Home

Miller Electric Auto-Axcess 450 User's Manual

Contents

1. 0 WIRE RETRACT m I 3 5 M 5 TORCH WATER FLOW SWITCH OPTIONAL 222 i TT gt CABLE 12 COND 16 HIGH FLEX F 21 21 v 2 2550 x 2 gt gt m PC11 BOARD x RD GND 219 267 B OM 210 540 Page 55 SECTION 9 PARTS LIST Hardware is common not available unless listed 22 15 Ref 803 247 0 Figure 9 1 Main Assembly OM 210 540 Page 56 Item Dia Par No Mkgs No Description Quantity Figure 9 1 Main Assembly 212543 Xfmr Control Toroidal 665 VAC Pri 1900 VA 60 Hz 1 PR 210492 TOO e sac aux ab pc diat ud A e UO RID HERR UE Ao C 1 iuter editi c 21048 1 Plate Mtg uuu incedere mae e rper dnt ere e tura 1 en fe deep eese nhi eaa Fig 9 33 TOD Tray ASSEIMDIY es odii deed dnce date 1 5 IM1 IM2 222959 MODULE inverter assy 300A Fig 9 2 2 ete db ec 198961 Panel Module Divider 1 eT ee Fig 9 4 Rear Panel Assembly 1 5 nn ne 227793 Panel Side W Insulator 2 pe 210482 BASE sn a x hence Rees EE omae uo fiip se tut tia 1 WI 180270 Co
2. 1 E 207896 BOX LOUVE 5 1 1906621 2 BOO GENENG arene dora nt di 2 21 1 2 PB3 199443 Switch Pb Mc Spst 10A 115VAC w BIk Panelmt 3 207902 Nameplate Front 1 PR re ee TS 210865 Terminal pwr output red 1 207698 Panel ne da ban eens donc tonte mas ER A A 1 210483 Bracket lift eye 1 m AREE 210358 Bolt eye shld thd stem 500 13 X 1 500 1 Recommended Spare Parts When ordering a component originally displaying a precautionary label the label should also be ordered 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 210 540 Page 62 Warranty Questions Call 1 800 4 A MILLER for your local Miller distributor Your distributor also gives 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 tou
3. 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 2 1 vaut dan M nd Te nd dad acte tea das a 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 4 Proposition californienne 65 Avertissements 8 2 5 Principales normes de s curit 9 255 IMO MALON EME a 3 4 a Sh eme odo adeb aded ide d und 9 SECTION 3 INSTAELATION 11 RE 11 de Dimensions ANd WEIGHT wana ener EO 11 os Duty Cycle And Ovemealing hse 12 54 SLA eA iid 12 9 05 Selecting A LOCA ie Sew ewes ee Laine eue aeons weeds 13 3 0 Conneccion Diagrams S Cote We Sees EI Seu eee Se vetoes Sevens s Sew ee ee ohn ss 13 3 7 Rear Panel Receptacles And Supplementary 0 5 14 9 0 Connecting TO Weld Terminals sages iae peeve ance ew ets ee Qe vee es nina oe Sev sea 15 9 9 Selecting Weld Cable Sizes ew ees Ne ees Nemo oe Se yeas aw ss 16 3 10 P
4. lt 69 MOLOVINOO NO Z z zu 5 m E dOlS 3 12031 2 B 5 lt NOD e 02 NOWNOO O 9 E Lt 9 NONNOD QN i 2 z size Sel 11758 dq IZ NOMNOO pe BHL i io i m L NONNO 252 Fg 52 82 GaHONOL amp 00 440 i RR il E lt ar anono No a A 10804 z du i O i 97031 xX 20A ON JONNI H3lVM NO x l z ON N3IVM 330 2 3 2 ezam 52 103130 INNO 440 E 5 5 dHonol WOD HONISIUIM oz o9 PR Ge XonISSUW gt 21 8g 2 103r 95 E a gt HONLSIHIM 6 2 ASONVLS a OS N 2 MOMH3 1 oO gt Lu m 10808 WOO Y 8 NONNO9 Cs Robot Interface In For 72 P ircuit Diagram Figure 8 3 C OM 210 540 Page 52 a ia o o 5 c WARNING Disconnect input power or stop engine before servicing e Do not operate with covers removed Have only qualified persons install use or service this unit ELECTRIC SHOCK HAZARD anis MIM VOLTAGE anis MIM INPUT WELD STUD 834 93 0 10VDC 83
5. 4 7 lt lt 7 7a RES gt lt ROS B 2 Ds Eu PER lt RCB 12 RC6 amp lt RC8 Z2 lt RCB 6 mE DE lt 10 53 PELA 41 lt lt RG B 3 BF denen L WI 207 903 G Part 1 Of 2 OM 210 540 Page 49 118 ee 1 77 Ans 4 lt 13 11 410 27 FB 2 PE 24 COMMON 905 dioe LIN H MATE eas es ut 4113 10 MOTOR CONTROL 410 3 SARE 5 MIGROFROCESSOR RETRACT BOARD 129 1 5 gt DT 113 2 J1 PLG40 2 gt 45 PLG42 SELECT isse J10 PLO43 RIGHT 724 41 ele zi J12 PLG44 737 lt d13 PLG4S D gt WATER lt 113 14 J14 PLG46 E FLOW J18 FLG47 TES 209 J17 PLG41 LEEK S136 414 55 272 p lt J12 11 114 1 E J14 7 zi ar 126 J5 1 12 4 psy EL J5 2 gt lt 412 1 eee DURS PL E 5 5 5 5 5555 5 SHEET 1 y VV MM CORE T EE RC5 EGND B K SHED S NS N 1 Mog eS GIN H o S ET b a ek D E P 7 5 gt 1 25 MOTOR Rc3 3 5 24 MOTOR PC1Z erap E STOP i BOARD naa T RC4A 0 RC1 PLG75 Rez PLC76 4 22 RG3 PLG77
6. Sn Ut9 gm a 2 ESF 13 22 SGO mnm LES a 2 12 6 SLT CE NN a nns u29 R55 32455 e EAN aces Co Ce fo Unp unn animnm 8 LE anh REO 82 Peer 6 c RI E 1 5 BELE 875 a BENE EL Sa 2 md 5 27 num e unii mus E 2 5 Oe Oe amm Anna ge aes gt 558 9 69 7 Ws zB gu i sila EN EBEN _ mam RESESE 5 8 2 aa CRE pe ge 8 a peg 087 073 07 as 07 ee onon QD nnn EE TEARS s 2 91169 T AE ag agaga 97 1 2 nnn LLC eu A sms nm m m m 95558 _ j e EME n 52 d e 14 ERE Emm mmm R26 5 3 4 1 13 15 1 216 956 A Ref 803 250 C 7 5 Diagnostic LED s On Process Control Module PC4 LED Status Diagnosis 1 On Indicates 25 volts dc is present on process control module PC4 Off Indicates 25 volts dc is not p
7. 0 10 VDC 5 TRIM VOLT GMAW P 100IPM VOLT VOLT 5V VOLT GMAW WFS INPUTS ANALOG RD COM OPEN CIRCUIT AT 0 VDC ACTIVATE BY SOURCING RD 24VDC OR ROBOT 24 ONLY IF INPUTS DIGITAL SOURCING ROBOT COM 200000 99910010 2 9 ROBOT INTERFACE PIN DETAIL HARDING 72 PIN FEMALE FRONT VIEW 219 266 C OM 210 540 Page 53 EXAMPLE ROBOT CONTROL CAUTION AXCESS PRODUCTS ARE 5VDC DO NOT PULL UP TO 24VDC INPUT DIGITAL SOURCING OUTPUT DIGITAL SINKING OR DRY CONTACT DETECTED COM ROBOT COM ROBOT TOUCH SENSE ENABLE TOUCH 2 Q o COM OoooooooooQo0 4 25 TOUCHED RD COMMON SENSOR ON INPUTS DIGITAL SINKING OPEN CIRCUIT AT 5VDC ACTIVATE BY SINKING TO RD ACTION WHEN TOUCH SENSED COMMON 24V SOURCE Figure 8 4 Circuit Diagram For Peripheral Motor Interface OM 210 540 Page 54 WARNING e Do not touch live electrical parts Disconnect input power or stop engine before servicing e Do not operate with covers removed Have only qualified persons install use or service this unit EXAMPLE REMOTE BOX WIREFEED MOTOR ASSEMBLY mM 39933999 7 74 777 221 n Q GAS PURGE GAS SOLENOID WIRE FEED DRIVE ROLL l LN ASSEMBLY
8. current transducer to ground terminal applicable use lugs of proper amperage capacity and correct hole size Welding Power Source Input Power Connections 2 Strain Relief Install strain relief of proper size for unit and input conductors Route conductors cord through strain relief and tighten screws Use large strain relief for input conductor size 8 and larger Use small strain relief with reducing washers for input conductor size 10 Connect input conductors as shown in illustration Route green or green yellow grounding conductor through current transducer and connect to welding power source grounding terminal first Then connect input conductors L1 L2 and L3 to welding power source line terminals Reinstall side panel onto welding power Source GND PE Earth Ground ELECTRIC SHOCK can kill SIGNIFICANT DC VOLTAGE exists after removal of input power Always wait 5 minutes after power Is turned off before working on unit Check input capacitor voltage and be sure it is near 0 before touching any parts 803 245 C Ref 803 766 A 218 005 A Disconnect Device Power Connections Input 3 Disconnect Device switch shown in the OFF position 4 Green Or Green Yellow Grounding Conductor 5 Disconnect Device Grounding Terminal 6 Input Conductors L1 L2 And L3 7 Disconnect Device Line Terminals Connect green or green yellow grounding conductor to disconnect device grounding
9. 4 5 Robot Calibration Mode 1 Program Volis Arc Length WireSpeed Amps Process Wirefeed Wire Type Gas Gas Type Contactor Adjust Arc Control Turn unit On Unit displays abbreviated name of robot detected where XXXX appears see Table 4 2 for a list of robot adapters that could be displayed WireSpeed amps Process Wirefeed Wire Type Gas Gas Type Contactor Arc Control To enter calibration mode while robot name appears on front panel press and hold wire feed amps button until ROBT CAL appears on front panel ROBT CAL message will not display until after the power up sequence is completed approximately 20 seconds Use robot pendant or other method to enter two weld schedules into the robot Maintain schedule 1 for at least 10 to 20 seconds minimum before moving on to schedule 2 Maintain schedule 2 for 10 to 20 seconds before ending the simulated weld Schedule data is shown below Schedule 1 Schedule 2 10 0 Volts 44 0 Volts 100 IPM 1000 IPM Program Volts Arc Length pA WireSpeed amps Process e Wireteed 9 Wire Type Gas Gas Type Contactor Adjust Arc Control When the robot calibration mode ends the ROBT CAL message stops and the unit will display normal front panel information Use the robot
10. Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 5 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 5060 Mississauga 1 6 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more th
11. lead to left bus terminal lead to right bus terminal lt 4 210 540 38 Typical Bleeder Resistor 25 to 1000 ohm 5 watt resistor 16 AWG 1000 volts dc insulation rating approx 3 in 76 mm leads Turn Off welding power source and disconnect input power Remove cover 1 Power Interconnect Board PC2 2 Voltmeter Measure the dc voltage across the bus terminal and bus terminal on PC2 as shown until voltage drops to near O zero volts Measure input capacitor voltage on both inverter assemblies before proceeding 3 Typical Bleeder Resistor An example of a typical bleeder resistor is shown on this page Proceed with job inside unit Reinstall cover when finished 802 985 Ref 803 250 C 7 4 Process Control Module PC4 Diagnostic LED s Nr n el u ala o A 51 1 Process Control Module PC4 Diagnostic LED s are visible inside unit located on PC4 mounted on the top tray Refer to Section 7 5 for information on diagnostic LED s Reinstall cover after checking diagnostic LED s 2147638 m gt Ef z el 1552 le 42525 Ge m CELL 58555 B nr e LED1 y nun ow it attis e 5 LED2 PTI 1 JE m uum Ui gt 1 1 M FT umm lel 53 8 Te E 4 us LP 2 ia sane TELL
12. 3 PLE7Z 4 1 1 RC42 X RC70 15 RELAY COMMON 26 ERROR lt RC70 Z STANDBY lt RC70 1 RELAY COMMON lt RC70 14 24VDC DIAHEN AUTONATION lt RC70 13 RD COMNON BOARD SENSE IIO RGB lt REB G Ro3 PLOSS 2 RC70 amp WIRE STUCK ZACH COMMON page Se pes ee 12 Seer lt ROB1 4 lt ROB E RC3 PLGSE lt 70 37 WATER ERROR TIE pr lt RCB1 7 lt RCB C RC15 PLDB2 lt 70 25 WATER ERROR NC lt ROBI B ROB H ROS2 PLE52 lt RC70 49 WIRE STUCK COM Ben B 278 ve pogi 2 ROB J Re le lt RC70 51 WIRE STUCK aes 273 ROBI 8 lt ROR F lt RC70 50 GAS VALVE ick ARAR MOTOR CONTROL _ 1094 lt 8070 69 CONTACTOR lt RC70 52 RD COMNON lt RC70 67 PURGE 28 CONDUCTOR lt RC70 44 RD COMNON lt RC70 64 lt RC70 70 RD COMNON RCAS lt RC70 58 RETRACT X RC70 568 RD COMNON lt RG70 88 RPS A lt RC70 63 RPS B QRC70 41 RPS C QRC70 57 RD COMNON lt RG70 66 AUTOSET lt RC70 54 AUTOSET A lt RC70 53 AUTOSET B lt RC70 65 AUTOSET D MOTOR CONTROL 109 com 2 4 2 lt 8 0 RC20 A RCB0 5 _ T RN RC3 1 RC25 B 80 3 gt lt RG3 3 nt REO 8 22 A 22 AL En lt RC3 2 RG25 D gt 55 27 EMAN RCSS RG25 c gt 78 MIT lt 7 1 267 KO COMMON
13. KRES INTERGONNECT 17 BOARD Ro1 PLel 1 R 3 PLCIZ 79 RCB PLE14 RECT RC3 3 T Ua 17 Li L2 REI 8 gt A Re5 amp RE1 1 gt 15 KRES 5 e a 5 nes 73 L1 RCI 3 gt CAES REI 7 gt lt 7 ee REI 2 gt 2 lt RCS 2 RGI B D RGF N T2 PANGE 22 VL ET 15 PLE21 Viet ET ORANGE i 19 GRANGE Ss AY 28 RS GRAY C 1 NVERTER MODULE 1 Ex 5 EG HEATSWK PLE16 1 2 32 RE7 3 gt 867 4 gt RO4 B gt 0 12 RIL CONTROL BOARD RCZ PLG2 RC3 PLG3 RG4 FLG4 RCO FLGO RC7 PLC7 RCB PLGB RC9 PLGH RC10 PLG10 TO FG4 SHEET 2 2 E STOP SHEET 2 SHEET 2 QN d TO PC10 SHEET 2 15V REPT Welding Power Source Part 1 Of 2 4 WARNING e Do not touch live electrical parts Disconnect input power stop engine before servicing e Do not operate with covers removed Have only qualified persons install use or service this unit PC1 CONTROL BOARD d STS nes 1 RS Resa Ds IT 5 RCZ PLGZ RCS PLES BOARD RCA PLGA4 RCS PLOS RC1 PLG1 1 RCG PLC RG3 PLG12 79 RG7 PLG7 RGE PLG1 4 REGT lt 2 2 RCS PLGE BUS SENGE 7E x lt PLEG RGF 1 RE10 PLE10 L1 L2 RC1 9 lt REI 1 gt 76 KRS 75 gt lt ROS 5 74 4 gt Ad L1 RE 22 063 72
