cables e Do not drape cables over your body e If earth grounding of the workpiece is required ground it directly with a separate cable do not use work clamp or work cab
36. ure The possible hazards are shown in the adjoining symbols Marks a special safety message F Means Note not safety related i OM 186 360 4 97 safety som 4 97 This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards A The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions 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 A Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away DAR SEPA d Touching live electrical pars can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the outputis 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 are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Donottouch live electrical par
37. vent d abord consulter leur m decin avant de s appro cher des op rations de soudage l arc de gou geage ou de soudage par points OM 186 360 Safety in Welding and Cutting norme ANSI 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 Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 del American Welding Society 550 N W Lejeune Rd 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 R gles de s curit en soudage coupage et proc d s connexes nor me CSA W117 2 del Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 518 de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Donn es sur le soudage lectrique
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