14. RG25 57 77 pe RCB07725 EE RP3 B RC25 M gt RC0 12 gt lt REI 10 RC25 L FILTER BONRD RCB0 PLG48 RG81 FLG48 RCB3 PLGSO X RC70 9 VOLTS COMMAND lt RC9 2 lt RC70 16 VOLTS COMMAND lt RC9 4 lt 70 5 WFS COMNAND lt RC9 1 lt 70 54 WFS lt RC9 5 lt RC70 2Z0 RA GOMMON 4 RC9 2 lt RC70 3 E STOP lt RC70 6 FB TO ROBOT FE lt 805 1 lt 8070 53 RA COMMON ps lt RCS 2 lt RC70 7 ROBOT pom lt RCS 3 ee lt RC70 B RA COMMUN lt RCS 4 lt RC70 10 NOTOMAN VOLTS COMMAND lt 15 1 lt 70 4 RA COMMON X RC15 2 RUJ lt 70 19 NOTOMAN WFS COMMAND4 STUD STUD Jr lt RC70 Z1 RD COMNON E STOP RC8 2 lt 70 22 PANASONIC 10V REF RC8 5 lt RC amp 1 RC70 46 ABB RETRACT lt RCB 4 lt RO70 35 ABB CONTACTOR RC70 47 ABB JOG lt 70 23 ABB PURGE lt RC70 36 RD COMNON RC70 41 ABE RPS A EGND lt 8070 12 ABB RPS B X RC70 24 ABB RPS C lt RGE 3 TO 115VAC 61 lt RC41 4 SHEET 1 145 RETURN 42 ee Rea 5 en 1 15VAC 2 lt RC70 48 115VAC RETURN WELD STUD 39 WELD STUD 40 J CHASSIS GND GRN 22 01 3 lt RC70 58 WELD STUD PC13 lt 2 TRANSMIT 4 70 71 CHASSIS RD70 72 WELD STUD SERIAL COMMUNICATION RG1 3 RE
15. 7 1 Set Value Mode Program Process Wire Type Gas Type The Set Value mode is a troubleshooting tool that allows certain robot command values to be manually over ridden 1 Setup Push Button 2 Arc Control Push Button 3 Adjust Knob 4 Wire Feed Speed Amps Display Push Button OM 210 540 Page 34 Volts Arc Adjust Wire Speed Amps Adjust Enter the Set Value mode by pressing the Setup and Arc Control push buttons at the same time When in the Set Value mode the display windows briefly shows SET VALU and the blinking LED s under the display windows indicate whether Volts Arc Adjust or Wire Speed can be changed turning the Adjust knob Depending on the defined weld process either volts MIG or arc adjust pulse Accu pulse or RMD optional can be changed in the top display Wire speed can be Wirefeed 4 Gas Contactor Arc Control 2 changed in the bottom display Press the Wire Feed Speed Amps push button to toggle between selecting information in the top display or bottom display The LED under the active display will blink to indicate the value that can be changed Rotate the Adjust knob to change values Exit the Set Value mode by pressing the Setup and Arc Control push buttons at the same time or turning power source off and then back on again 7 2 Diagnostics The following error messages are shown on the upper and lower displays to indicate
16. C7 Indicates special instructions This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards FIRE OR EXPLOSION hazard e Do not place unit on over or near combustible surfaces e Do not service unit near flammables FLYING METAL or DIRT can injure eyes e Wear safety glasses with side shields or face shield during servicing e Be careful not to short metal tools parts or wires together during testing and servicing HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on equipment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns EXPLODING PARTS can cause injury e Failed parts can explode or cause other parts to explode when power is applied to inverters e Always wear a face shield and long sleeves when servicing inverters SHOCK HAZARD from testing e Turn Off welding power source and wire feeder or stop engine before making or changing me ter lead connections e Use at least one meter lead that has a self retaining spring clip such as an alligator clip e Read instructions for test equipment FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Us
17. Visit our website at www MillerWelds com ams Q Miller OM 210 540S 2007 10 Processes MIG GMAW Welding Pulsed MIG GMAW P Flux Cored FCAW Welding 4 Automatic Welding Description Automatic Welding Interface And Arc Welding Power Source Auto Axcess 450 OWNER S MANUAL File Advanced Manufacturing Systems 5 a 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 Ir RU E El ZA eem 04 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 Working as hard as you do i every power source from will help you protect yourself against potential hazards on the worksite Miller is backed by the most We ve made installation and operation quick B warranty in
18. e Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained 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 ARC WELDING can cause 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 lfinterference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area OM 210 540 Page 3 1 4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq
19. s dans le texte Indique une situation dangereuse qui si on l vite pas Les dangers possibles sont montr s par les symboles peut donner la mort ou des blessures graves Les dan gers possibles sont montr s par les symboles joints ou sont expliqu s dans le texte NOTE Indique des d clarations pas en relation avec des blessures personnelles 2 2 Dangers relatifs au soudage l arc gt gt sh Les symboles repr sent s ci dessous sont utilis s dans ce ma pour attirer l attention et identifier les dangers possibles En pr sence de l un de ces symboles prendre garde et suivre les instructions aff rentes pour viter tout risque Les instructions en matiere de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus completes fournies dans les normes de s curit num r es dans la Sec tion 2 5 Lire et observer toutes les normes de s curit Seul un personnel qualifi est autoris installer faire fonc tionner entretenir et r parer cet appareil Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil UNE D CHARGE LECTRIQUE peut entrainer la mort Le contact d organes lectriques sous tension peut provoquer des accidents mortels ou des br lures graves Le circuit de l lectrode et de la pi ce est sous tension lorsque le courant est d livr la sortie Le circuit d alimentation et
20. terminal first Connect input conductors L1 L2 and L3 to disconnect device line terminals 8 Over Current Protection Select type and size of over current protec tion using Section 3 12 fused disconnect switch shown Close and secure door on disconnect device Remove lockout tagout device and place switch in the On position 3 14 Touch Sensor Operation The touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source The weld output terminals provide a path for touch sensor voltage when this feature is turned on at the peripheral receptacle Turning on touch sensor causes a dc voltage to be present on the welding wire When welding wire touches the weldment the voltage sensing circuit closes and a 24 volts dc output signal is sent to the robot control indicating weldment detection Touch sensor dc voltage on the welding wire is 80 volts DC As soon as touch sensor turns on WIRE LIVE appears on the front panel display 3 15 Remote Program Select 7 Remote Program Select is factory set to On WaveWriter File Management software is required to turn this function Off When Remote Program Select is On a remote device or robot pendant may be used to select programs When Off program selection must be done from the welding power source front panel 3 16 Remote Program Setting When Remote Program Select is program selection will be determined by remot
21. that can burn eyes and skin Sparks fly off from the 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 see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc Wear protective clothing made from durable flame resistant mate rial leather heavy cotton or wool and foot protection WELDING can cause fire or explosion m 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 can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers Do not weld where flying sparks can strike flammable material Protect yourself and others from flying sparks and hot metal Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bul
22. will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OVERUSE can cause OVERHEATING 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 H F RADIATION can cause interference 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 install test and service H F producing units e Theuseris responsible for having a qualified electrician prompt ly correct any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked an
23. RC2 1 gt pu RC4 PLG78 on RC PLC91 RC7 PLGB4 45 1 gt 128 1 T LUE 45 35 ma LUE CLAMP RP EEEE 15 2 gt p VV vM J5 4 gt lt J10 1 SHEET 1 45 22 lt 410 2 PROCESS CONTROL J6 555 424 ex 124 COMMON 20 28 ito 3 d 1 amp 155 CAN H Les va 06 452 24 CAN J2 PLG34 lt ARE SHIELD Rca 2 99 224 72 SUMMED ss v rre 46 3 RG6 10 gt SU COURANTE lt 1 3 J4 PLG82 l 217 SUMMED COM J5 FLGSS g J6 PLG37 e 278 COMMAND COM a TO T2 N 279 DVER POWER SASA 45 1 y css lt 2 1 43 2 GRAY me MC anes gt 222 OC LATCH lt Dee Sar SHEET 9 223 NOT READY eee TO RCG 2 gt lt 42 7 RG6 PLG6 INVERTER 1 RC 4 022 _______ 44 25 227 gt AN J4 3 gt gt 42 BK EGND Figure 8 2 Circuit Diagram For Welding Power Source Part 2 Of 2 OM 210 540 Page 50 WARNING e Do not touch live electrical parts Disconnect input power or stop engine before servicing e Do not operate with covers removed Have only qualified persons install use or service this unit RC70 27 SENSOR SINK XRC70 29 SENSOR ON SOURCE lt RC70 17 RD COMNON 28 PREMIER lt RC70 28 TQUCHED SINK RC70 18 TOUCHED SOURCE lt 44 2 7 lt J4 5 DISPLAY lt 4 1 MODULE lt V1 PL673 lt
24. Resistors W Leads amp Plug 1 ene 196840 Insulator Resistors Interface Board 1 OOM oa tke bi peu Bee 109056 Core Ferrite E 2 164 Lg X 1 094 High X 826 Wide 1 up E 196514 Gasket Inductor Mounting 2 ACE RTE TE 196512 Bracket Inductor Mounting 2 196330 Heat Sink Power 1 Res E2 sensus 196345 Coil Inductor Pre regulator 1 Kunis OO TE 196588 Baffle Foam Rubber 1 TP 196365 2 Plugs W Eeads Fan c tton se eme 71 EE 199136 Plugs w Leads PC2 To PC1 1 aco ss 214523 Circuit Card Assy Control Inverter 300A 1 zu Qi RAS to ee ta tet Oia des 204646 Insulator 5 4 To 083147 Grommet Scr No 8 10 Panel Hole 312 Sq 500 4 Recommended Spare Parts When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial num
25. Superin tendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 telephone 1 866 512 1800 il y a 10 bureaux r gionaux le t l pho ne de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov 1 Garder les c bles ensemble les torsader les scotcher ou les recouvrir d une housse 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de VOUS 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concerne les implants m dicaux Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de soudage par points de gougeage du coupage plasma ou de chauffage par induc tion Si le m decin approuve il est recommand de suivre les proc dures pr c dentes OM 210 540 Page 9 OM 210 540 Page 10 SECTION 3 INSTALLATION 7 Appearance of actual unit may vary from unit shown in manual 3 1 Specifications Input At Rated Load Output 60 i i mperes Inpu ated Load Outpu Z Input Voltage p Three Phase Input Input Power elding Range pee M lameter Circuit kVA KW Output Range Range cus 208 V 230 V 400V 460 V
26. all Safety Standards Only qualified persons should install operate maintain and repair this unit During operation keep everybody especially children away ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is 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 Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are required when any of the follow ing electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid abl
27. and RMD optional CV weld process with individual settings of voltage and wire speed Conventional pulse program using peak background pulse width frequency and peak voltage as factory taught data Adaptive method is controlled by frequency adjustment Pulse process utilizing constant current ramps with constant voltage control of peaks and backgrounds Adaptive response is controlled by peak and minimum current levels Benefits are shorter arc lengths better puddle control more tolerant of tip to work variation less audible noise no arc wandering allows weld to fill in at toes increasing travel speed and deposition and more tolerant to poor fit up and gaps CV Pulse process designed for high travel speeds Typically used in Robotic applications Arc is designed to be tight and fast Front panel display is ACCU SPED CV Pulse process using a pulse waveform with modified curves at particular locations within the waveform Has a distinguished change in arc characteristics Front panel display is ACCU CURV RMD refers to Regulated Metal Deposition A precisely controlled short circuit transfer Benefits of RMD are well suited to thin materials improves gap filling and spatter reduction Provides less heat input into workpiece minimizes distortion and allows use of larger diameter wire on thin gauge materials Selection of wire type by alloys and classification Selection of shielding gas being used in application Selection p
28. boards LED31 on the AIM circuit board Status Diagnosis Off There 15 no power applied to the circuit board or the board software is not executing its functions Green The circuit board is operating normally Flashing Red The circuit board has encountered a recoverable fault Wait or cycle power to clear fault Red The circuit board has encountered an unrecoverable fault OM 210 540 Page 45 7 13 Troubleshooting Trouble Remedy No weld output completely inoperative Place line disconnect in On position See Section 3 13 Check and replace line fuse s if necessary or reset circuit breaker see Section 3 13 Check for proper input power connections see Section 3 13 No weld output meter display on with no error displayed Check to see if the contactor indicator light is lit when contactor line is asserted on Erratic or improper weld output with no errors displayed Use proper size and type of weld cable see Section 3 9 Check that proper program for wire size process and shielding gas is loaded Clean and tighten all weld connections No 115 volts AC at the duplex receptacle Reset supplementary protector CB1 see Section 3 7 Wire does not feed Check supplementary protector CB2 and reset if necessary see Section 3 7 Check motor control cable connections Wire feeds erratically Readjust hub tension Readjust
29. calibration mode to custom calibrate the power source to the robot command signals This ensures the wire speed voltage and arc adjust are the same on the robot pendantas on the power source gt The factory recommendation is to perform the calibration on all installations or code updates Follow this procedure if the factory settings are not as accurate as desired Synchronization of the robot and power source signals makes installation easier and improves the operation of the system 7 The robot pendant must have Weld enabled and there can be no start stop crater conditions set in the robot The calibration mode will execute as a dry run from the operator s perspective The welding power source provides the robot with feedback so the robot thinks a weld is underway yet the robot torch need not move during the calibration 5 If you wish to stop the calibration procedure turn unit input power off and then on again If the calibration is performed correctly the ROBT CAL message stops being displayed however if it is performed incorrectly the message remains on the display To start the calibration procedure over again turn unit input power off and then on again following the calibration setup steps following the calibration setup steps 198 993 OM 210 540 Page 27 4 6 Robot Auto Calibration Sample Programs C7 It is critical to make certain that NO start power start conditions run in or crater pa
30. dc J Tach B K Gas valve OM 210 540 Page 18 3 12 Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard These recommenda tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source NOTICE INCORRECT INPUT POWER can damage this welding power source This welding power source requires a CONTINUOUS supply of input power at rated frequency 1096 and voltage 10 Phase to ground voltage shall not exceed 10 of rated input voltage Do not use a genera tor with automatic idle device that idles engine when no load is sensed to supply input power to this welding power source C7 Actual input voltage should not exceed 10 of indicated required input voltage If actual input voltage is outside of this range output may not be available 60 Hz Three Phase Input Voltage 208 230 400 460 575 Input Amperes At Rated Output 67 59 34 29 23 Max Recommended Standard Fuse Rating In Amperes Circuit Breaker Time Delay 80 70 40 35 25 Normal Operating 100 90 50 45 35 Min Input Conductor Size In AWG 4 4 6 8 10 10 Max Recommended Input Conductor Length In Feet Meters 53 res De 152 Min Grounding Conductor Size In AWG 4 8 8 8 10 10 Reference 2005 National Electrical Code NEC including article 630 1 Choose a circuit breaker with time current
31. de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes L4W 5NS t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 de American National Standards Institute 11 West 43rd Street New York NY 10036 8002 t l phone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 t l phone 617 770 3000 site Internet 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 de U S Government Printing Office
32. de Be 227879 Circuit Card Assy Switches 1 boe Uf eee IPGL 221278 User Interface Module 1 C 200416 Circuit Card Assy Display 1 VTL eas fee Th ate 199376 Circuit Card Assy User Interface 1 TDI FM 196313 Fan Muffin 115V 50 60 Hz 3000 Rpm 6 378 Mtg Holes 2 TL PME 208071 Circuit Card Assy ISO COMM 1 ara 10975 C6 C77 G8 sas 2900979 4 ASSY howe oci En V D mes oU AD OU RI 3 ted 213102 Choke Common Mode w Leads 2 Nu EPIIT 025248 Stand off Insul 250 20 X 1 250 Lg X 437 Thd 2 cr 207997 2s BUS e sos wagner RE NS em ndis 2 P EP 210866 Terminal pwr output black 1 Ni Lo us PO tts 214664 Receptacle Common Mode Choke 1 OM 210 540 Page 61 No Mkgs No Description Quantity Figure 9 5 Front Panel Assembly Fig 9 1 Item 14 Continued 216966 Cover Connector D sub 9 pin Male w Chain 1 Pr 216965 Cover Connector D sub 9 skt Female w Chain 1 ED 219943 Label VOIR SENSE 224 ire d ri
33. drive roll pressure Clean or replace dirty or worn drive rolls Remove weld spatter around the nozzle opening Replace contact tip or liner See gun Owner s Manual Check motor control cable connections Wire feeds as soon as power is supplied Check gun trigger See gun Owner s Manual Wire stubbing on low end using a constant current power source Increase output setting of the power source Check voltage sense lead connection clean and tighten if necessary Gas does not flow or does not stop flow ing wire feeds Check gas valve and flow meter Wire burns back to gun contact tip when using electrode negative straight polarity process Check to be sure that volt sense lead is connected to the work OM 210 540 Page 46 Notes OM 210 540 Page 47 SECTION 8 ELECTRICAL DIAGRAMS RC1 42 RGI 2 gt RGI 1 gt PCS AUXPOWER RcI PLG1 amp RCZ PLG19 RCZ 3 gt REZ 1 gt NOTE POWER CABLE TO BE SUPPLIED OM 210 540 Page 48 BY CUSTOMER NSTALLED Figure 8 1 Circuit Diagram For NEGATIVE Ras gt gt 27 2 4 WHT 2 BR lt RE2 1 gt lt RES A 7 ge RES Res M 0 x5 15 gt 2 __ RES 7 1 gt 46 Less AK lt lt 2 4 ROE WT
34. la soudure e lsoler la pince de masse quand pas mis pi ce pour viter le contact avec tout objet m tallique e Ne pas raccorder plus d une lectrode ou plus d un c ble de masse une m me borne de sortie de soudage OM 210 540 Page 5 reste une TENSION DC NON N GLIGEABLE dans les sources de soudage onduleur quand on a coup l alimentation e 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 DES PIECES CHAUDES peuvent provoquer des br lures graves e Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pieces chaudes utiliser les outils recomman d s et porter des gants de soudage et des v tements pais pour viter les br lures LES FUMEES ET LES GAZ peuvent tre dangereux 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 A l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est m diocre porter un respirateur anti vapeurs approuv e Lire et comprendre les sp cifications de s curit des mat riaux MSDS et
35. les circuits internes de la machine sont galement sous tension lorsque l alimentation est sur Marche Dans le mode de soudage avec du fil le fil le d rouleur le bloc de commande du rouleau et toutes les parties m talliques en contact avec le fil sont sous tension lectrique Un quipement install ou mis la terre de mani re incorrecte ou impropre constitue un danger Ne pas toucher aux pi ces lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous 9 isoler de la piece couper et du sol en utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol 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 UNIQUE MENT si le proc d de soudage le demande Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip D autres consignes de s curit sont n cessaires dans les condi tions suivantes risques lectriques dans un environnement humide ou si l on porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y a un risque lev de contact in vit
36. les instructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d grais Seurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation 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 Ne pas 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 for mer 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 en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES RAYONS DE L ARC peuvent provoquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudag g n re des rayons visibles et invisibles intense ultraviolets et infrarouges susceptibles de provoquer des br lure dans les yeux et sur la peau Des tinc
37. ohms Visually inspect electrolytic capacitors C1 and C2 for any possible damage In the event of an over voltage condition R1 and R8 could open potentially causing an imbalance in the power circuit This condition would create excessive current in the inverter primary transformer and result in the OVER CRNT error 7 2 Diagnostics Continued STUK UNKN Indicates a contactor Indicates a trigger Indicates an on error closed error unknown error REL TRIG ERR UNKN e The release trigger error indicates the The unknown error indicates an error was user held the gun trigger after an E stop was sent from the PCM board to the UIM but reset causing the contactor to remain on error condition is unknown Make sure Press Jog Purge button to clear error welding power source is isolated from the TRIG STUK welding fixture Press Jog Purge button to e The trigger stuck error indicates the user clear error held the gun trigger during power up Release trigger and turn power off and back on OM 210 540 Page 37 7 3 Removing Cover and Measuring Input Capacitor Voltage A 900 Volts dc can be present on the capacitor bus and significant DC voltage can remain on capacitors after unit is Off Always check the voltage on both inverter assemblies as shown to be sure the input capacitors have discharged before working on unit abs Tools Needed lead to left bus terminal lead to right bus terminal
38. ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande gt OM 210 540 Page 7 LES FILS DE SOUDAGE peuvent provoquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres per sonnes ou toute pi ce m canique en enga geant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures ES S abstenirde toucher des organes mobiles tels que des ventilateurs e Maintenirferm s et verrouill s les portes pan neaux recouvrements et dispositifs de protec tion e Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien e Remetire les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant de rebrancher l alimentation lectrique LIRE LES INSTRUCTIONS e Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil e N tiliser que les pieces de rechange recom mand es par le constructeur e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une d
39. the and easy With Miller you can count on years 00012000 of reliable service with proper maintenance And for some reason the unit needs repair QUALITY SYSTEM there s a Troubleshooting section that will help you figure out what the problem is The Miller is the first welding parts list will then help you to decide the equipment manufacturer in 2122 20 exact part you may need to fix the problem the ISO 9001 2000 Quality Warranty and service information for your Sysiem Standard particular model are also provided 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 specification sheets To locate your nearest distributor or service agency call 1 800 4 A Miller or visit us at www MillerWelds com on the web 2 Miller Mil Thank 4 05 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 Ths Symbol US aeu ne nt abatement OE ae wens 1 127 Are Welding EE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 124 Galifornia Proposition 6S Warnings sacs ux iex eni m ieee wach 4 1582 Principal Safety Standards suum ater 4 1 62 d SE OO
40. then turn the power to the unit off and then on again for the changes to be carried out by the unit 14 Volts And Arc Adjust LED s The lit LED indicates whether voltage or arc length is being displayed 15 Upper Display The upper display shows different information depending on the active function of the unit and the weld process being used When the display shows voltage for a MIG process the Volts LED lights When it shows arc adjust for a pulsed and RMD optional weld process the Arc Adjust LED lights However during any weld process MIG and pulse the unit will display actual arc voltage unless a PDA with File Management WaveWriter software has set the unit in the Display Command Values mode Table 4 1 Welding Wire And Gas Abbreviations Wire Description Wire Abbreviation Alloy Type Gas Type Gas Abbreviation Steel STL E70 E100 E120 10096 CO CO2 90 Argon 10 CO C10 85 Argon 15 CO C15 75 Argon 25 CO C25 95 Argon 5 CO C5 95 Argon 5 Os OX5 98 Argon 2 OX2 Stainless Steel SS 308 309 312 316 98 Argon 2 OX2 81Ar 18HE 1CO gt Tri Gas Accu pulse 9O0HE 7 1 2Ar 2 1 2CO gt Tri Gas MIG RMD Accu pulse Cored Tubular Wire MCOR 71 76 86R 409 90 Argon 10 C10 oF 98 Argon 2 OX2 Aluminum ALUM bXXX 100 Argon ARGN Not all wire types may be available with your unit OM 210 540 Page 25 Table 4 2 Robot Ab
41. this unit During servicing keep everybody especially children away 9 ELECTRIC SHOCK can kill e Do not touch live electrical parts e Turn Off welding power source and wire feeder and disconnect and lockout input power using line disconnect switch circuit breakers or by removing plug from re ceptacle or stop engine before servicing unless the procedure spe cifically requires an energized unit e Insulate yourself from ground by standing or working on dry insulat ing mats big enough to prevent contact with the ground e Do not leave live unit unattended If this procedure requires an energized unit have only personnel familiar with and following standard safety practices do the job e When testing a live unit use the one hand method Do not put both hands inside unit Keep one hand free e Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source 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 Troubleshooting Section be fore touching any parts 79 gt gt STATIC ESD can damage PC boards 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 OM 210 540 Page 32 OM 210 5405 2007 10 safety_stm 2007 04
42. 17 770 3000 web site 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 Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 7954 phone 1 866 512 1800 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator Do not coil or drape cables around your body 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 possi ble About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cuiting or induction heating operations If cleared by your doctor then following the above procedures is recom mended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION fre som 2007 04 Se prot ger et prot ger les autres contre le risque de blessure lire et respecter ces consignes 2 1 Symboles utilis s DANGER Indique une situation dangereuse qui si on l vite pas peut donner la mort ou des blessures graves joints ou sont expliqu
43. 190332 MVIDCOLUTIDOL RA eot ates SR Roach o EDU tn 1 TRE Dm 030170 Bushing Snap in 750 Id X 1 000 Mtg Hole Cent 2 he RER 196259 Plugs w Leads amp Current Xfmr including 1 PTT 115092 Housing SKIS aaa 1 2 T15091 5 22 5 HOUSING PIUG amp SKIB xo d rore uo ade LR RE esse d TTC CT1 196231 Xfmr Current Sensing 200 1 1 c 201695 Clamp Capacitor 2 meals G2 226081 Capacitor Elctlt 2400 Uf 500 Can 2 50 Dia 2 210507 Clamp Capacitor Machined 2 Iud oe er een ae ae 217625 Kit Input Pre regulator And Inverter Module 1 24 RT1 RT2 RT3 214015 Thermistor NTC 30K Ohm 25 Deg 7 amp 18in Lead 3 POZ uides 222661 Circuit Card Assy Power Interconnect 1 D Rods esie 196143 Capacitor Polyp Met Film 16 Uf 400 10 1 p ER 196378 Bracket Mtg Current Xfmr 1 me CO Dies 182918 Transducer Current 400A Module Supply V 15 1 196384 55 Gable Transducer 20 DER d RIB Li 196343
44. 575 V Three 450 A 10 44 Standard 035 062 in 80 67 0 59 0 34 0 29 0 23 0 23 8 22 9 Phase 44 V DC 50 1400 0 8 1 6 mm 0 1A 0 1A 0 1A 0 1A 0 1A 0 8 0 17 100 ipm Duty 1 3 35 6 Cycle mpm While idling Input amperage fluctuates while idling and is always less than one Ampere Use one Ampere for power efficiency calculations Wire feed speed ranges are for GMAW welding While pulse welding wire feed speed ranges may be more limited 3 2 Dimensions And Weight Hole Layout Dimensions 22 1 2 in 572 mm A 17 3 32 in 434 mm nm d B 17 3 8 in 441 mm 31 in C 19 3 32 in 485 mm 787 mm D 16 3 32 in 409 mm E 1 2in 13 mm d Weight PA 17 3 32 in 434 mm 163 Ib 74 kg Net SW 180 Ib 82 kg Ship we Ref 803 244 B OM 210 540 Page 11 3 3 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating 3 PHASE If unit overheats thermostat s ERATION opens output stops and cooling fan runs Wait fifteen minutes for unit to cool Reduce amperage or duty cycle before welding NOTICE Exceeding duty cycle can damage unit and void warranty RES WELD AMP TE TES DUTY CYCLE 100 Duty Cycle At 450 Amperes 60 Duty Cycle At 580 Amperes Continuous Welding 6 Minutes Welding 4 Minutes Resting Overheating Minutes Reduce Duty Cycle duty1 4 95 220 485 A 3 4 Volt Ampere C
45. 7 nnl ZEE PO 9 034 2 cr cle s mmm e e 50 055 5 J4 06 y x 1 User Interface Module PC7 Diagnostic LED s are visible inside unit located on PC7 mounted behind the front Reinstall cover after checking diagnostic LED s panel 2 Switch 51 Refer to Section 7 9 for information on diagnostic 3 Dip Switch S2 7 9 Diagnostic LED s On User Interface Module PC7 J e e 218 559 803 251 Dip switches are used to identify each circuit board on the internal network Dip switch settings are different for each circuit board For proper operation do not change dip settings from those shown LED Status Diagnosis 152 See Network Status Table Section 7 12 Off See Network Status Table in Section 7 12 OM 210 540 Page 41 7 10 Automation Interface Module PC9 Diagnostic LED s NS eI 8 8 o HHG FB2 LED1 LED2 LEDS LED4 a unnm tat nummi Aka a es LED LEDG LED LED8 LEDS LED10 LED33 1 Automation Interface Module PC9 Diagnostic LED s are visible inside unit located on PC9 mounted on left side Refer to Section 7 9 for information on diagnostic LED s OM 210 540 Page 42 R74 R7 au a LED20 LED19 LED18 LED16 LED11 LED28 LED12 LED13 LED25 LE
46. 95 4 0 120 2 70 2x95 2x120 3x95 3x95 2ea 2 0 2 3 0 2 4 0 3 3 0 3 ea 40 3 ea 4 0 B 070 3 0 95 4 0 120 2470 2x95 2x120 3x95 3x120 3x120 Positive Negative 700 410 120 2 ea 2 0 2 ea 3 0 2ea 4 0 3 ea 3 0 3 4 0 3 4 0 4 ea 4 0 Ref 803 246 B 2x70 2x95 2x120 8x95 3x120 8x120 4x120 800 4 0 120 2 ea 2 0 2ea 3 0 2 4 0 3 4 0 3ea 4 0 4ea 40 4 ea 4 0 2x70 2x95 2x120 3x120 8x120 4x120 4x120 This chart is a general guideline and may not suit all applications If cable overheating occurs use next size larger cable Cable should be sized for Peak Amperage Apk for pulse welding applications Weld cable size AWG is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere mm for metric use For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 S 0007 E In pulse welding applications using inverter power sources peak currents can result in extreme voltage drops producing poor welding characteristics with undersized cables A recommendation for weld cable size is a minimum of 2 0 for 300 ampere welding power sources and 4 0 for 450 ampere welding power sources when total cable length is less than 100 ft 30m OM 210 540 Page 16 3 10 Peripheral Receptacl
47. CEME BOARD lt 1 5 COMMON EGND RC2 PLGE3 X RC1 7 READY TO SEND _ RET lt RC1 B CLEAR TO SEND gt RC3 2 gt RC3 3 TRANSMIT gt RC3 5 common gt RO3 7 READY TO SEND gt RC3 B CLEAR TO SEND 207 903 G Part 2 Of 2 OM 210 540 Page 51 TYPICAL ROBOT CONTROL Fe lt NOWNOD O I E gt Q3 8 LE E MEN gt NOWNOD QM a nOz lt 52 626 NOWWOO Gu Aeae te ug Nos amp Li lt lt 99 ousonv Tlale cd EE 5 5 tS ZE 8 lt lt p SRG eae lt lt v I3S0inv NO g bey 12 NO HNOSN3S vL 9 Fly Z c 5 5 4 Sd NO 2 5 9 20509 lu o Sda z 2 S 5 amp amp z 5 3 5 asa O NO Qm S SISSE lt 5 Li I x 89 v SdM an z z z 5 ec v Sd lt a c gt lt Ps x p lt 84 NO IL 4 2 5 ble x E x 1 1 Nm sor Q v9 95 Bo 7 L9 wound Zi am j gt 1 x dz wound O lt 5 2
48. CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire e Utiliser un quipement de levage de capacit suffisante pour lever l appareil e En utilisant des fourches de levage pour d placer l unit s assu rer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil L EMPLOI EXCESSIF peut SUR CHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement re specter le cycle op ratoire nominal e R duire le courant ou le facteur de marche avant de poursuivre le soudage e Ne pas obstruer les passages d air du poste LES TINCELLES VOLANTES ris quent de provoquer des blessures e Porter cran facial pour prot ger le visage el les yeux e Affuter l lectrode au tungst ne uniquement la meuleuse dot e de protecteurs Cette manoeuv re est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute sub stance inflammable 79 Q gt a LES CHARGES ELECTROSTATI QUES peuvent endommager les circuits imprimes tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces Utiliser des pochettes et des bo tes antistati ques pour stocker d placer
49. D14 027 c 988 L dew rH 31 is UN m mci TL mma gue od az 8 7 e 3 S D as A F D 0 ose EE M d T we 159 54 2 N e o QUE LED21 LED17 Reinstall cover after checking diagnostic LED s 2 Switch 54 s Hoo H90 5 H00 HN E RE e LL gre TH AH lala U27 m BREDER mous m Mp numm 057 m UM au Vu 8 rr n n a m ES Te 2 36 ie rm LED31 LED30 iem innr ol 5 n 6 t 022 LED23 LED24 LED26 LED29 216 958 A Ref 803 250 C Dip switches are used to identify each circuit board on the internal network Dip switch settings are different for each circuit board For proper operation do not change dip settings from those shown 7 11 Diagnostic LED s On Automation Interface Module PC9 LED Status Diagnosis 1 On Input signal On from robot for jog advance Off Input signal Off from robot for no jog advance 2 On Input signal On from robot to energ
50. ED s On Automation Interface Module PC9 43 7 12 Network And Module Status LED s 45 Tatas MOUDICSNOOUNO m iit a db o p d a ae et aS 46 SECTION 8 ELECTRICAL DIAGRAMS TERIS 48 SECTIONS PARTS its ses Cases ee 56 WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING som 2007 04 Protect yourself and others from injury read and follow these precautions 1 1 A Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 1 2 Arc Welding Hazards 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 5 Read and follow
51. ED lights to indicate one of the setup modes is active 7 Setup Push Button Press button to select Process Wire Type Wire Diameter or Gas Type parameters In order for selections to be retained in memory the Setup push button must be pressed six times before any other push button is pressed once to select Process again to select Wire Type again to select Wire Alloy again to select Wire Size again to select Gas Type and a sixth time to store selections in memory The displays will temporarily show PROG LOAD to indicate the data is being stored in memory 4 3 Front Panel Controls Continued See Section 4 2 8 Arc Control LED The LED lights to indicate the Arc Control button is active Light goes out when button is inactive 9 Arc Control Push Button This push button allows fine tuning inductance for MIG programs and Arc Control for programs other than MIG When the push button is pressed the upper display item 15 shows INDU for inductance or ARC for Arc Control to indicate which parameter is selected for change The range of possible values is 0 99 for inductance and 0 50 for arc control Turn the Adjust knob to change the parameter value Press button to deactivate arc control mode LED goes out 10 Wire Feed Gas Contactor LEDs The Wirefeed LED lights when the wire feeder is energized For example when the front panel Jog or Retract button is pressed the Wirefeed LED lights The G
52. INPUT ANALOG ANALOG 0 15VDC OPTIONAL OUTPUT SIN 0 10VDC WIL OUTPUT ANALOG 05 35 HONOL 2 5 8 Sd3 vV SdH 5 81 38 90r 39und MOLOVINOO r 30A L OPTIONAL OUTPUT DIGITAL SOURCING RECOMMENDED CABLE 2 22 20 COND 4 PAIR SHIELDED cc t Re lt LL lt os 6S lt 09 L lt 9 9 OOOO 229 7 65 22 C2 000000 01010010 5 9 99 9 QOOONQIO 3sn 3unind 3sn LON FUSED 1 4 OWA SII 115V FOR MILLER OVA SLI 10804 01 84 10404 OL NOWWOO va anis anis 10V OUT ANALOG 1VDC OUTPUT NONHO9 va NOWMOO va NOWMOO 43H AOL SOTWNY OINOSVNVd 33M NVWOLOW NVWOLOW SINGLE ENDED SCALED IN QNVNNOO SIM QNVNNOO SIM ONVNWNOD SLIOA DIFFERENTIAL QNVWNNOO SLIOA WELDER NO YOSN3S 2 SdM BBV 89 595 V Sdu 88v LOVYLSY oor 88V 88v YOLOVLNOS NO ti NO v NO I NO NO 11 97 NO 031 NO ZI 97 NO z aJl CHASSIS GROUP NOT FOR CUSTOMER USE 100A OUT 1VDC 57
53. Man Reset 1P 15A 250VAC Frict 1 les 216213 Circuit Card Assy Motor Filter Hf 1 lisses ROZ nasus 604176 Receptacle w Leads 115V Duplex 1 ls RP meee eee 216596 Strap Grounding 4 50 in long 1 Recommended Spare Parts When ordering a component originally displaying a precautionary label the label should also be ordered 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 210 540 Page 60 Hardware is common not available unless listed Ref 803 249 C Figure 9 5 Front Panel Assembly Item Dia Par NO Mkgs NO Description Quantity Figure 9 5 Front Panel Assembly Fig 9 1 Item 14 TUS ai Olt esata 207456 Switch Assy Rotary 2 Posn 1P 40A 600VAC PNLMTG 90Deg 1 207895 Insulator Switch Power 1 179851 Knob Pointer 1 670 Dia X 250 Id Push W Spring 1 D er ei 204393 Panel Card Front including 1 204394 Panel Card Switch Overlay including 1 ee eee 200410 Nameplate Overlay 1 us O ass LG Osi
54. ON 6 SAFETY PRECAUTIONS FOR 32 USAGE retenti Ci aaa 32 Hazards Sons ad aan Led de add et eq mates 32 6 3 California Proposition 65 05 2 33 6 42 oto RSR t pe auo d he s idc bulo t eit 33 TABLE OF CONTENTS SECTION 7 TROUBLESHOOTING 52 rer tiie Oui SA 34 1 12 oer ValuedVlOdB cas s basses eke qu aa RR AD we gu Reale ake dama ed mte 34 505 ASS C OD SOIT Sn 35 7 3 Removing Cover and Measuring Input Capacitor Voltage 38 7 4 Process Control Module PC4 Diagnostic LED s 39 7 5 Diagnostic LED s On Process Control Module PC4 39 7 6 Wire Feed Module PC6 Diagnostic LED s And Dip Switch Settings 40 7 7 Diagnostic LED s On Wire Feed Module 6 40 7 8 User Interface Module PC7 Diagnostic LED s 41 7 9 Diagnostic LED s On User Interface Module 7 41 7 10 Automation Interface Module PC9 Diagnostic LED s 42 7 11 Diagnostic L
55. able ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu 1 un poste souder DC tension constante gt Indique des instructions sp cifiques Ce groupe de symboles veut dire Avertissement Attention DANGER DE CHOC ELECTRIQUE PIECES EN MOUVEMENT et PIECES CHAUDES Consulter les symboles et les instructions ci dessous y aff rant pour les actions n cessaires afin d viter le danger fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est re command e En outre ne pas travailler seul Couper l alimentation ou arr ter le moteur avant de proc der l in stallation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 1910 147 voir nor mes de s curit e Installer le poste correctement et le mettre la terre convenable ment selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales e Toujours v rifier la terre du cordon d alimentation V rifier et s assurer 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 e Eneffectuant les raccordements d entr e fi
56. aintain 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 210 540 Page 59 Hardware is common not available unless listed 803 248 D Figure 9 4 Rear Panel Assembly ltem Dia Par No Mkgs No Description Quantity Figure 9 4 Rear Panel Assembly Fig 9 1 Item 8 sie his I PO 221279 Automation Interface Module 1 199297 Stand off no 6 32 amp no 8 32 2 50 Ig 312 hex alm m 4 2 214855 Circuit Card Assy Robot Interface Filter HF 1 NE 199295 Stand off 8 32 500 lg 312 hex al 4 Te 217297 Cover Receptacle Weatherproof Duplex Rept 1 D rn 207094 Patel esf a Rd cette duty C ee eo RRL bb RU oe OIN 1 mco ect dem 210358 Bolt eye shld thd stem 500 13 X 1 500 1 UE P DET 2105052 1 BOSE x ence et SEXE Ue 1 2010585 Conn clor PINASSY ware dO E 1 PEU MEET 210483 Bracket Ilt Eye RR EE Ree See eg 1 pan Dd ances OBT eus 083432 Supplementary Protector Man Reset 1P 10A 250VAC Frict 1 less OCDE 093995 Supplementary Protector
57. an 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 210 540 Page 4 For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Ontario Canada LAW 5NS phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 48rd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 phone 6
58. an injure or kill Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator MAGNETIC FIELDS can affect Implanted Medical Devices Wearers of Pacemakers and other Implanted Medical Devices should keep away Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding spot welding gouging plasma arc cutting or induction heating operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged 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 Protect compressed gas cylinders from excessive heat mechani cal shocks physical damage slag open flames sparks and arcs 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 fit tings designed for the specific appl
59. as LED lights when the gas valve is energized The Contactor LED lights when the output contactor is energized making the weld output terminals live 11 Wire Speed And Amps LED s The lit LED indicates whether wire speed or amps are being displayed 12 Wire Feed Speed Amps Display Push Button 13 Lower Display Press Wire Feed Speed Amps Display button to show weld amperage or wire feed speed in lower display the applicable LED under the lower display lights to indicate which is shown When welding actual value is shown If amperage was selected for display the unit will show actual welding amperage prior to and while welding unless the the unit is in Display Command Values mode Only wire speed command will be displayed while welding if the unit is set in Display Command Values mode even if the Wire Feed opeed Amps Display button is pressed Displays show actual or command values as determined by configuration menu when using a PDA with File Management WaveWriter software Command values are displayed prior to welding and actual values are displayed while welding unless a PDA with File Management software was used to set the unit in the Display Command Values mode In the Display Command Values mode command values are displayed while welding Ifa PDA with File Management WaveWriter software is used to change wire feed units IPM MPM or display welding information command or actual save the changes and
60. ber required when ordering parts from your local distributor OM 210 540 Page 58 Hardware is common not available unless listed 11 6 8 802 916 B Figure 9 3 Top Tray Assembly Item Dia Par NO Mkgs NO Description Quantity Figure 9 3 Top Tray Assembly Fig 9 1 Item 4 sue h agaaa 209676 Circuit Card Assy 1 2 231928 Circuit Card Assy Aux Power 1 210490 PG Card isi e beds 1 MER 134201 Stand Off PC Card 312 375 Post amp Lock 43 4 ee ee 083147 Grommet SCR No 8 10 Panel Hole 312 Sq 500 High 24 ues 221277 Process Control MOGUl cour 1 sos 170647 Bushing Snap in 1 312 Id X 1 500 Mtg Hole 1 Drame Miata tare ane ahaa ete 210491 Tray MOPO Cad aae ma qo adm 1 223439 Insulator Circuit Card Aux Power 1 198122 Stand Off Support PC Card 250 w Post amp Lock 500 1 Rasa POO ss 221280 Wire Feed Module 1 Recommended Spare Parts When ordering a component originally displaying a precautionary label the label should also be ordered To m
61. breviations 4 4 Front Panel Switches 1 Power Switch Turns unit On or Off The power up sequence may last up to 30 seconds before the unit is ready to weld During power up the front panel will display messages indicating the status of the unit The first message Is NET WAIT NET WAIT is an abbreviation for network updating and means the internal control network is powering up The next message is XXXX Robot Type XXXX identifies the robot adapter being used as identified by the unit see Table 4 2 for a list of robot adapters that could be displayed To ensure proper operation of the system verify the robot displayed corresponds to the actual robot being used The final message is OM 210 540 Page 26 AUTO 450 AUTO 450 indicates the software being loaded 2 Contactor LED Contactor LED illuminates when weld output is energized 3 Purge Push Button Press button to purge gas line 4 Gas LED Gas LED illuminates when Purge push button is pressed 5 Jog Push Button Press button to jog wire Ref 803 246 B 6 Wirefeed LED Wirefeed LED illuminates when wire feeds or retracts 7 Retract Push Button Press button to retract wire Wirefeed LED illuminates when Retract push button is pressed Auto Threading feature is activated by pressing the Jog and Retract buttons simultaneously Pressing the Jog Purge or trigger switch will turn off the Auto Threading feature 8 PDA Port 9 PC Port
62. cription Quantity Figure 9 2 Windtunnel Assembly LH And RH Fig 9 1 Item 6 T Mec 214597 Windtunnel LH w Components including 1 o ee 19635 T ET s s on ai inta od aie Mudd 1 FPS RE 213940 22 INGUCION INPUT q 3 eon ed 1 TL CM 214519 Insulator Heat Sink Rectifier 1 T ses CN Oo ei che 293092 gt RESIST rri dox cedet tmv decade 1 199840 Bus Bar Diode 2 OX wee Dui 201531 Kit Diode Power Module 2 TE CEU stata 196347 Heat Sink Rectifier 2 23 eese yan 1 E PET 196349 Spacer 3 LE eee inact 2094082225 seen a stg Desde Sie ai armee 1 7 4 220496 Output Inductor ASSY 1 TO 170647 Bushing Snap in 1 312 Id X 1 500 Mtg Hole 2 vdd E 179276 Bushing Snap in Nyl 1 000 Id X 1 375 Mtg Hole Cent 4 ERE 196355 lt Ins latot SChEW ean ek RR eR uM EN 6 TN DT MD 010546 Bushing Snap in Nyl 375 Id X 500 Mtg Hole 1 ro 222958 Windtunnel RH w Components including 1 ramo
63. curves comparable to a Time Delay Fuse 2 Time Delay fuses UL class 5 3 Normal Operating general purpose no intentional delay fuses are UL class K5 up to and including 60 amp and UL class H 65 amp and above 4 Conductor data in this section specifies conductor size excluding flexible cord or cable between the panelboard and the equipment per NEC Table 310 16 If a flexible cord or cable is used minimum conductor size may increase See NEC Table 400 5 A for flexible cord and cable requirements OM 210 540 Page 19 3 13 Connecting Input Power Tools Needed BS 5 16 in Turn Off welding power source and check voltage on input capacitors according to Section 7 3 before proceeding Installation must meet all National and Local Codes have only qualified persons make this installation Disconnect and lockout tagout input power before connecting input conductors from unit Make input power connections to the welding power source first gt Always connect green or green yellow conductor to supply grounding terminal first and never to a line terminal 1 Input Power Conductors Customer Supplied Cord Select size and length of conductors using Section 3 12 Conductors must comply with national state and local electrical codes If OM 210 540 Page 20 Route input power cable through tubing inside unit Route ground conductor through
64. d maintained 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 READ INSTRUCTIONS e Use Testing Booklet Part No 150 853 when servicing this unit e Consult the Owner s Manual for welding safety precautions e Use only genuine replacement parts from the manufacturer For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproduc tive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm 1 Keep cables close together by twisting or taping them or using a cable cover 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your 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 possi ble About Implanted Medical Devices Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding spot welding gouging plasma arc cutting or induction heating operations If cleared by your doctor then following the above procedures is recom mended OM 210 540 Page 33 SECTION 7 TROUBLESHOOTING
65. e Functions Function Socket Socket Information A Not used B Not used Circuit common Purge D Contact closure to C completes 40 volts dc solenoid circuit to purge shielding gas line E Contact closure to F indicates coolant flow switch is Coolant Flow closed and recirculating coolant system is Switch Input operational Signal Circuit H Contact closure to circuit common advances welding wire at wire drive assembly Retract J Contact closure to circuit common retracts welding wire at wire drive assembly K Contact closure to L energizes Touch Sensor circuitry Touch Sensor ON E And Output Signal L Circuit common M Part touched 24 volts dc output signal referenced Ref 803 245 B to circuit common Circuit common is same electrical reference point Speed of Jog advance and Jog retract is 60 ipm for seconds then it automatically changes to 700 ipm Note A customer supplied matching amphenol plug factory Part No 194 847 Amphenol Part No 97 3106A 20 33P B 621 and strain relief clamp 97 3057 12 0621 is required to use peripheral receptacle OM 210 540 Page 17 3 11 Motor Control Receptacle Functions Ref 803 245 B Socket Socket Information A Not used B Motor negative C Tach A D Motor positive E Tach common F Gas valve G Electrode sense H Tach 5 volts
66. e 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 amp Arc Stud Guns Racks Running Gear Trailers Plasma Cutting Torches except APT SAF Models 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 Bernard Branded Mig Guns No Labor Weldcraft Branded TIG Torches Labor Subarc Wire Drive Assemblies 4 6 Months Batteries 5 90 Da
67. e equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit MOVING PARTS can cause injury Keep away from moving parts such as fans e Keep away from pinch points such as drive rolls e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Keep hands hair loose clothing and tools away from moving parts e Reinstall doors panels covers or guards when maintenance is finished and before re connecting input power MAGNETIC FIELDS can affect Implanted Medical Devices e Wearers of Pacemakers and other Implanted Medical Devices should keep away from serv icing areas until consulting their doctor and the device manufacturer 6 3 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 6 4 Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables
68. e input once a weld is initiated Prior to welding program selection can be done in a normal manner from the welding power source front control panel See the following table for the remote program select binary code Program No Output A Output B Output C 1 Off Off Off 2 On Off Off 3 Off On Off 4 On On Off 5 Off Off On 6 On Off On 7 Off On On 8 On On On OM 210 540 Page 21 SECTION 4 OPERATION 4 1 Operational Terms The following is a list of terms and their definitions as they apply to this interface unit General Terms Synergic Arc Adjust Program Process MIG Pulse Accu pulse Accuspeed AccuCurve RMD optional Wire Type Gas Type Process Set Up Program Load Volts Time Arc Length WFS Amps Arc Control Inductance Sharp Arc Adjust Sequence Preflow OM 210 540 Page 22 Synergic refers to the unit s ability to use preprogrammed pulse parameters to determine the actual pulse settings of Peak Amperage Background Amperage Pulse Frequency and Pulse Width at any specific wire feed speed setting Term used to represent arc length adjustments in pulse programs Increasing Arc Adjust increases the actual arc length Likewise decreasing arc adjust shortens arc length Arc Adjust is replaced by volts in MIG programs Eight active slots for selection of various processes wire types and parameters A selection made for MIG Pulse Accu pulse
69. e or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC 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 alone 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 Properly install and ground this equipment according to its Owner s Manual and national state and local codes C7 Indicates special instructions zf This group of symbols means Warning Watch Out ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult sym bols and related instructions below for necessary actions to avoid the hazards 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 When making input connections attach proper grounding conduc tor first double check connections Keep cords dry free of oil and grease and protected from hot metal and sparks Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment whe
70. e reset The reset message is displayed for 2 seconds while factory program settings are being reloaded During the reset mode the following factory default programs are loaded into the unit Pulse 035 Mild Steel 90 Argon 10 CO Program 2 MIG 035 Mild Steel 15 Argon 25 Accu pulse 035 Mild Steel 90 Argon 10 O2 Program 4 Pulse 045 Mild Steel 9096 Argon 1096 CO Program 5 MIG 045 Mild Steel 15 Argon 25 Accu pulse 045 Mild Steel 9096 Argon 1096 O2 Program 7 Pulse 052 Mild Steel 9096 Argon 1096 CO Program 8 MIG 052 Mild Steel 15 Argon 25 1 Program 3 Program 6 gt Reset mode is not active when Program Lock is enabled The reset mode allows the operator to reload factory program settings for all eight active programs in the unit gt System configuration data will be lost during the Reset operation Wireteed Wire Type Gas Gas Type Contactor Adjust Arc Control Cycl Pwr message appears on the display when programs complete loading Turn power off wait 10 seconds and turn power back on again to complete the reset operation gt After Reset is complete be sure to load appropriate programs that contain the correct wire size process and shielding gas for the welding operation 198 993 803 246 B SECTION 5 MAINTENANCE 5 1 Routine Maintenance A Disconn
71. e set with the optional PDA with File Manage ment software Sequence function that allows the wire to move back towards the contact tip when a welding operation is completed Setting is both speed IPM and time sec only available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes and can only be set with the optional PDA with File Management software Method of jogging wire without holding jog or trigger switch Pressing Jog and Retract simultaneously will automatically feed wire Default setting is 72 inches at a feed rate of 700 ipm Pressing jog purge or trigger switch will terminate the auto threading feature These values can be changed using a PDA with File Management WaveWriter software OM 210 540 Page 23 3 Process Wire Gas Program Front Panel Controls See Section 4 3 INT Volts Arc Adjust Wire Speed Amps A Wirefeed Gas Contactor Arc Contro When LED is lit it means the related function is active 1 Program Display Displays the number of the active program 2 Adjust Knob Turn the Adjust knob to change program number Setup Arc Control and weld parameters 3 Program Push Button LED The LED lights when the Program Push Button is active 4 Program Push Button Press push button LED lights and turn Adjust knob to select active program The letter C is dis
72. ect power Maintain more often before maintaining during severe conditions Check Change Clean Replace Reference To be done by Factory Authorized Service Agent 2 54 3 Unreadable Labels Weld Terminals x Damaged Gas Hose x Weld Cables Months X Cords X Gun Cables Every 6 Months Drive Rolls Inside Unit 5 2 Blowing Out Inside Of Unit A Do not remove case when blowing out inside of unit To blow out unit direct airflow through front and back louvers as shown Ref 803 244 B OM 210 540 Page 31 SECTION 6 SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury read and follow these precautions 6 1 Symbol Usage DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury The possible hazards are shown in the adjoining symbols or explained in the text Indicates a hazardous situation which if not avoided could result in death or serious injury The possible hazards are shown in the adjoining symbols or ex plained in the text NOTICE Indicates statements not related to personal injury 6 2 Servicing Hazards 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 Only qualified persons should test maintain and repair
73. ed according to this manual If interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding 350 ft 400 ft 150 ft 200 ft 250 ft 300 ft 100 ft 30 m or Less 45m 60m 70m 90 m 105 120 m m Weld Output Terminals A Turn off power before Weldi 10 60 60 100 amperes Duty Duty 10 100 Duty Cycle Cycle A Do not use worn dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 4 0 4 0 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 120 120 4 0 2 ea 2 0 2ea 2 0 250 2 35 1 50 1 0 60 2 0 70 3 0 95 120 2x70 2x70 4 0 2 ea 2 0 2 3 0 2 3 0 300 1 50 1 0 60 2 0 70 3 0 95 120 2x70 2x95 2x95 4 0 2 ea 2 0 2ea 3 0 2ea 3 0 2ea 4 0 350 1 0 60 2 0 70 3 0 95 120 2x70 2x95 2x95 2x120 4 0 2ea 2 0 2ea 3 0 2ea 4 0 2ea 4 0 400 1 0 60 2 0 70 3 0 95 120 2x70 2x95 2x120 2x120 2 ea 2 0 2 ea 3 0 2 4 0 3 ea 3 0 3 ea 3 0 500 2 0 70 3 0
74. ehome Sample Auto Calibration Routine For ABB Robot Move J home v500 z50 tweldgun Arcl on V500 sm1 wd1 250 tweldgun Arcl off v500 sm1 1 wvO 250 tweldgun WaitTime 5 Arcl on V500 sm1 wd2 250 tweldgun Arcl off v500 sm1 wd2 250 tweldgun Move J home v500 z50 tweldgun Seam Data values must all be set at zero Weld Data 1 Weld Data 2 weld_sched 0 weld_sched 0 weld_speed 5 weld_speed 5 weld_voltage 10 weld_voltage 44 weld_wfs 100 weld_wfs 1000 org_weldspeed 0 org_weldspeed 0 org_weldvoltage 0 org_weldvoltage 0 org_weldwfeed 0 org_weldwfeed 0 OM 210 540 Page 29 4 7 Reset Mode Volts Arc Length Process i Wire Type Gas Type Adjust Arc Control Enter reset mode by turning power On and pressing the Program Push Button until the RST NO message is displayed RST NO message will not display until after the power up sequence is completed approximately 20 seconds V RST _ Program Volts Arc Length YES HA WireSpeed Amps Process e Wireteed Wire Type Gas Gas Type Contactor of Sup Adjust Are Control fo Rotate Adjust knob to change NO to YES OM 210 540 Page 30 Volts Arc Length YES HA WireSpeed Amps Process e Wireteed Wire Type Gas Gas Type Contactor Adjust Arc Cont 7 Press the Arc Control button to confirm th
75. elected 18 On Input signal On Autoset D selected Off Input signal Off Autoset D not selected 19 On Input signal On Remote Retract on from peripheral plug Off Input signal Off Remote Retract off from peripheral plug 20 On Input signal On Remote Water Flow on from peripheral plug Off Input signal Off Remote Water Flow off from peripheral plug 21 On Input signal On from robot for no emergency stop Off Input signal Off from robot for emergency stop 23 On Input signal On from relay K3 for welding power source ready and no detected errors present Off Input signal Off from relay K3 for welding power source not ready detected errors are present or unit is in operating mode preventing the weld ready signal from being enabled OM 210 540 Page 43 LED Status Diagnosis 24 On Input signal On from relay K4 to indicated wire stuck in weld joint Off Input signal Off from relay K4 to indicate wire is not stuck in weld joint 25 On Indicates 5 volts dc is present on automation module PC9 Off Indicates 5 volts dc is not present on automation module PC9 26 On Input signal on from relay 5 for flow shielding gas or coolant present Off Input signal off from relay K5 for flow shielding gas or coolant not present 27 On Indicates 15 volts dc is present on automation interface module PC9 Off Indicates 15 volts dc is not present on automation interface module PC9 28 On Indicates 15 vol
76. elles sont projet es pendant soudage e Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit e Porter des lunettes de s curit avec crans lat raux m me sous votre casque e Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc e Porter des v tements confectionn s avec des mati res r sistan tes et ignifuges cuir coton lourd ou laine et des bottes de protection OM 210 540 Page 6 LE SOUDAGE peut provoquer un in cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tel que des r servoirs tambours ou des conduites pet provoquer leur clatement Des tincelles peuver tre projet es de l arc de soudure La projection d tincelles des pi ce chaudes et des quipements chauds peut provoquer des incendies des br lures Le contact accidentel de l lectrode avec des objet m talliques peut provoquer des tincelles une explosion un surchaut fement ou un incendie Avant de commencer le soudage v rifier s assurer que l endroit ne pr sente pas de danger D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir so
77. eripheral Receptacle Functions 17 3 11 Motor Control Receptacle Functions 18 9 12 clectical Sewice sn 19 2 13 Connecting ad 20 3 14 Touch Sensor 2 md ed E qr suu EE ag 21 3 15 Remote Program das 21 3516 REMOLe Foghat Send dst hr Ee ______ ________ 21 SECTION 4 OPERATION 527244525245 22 4 1 Operational TES atis e Hera ane o sce d sce M pa ecd 22 4 2 Front Panel Controls See Section 4 3 24 4 3 Front Panel Controls Continued See Section 4 2 25 Front Panel WICE S ou darse Et EE dran bb tc 26 4 5 Robot Calibratlore ModE 3 552 bn PERI ERN E Na e bre euge id d 27 4 6 Robot Auto Calibration Sample Programs 28 A YD EROS M00 RETE I m LU T E 30 SEGTION 5 MAINTENANCE corar iaer dca oon a OR oor dog a c Fo a Ros C E ea 31 9 1 ROUE Maintellari6e asera a scs eld eR TES 31 5 2 Blowing Our InSId OP DIES er Ras aw RUF DN NEU Edd Bee 31 SECTI
78. es malformations cong nitales ou autres probl mes de procr ation 2 5 Principales normes de s curit Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 de Global Engineering Documents telephone 1 877 413 5184 site Internet www global ins com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS 41 de Global Engineering Documents t l phone 1 877 413 5184 site Internet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protec tion Association P O Box 9101 Quincy MA 02269 9101 telephone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 4221 Walney Road 5th Floor Chan tilly VA 20151 telephone 703 788 2700 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association 5060 Mississauga Ontario Canada 2 6 Information EMF Considerations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les cables de sou causera des champs lectromagn tiques Il y a eu et a encore un certain souci propos de tels champs Cependant apr s avoir exa min plus de 500 tudes qui ont t faites pendant une p riode de recherche
79. facturer s Transportation Department PRINTED IN USA C 2007 Miller Electric Mfg Co 2007 01 Miller Electric Mfg Co An Illinois Tool Works Company 1635 West Spencer Street Appleton WI 54914 USA International Headquarters USA USA Phone 920 735 4505 Auto Attended USA amp Canada FAX 920 735 4134 International FAX 920 735 4125 European Headquarters United Kingdom Phone 44 0 1204 593493 FAX 44 0 1204 598066 www MillerWelds com Miller
80. gh welding questions Contact your distributor The expertise of the distributor and Miller is there to help you every step of the way 2 Miller 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 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 th
81. he 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 miller_warr 2007 01 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip For Service Contact a DISTRIBUTOR or SERVICE AGENCY near you Always provide Model Name and Serial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks To locate a Distributor or Service Agency visit www millerwelds com or call 1 800 4 A Miller Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manu
82. ication maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient num ber of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING e Allow cooling period follow rated duty cycle e Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit FLYING SPARKS can cause injury e Weara face shield to protect eyes and face e Shape tungsten electrode on
83. igneusement avec des protections homologu s e Ne pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e 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 par s correctement conform ment AWS F4 1 voir les nor mes de s curit e Ne soudez pas si l air ambiant est charg de particules gaz ou va peurs inflammables vapeur d essence par exemple e Brancherle c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provo quant des risques d lectrocution d tincelles et d incendie 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 fil la pointe de contact e Porter des v tements de protection d pourvus d hui
84. istan ce correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles LE RAYONNEMENT HAUTE FR QUENCE risque de provoquer des interf rences e Le rayonnement haute fr quence H F peut provoquer des interf rences avec les quipe ments de radio navigation et de communica tion 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 e Lutilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l ap pareil LE SOUDAGE L ARC risque de provoquer des interf rences e l nergie lectromagn tique risque de provo quer des interf rences pour l quipement lec tronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots e Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement e Pour r duire la possibilit d interf rence maintenir les cables de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre e Veiller souder une distance de 100 metres de tout quipe ment lectronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre confor
85. itive voltage sensing lead is contained in the motor cable 12 Positive Weld Cable Ref 803 244 B Ref 801 915 A OM 210 540 Page 13 3 7 Rear Panel Receptacles And Supp OM 210 540 Page 14 lementary Protectors 1 115V 10 A AC Receptacle RC2 Receptacle supplies 60 Hz single phase power Maximum output from RC2 is limited by supplementary protector to 10 amps 2 Supplementary Protector 3 Supplementary Protector CB2 CB1 protects 115 volt receptacle RC2 from overload If CB1 opens RC2 does not work CB2 protects the wirefeed motor from overload If CB2 opens the wirefeeder does not work gt Press button to reset breaker If breaker continue to open contact a Factory Authorized Service Agent 4 Wirefeed Gas Receptacle RC8 Use receptacle to connect gas and motor control cable to power source see Sections 3 6 and 8 for additional information 5 Peripheral Receptacle RC25 Receptacle provides connection to touch sensor water flow switch jog and I O relay contacts circuitry see Section 3 10 6 Robot Interface Receptacle RC72 Use receptacle to connect robot input output cable see Sections 3 6 and 8 for additional information Ref 803 245 B 3 8 Connecting To Weld Terminals gt If using an electrode negative straight polarity process the volt sense lead must be connected to the work Tools Needed 3 4 in 19mm Turn off powe
86. ize contactor Off Input signal Off from robot to not energize contactor 3 On Input signal On remote program A selected Off Input signal Off remote program A not selected 4 On Input signal On remote program C selected Off Input signal Off remote program C not selected 5 On Input signal On from E stop board PC12 for no emergency stop Off Input signal Off from E stop board PC12 acknowledges E stop is On from robot 6 On Spare 1 not assigned Off Spare 1 not assigned 7 On Input signal On Autoset C selected Off Input signal Off Autoset C not selected 8 On Input signal On Autoset B selected Off Input signal Off Autoset B not selected 9 On Input signal On Remote Jog on from peripheral plug Off Input signal Off Remote Jog off from peripheral plug 10 On Input signal On Remote Purge on from peripheral plug Off Input signal Off Remote Purge off from peripheral plug 11 On Input signal On from robot for jog retract Off Input signal Off from robot for no jog retract 12 On Input signal On from robot for purge Off Input signal Off from robot for no purge 13 On Input signal On remote program B selected Off Input signal Off remote program B not selected 14 On Input signal On Touch Sensor on from robot or peripheral plug Off Input signal Off Touch Sensor off from robot or peripheral plug 15 On Spare 0 not assigned Off Spare 0 not assigned 16 On Spare 2 not assigned Off Spare 2 not assigned 17 On Input signal On Autoset A selected Off Input signal Off Autoset A not s
87. khead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see 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 OM 210 540 Page 2 Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use Wear oil 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 After completion of work inspect area to ensure it is free of sparks glowing embers and flames Use only correct fuses or circuit breakers Do not oversize or by pass them Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL or DIRT can injure eyes Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet BUILDUP OF GAS c
88. le tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaussures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos po ches telles qu un allumeur au butane ou des allumettes e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes e Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Une fois le travail achev assurez vous qu il ne reste aucune trace d tincelles incandescentes ni de flammes Utiliser exclusivement des fusibles ou coupe circuits appropri s Ne pas augmenter leur puissance ne pas les ponter e Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PIECES DE METAL ou DES Ep SALETES peuvent provoquer des blessures dans les yeux e Le soudage l caillement le passage de la piece la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la 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 cran facial LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur cas de non utilisati
89. ly on grinder with proper guards in a safe location wearing proper face hand and body protection e Sparks can cause fires keep flammables away e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards le MOVING PARTS cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury Do not press gun trigger until instructed to do 50 e Do not point gun toward any part of the body other people or any metal when threading welding wire 53 STATIC ESD can damage PC boards MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place se e Have only qualified persons remove doors panels covers or guards for maintenance as necessary e Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS e Read Owner s Manual before using or servic ing unit e Use only genuine replacement parts from the manufacturer H F RADIATION can cause interference 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
90. m ment ce mode d emploi e En cas d interf rences apr s avoir pris les mesures pr c den tes 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 protec teurs dans la zone de travail 2 4 Proposition californienne 65 Avertissements Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l Etat de Californie reconna t qu ils provoquent des mal formations cong nitales et dans certains cas des cancers Code de sant et de s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimi ques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipu lation OM 210 540 Page 8 Pour les moteurs essence Les gaz d chappement des moteurs contiennent des duits chimiques dont l Etat de Californie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel Les gaz d chappement des moteurs diesel et certains de leurs composants sont reconnus par l Etat de Californie com me provoquant des cancers et d
91. n not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a separate cable Do not touch electrode if you are in contact with the work ground or another electrode from a different machine Do not touch electrode holders connected to two welding ma chines at the same time since double open circuit voltage will be present Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level 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 Insulate work clamp when not connected to workpiece to prevent contact with any metal object Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverter type welding power sources after removal of input power Turn Off inverter disconnect input power and discharge input Capacitors according to instructions in Maintenance Section before touching any parts HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling period before working on gun or torch To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to
92. ntactor DEF PRP 404 24VAC Coil W Boxlug 1 eae 213386 Assembly Filter Primary 1 12 HD2 182918 Transducer Current 400A Module Supply V 15V 1 LS umore bots 198951 Block Terminal 3 Pole 1 ues 148025 Lug Univ W SCR 600 2 0 6 Wire 266 Stud 1 SEE NEN 213372 Filter Assy Secondary 2 matos Fig 9 5 Front Panel Assembly 1 eee 227855 Kit Connectors W Washer For Power Cables Includes 1 ere ee ee ere 010467 Connector Clamp Cable 1 250 1 te Ordi 225840 Washer Reducer 1 25 in 0 75 1 2 TWO Sr uns aes 010916 Connector Clamp Cable 0 750 1 Recommended Spare Parts When ordering a component originally displaying a precautionary label the label should also be ordered 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 55 802 955 A Figure 9 2 Windtunnel Assembly LH And RH OM 210 540 Page 57 No Mkgs No Des
93. on e Veiller toujours bien a rer les espaces confi n s ou se servir d un respirateur d adduction d air homologu LES CHAMPS MAGNETIQUES peuv ent affecter des implants m dicaux e Porteur de simulateur cardiaque ou autre im plants m dicaux rester distance e Les porteurs d implants doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de sou par points de gougeage du coupage plasma ou de chauf fage par induction LE BRUIT peut endommager l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv es pour les oreilles si le niveau sonore est trop lev LES BOUTEILLES peuvent exploser si elles sont endommag es Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de sou dage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les 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 Tenirles bouteilles loign es des circuits de soudage ou autres circuits lectriques e Ne jamais placer
94. on 7 12 OM 210 540 Page 40 7 8 User Interface Module PC7 Diagnostic LED s D 08 020 022 023 024 025 027 031 Q3 e a e LED1 3l d CE 021 026 JE R46 010 m5 CLK1 aon R34 m m ago BE RT mof LED2 OOT ITIR o RJ S s zu 5 LEDI T m aTa E e mulo RESET 54 05 om omm 5 06 E Init 2 m ym E meee gt gt R2 m 2 a o Qu LE an 73 ___________ _ R49 LED3 Save ee 5 mem mur 08 m 65 14188 a Wa 08 a a r gpm 299 iti H e ae ER gu 1 zs 2 nas num LLL RI RPC 22 ee J2 d a a mua 04 Pr ARE LU Ven ll la m 5 mea C66 m 7 595888 an 02 gt N 2 BERNINA gf op eu c10 C64 c65 e RB n5 R45 jog e 2 el le oa aem a 20 e o o AL He RIRE rz
95. or indicates input power is outside of unit operating range Check and correct input power Press Jog Purge button to clear error ERR ARC e The arc error indicates an arc outage occurred possibly from a wire feeder error or power source error Check wire feeder and power source Press Jog Purge button to clear error OM 210 540 Page 35 7 2 Diagnostics Continued Low Indicates a UIM communication error ROBT STOP Indicates a CRC robot memory error Indicates an emergency stop error Indicates a low WFS command error Indicates a motor communication error Indicates a weld cycle wait error Indicates RMD demo is done Indicates an over WELD WAIT e The weld wait error indicates unit was not ready for a weld sequence Press Jog Purge button to clear error MOTR COM e The motor communication error indi cates motor board lost data communica tions Press Jog Purge button to clear error If condition persists contact nearest factory authorized service agent PLS WAIT e The uim communication error indicates user interface board lost data communications Press Jog Purge button to clear error If condition persists contact nearest factory authorized service agent LOW WFS e The low wire feed speed error indicates actual wire feed speed is lower than wire feed speed command Check for obstructions in the wire feed system or a faulty wire drive system Press Jog Purge b
96. played with the program number if the program has been changed from the factory settings using the optional PDA with File Management WaveWriter software see File Management WaveWriter Owner s Manual The program cannot be changed through the front panel while welding Press and hold button to see program name Custom programs are named using optional OM 210 540 Page 24 PDA with File Management WaveWriter software Program name is shown in upper and lower displays items 13 and 15 5 Setup Mode Indicators The lit LED indicates which setup mode is active Setup mode parameters are shown in Display Windows see Items 13 and 15 Process LED When this LED is lit turn the Adjust knob to select the desired weld process Choices include pulse welding displayed as PULS Accu pulse MIG welding MIG and Accu Puls RMD Regulated Metal Deposition optional Wire Type LED When this LED is lit turn the Adjust knob to select the desired wire type wire alloy and size Wire type and size choices vary according to the selected weld process Choices may include steel displayed as SIL stainless steel SS metal core MCOR aluminum ALUM See Table 4 1 for all wire abbreviations 198 993 Gas Type LED When this LED is lit turn the Adjust knob to select the desired weld gas Gas type choices vary according to the selected weld process See Table 4 1 for all gas abbreviations 6 Setup Push Button LED The L
97. prevent burns OM 210 540 Page 1 FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use local forced ventilation at the arc to remove welding fumes and gases If ventilation is poor wear an approved air supplied respirator Read and understand 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 level causing injury or death Be sure the breath ing air is safe Do not weld in locations near degreasing cleaning or spraying op erations 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 while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays
98. propriate 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 t
99. r before connecting to weld output terminals Failure to properly connect weld cables may cause excessive heat and start a fire or damage your machine Determine total cable length in weld circuit both positive and negative cables combined and maximum welding amperes See Section 3 9 to select proper Do not place anything between weld cable terminal and copper bar Correct Installation cable size 1 Positive Weld Output Terminal 2 Negative Weld Output Terminal Connect positive weld cable to Positive weld terminal and negative cable to Negative weld terminal 3 Output Terminal 4 Supplied Weld Output Terminal Nut 5 Weld Cable Terminal Incorrect Installation Ref 803 244 B 803 778 A 6 Copper Bar Remove supplied nut from weld output terminal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against copper bar Do not place anything between weld cable terminal and copper bar Make sure that the surfaces of the weld cable terminal and copper bar are clean OM 210 540 Page 15 3 9 Selecting Weld Cable Sizes A ARC WELDING can cause Electromagnetic Interference To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operation 100 meters from any sensitive electronic equipment Be sure this welding machine is installed and ground
100. rameters of any kind are present in the robot program The welding power source is looking for 2 distinct welding conditions If there is a start power condition the welding power source will equate this as the first condition and fail to execute Auto Cal correctly If there is a crater fill condition the welding power source will equate this as the second condition and fail to execute Auto Cal correctly Actual Motoman Welder Condition File lt Welding Current Output Char gt NO REF V MEASURE A 01 0 01 1 02 7 00 500 03 13 99 999 04 0 00 000 lt Welding Voltage Output Char gt NO REF MEASURE V 01 0 14 0 5 02 7 00 25 0 03 14 00 50 0 04 Sample Auto Calibration Routine For Motoman Robot 0000 NOP 0001 Mov J 0002 AWELD 1 40 AWELD direct input of 1 40Volts 100 ipm 0003 VWELD 2 80 VWELD direct input of 2 80Volts 10 0 volts 0004 Arcon 0005 Timer T210 00 0006 Arcof 0007 AWELD 14 00 AWELD direct input of 14 00 Volts 1000 ipm 0008 VWELD 12 32 VWELD direct input of 12 32Volts 44 0 volts 0009 Arcon 0010 Timer T 10 00 0011 Arcof 0012 End OM 210 540 Page 28 Sample Auto Calibration Routine For Fanuc Robot 1 Safehome 2 40 Fine Arcstart 10 0Volts 100 0IPM 3 LP 2 10 0 sec Fine Arc End 0 0Volts 0 0IPM 0 0Sec 4 Wait 1 00 Sec 5 J P 3 40 Fine Arcstart 44 0Volts 1000 0IPM 6 L P 4 10 0 sec Fine Arc End 0 0Volts 0 0IPM 0 0Sec 7 Call Saf
101. resent on process control module PC4 2 On Indicates 25 volts dc is present on process control module PC4 Off Indicates 25 volts dc is not present on process control module PC4 3 4 On See Network Status Table in Section 7 12 Off See Network Status Table in Section 7 12 OM 210 540 Page 39 7 6 Wire Feed Module PC6 Diagnostic LED s And Dip Switch Settings 1 Wire Feed Module PC6 2 Diagnostic LED s are visible inside unit located on PC6 mounted on the top tray assembly Refer to Section 7 7 for information on diagnostic LED s Reinstall top cover after checking diagnostic LED s 2 Dip Switch 51 Dip switches are used to identify each circuit board on the internal network Dip switch settings are different for each circuit board For proper operation do not change dip settings from those shown LED1 p DT S a ETE EX Geo Ose LED2 1 5 M1 __ 83000843 36836 WY CL R77 ad C 021 217 333 803 251 7 7 Diagnostic LED s On Wire Feed Module PC6 LED Status Diagnosis 1 On Indicates 15 volts dc is present on wire feed module PC6 Off Indicates 15 volts dc is not present on wire feed module PC6 2 On Indicates 5 volts dc is present on wire feed module PC6 Off Indicates 5 volts dc is not present on wire feed module PC6 3 4 On see Network Status Table in Section 7 12 Off See Network Status Table in Secti
102. rocedure for entering program Enters selected program information process wire type gas etc into program slot 1 8 Preset voltage in MIG mode at idle actual voltage while welding and 3 seconds hold value at end of weld Indicates time values being set for timed functions e g Preflow Postflow which are only available in the Arc On and Analog input or the Arc On and No Analog input modes Distance from end of wire electrode to workpiece Term used to represent wire feed speed In MIG mode wire feed setting is independent of voltage setting In pulse Accu pulse and RMD optional adjusting wire feed speed also increases power level on wire electrode one knob control Indicates average amperage while welding and 3 seconds hold value at end of weld Pressing this button will allow setting of inductance in MIG mode and sharp arc in pulse Accu pulse and RMD optional In short circuit GMAW welding an increase in inductance will decrease the number of short circuit transfers per second provided no other changes are made and increase the arc on time The increased arc on time makes the welding puddle more fluid In pulse and Accu pulse mode this adjustment changes the arc cone by adjusting the preprogrammed factory pulse data In RMD optional this control will affect the arc in much the same way as inductance Control knob used to change or set parameters and functions Selecting Sequence will allow setting of preflow
103. specific errors Explanations are in the text below Indicates a motor error Indicates a tachometer error Indicates a coolant flow error Indicates a ground current error ERR TACH e Tach error for Tach A occurs 2 seconds after the loss of tachometer feedback The motor speed is regulated through the monitoring of voltage and current Press Jog Purge button to clear error Tach error for Tach B occurs 2 seconds after the loss of tachometer feedback The motor speed is regulated through the monitoring of voltage and current Press Jog Purge button to clear error ERR MOTR e The motor error indicates that the motor has been drawing too much current for too long To remedy this reduce the wire feed speed or the wire feeder torque load duty cycle Press Jog Purge button to clear error ERR WFS e The wire feed speed error indicates actual wire feed speed does not match wire feed speed command Press Jog Purge button to clear error ERR STRT e The start error when enabled occurs if the trigger is held longer than three seconds without an arc start The error may be cleared by releasing the trigger and pressing the Jog Purge button Indicates an arc start error Indicates a wire feed speed error Indicates a temperature error Indicates a wire stuck error ERR STOP e The stop error occurs as result of obstructions in the wire feed system or a faulty wire drive system Check wire feed and
104. start crater postflow and retract times and parameters only available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes Setting a time value for gas flow prior to arc start only available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes and can only be set with the optional PDA with File Management software 4 1 Operational Terms Continued Start Weld Crater Postflow Retract Auto Thread Provides voltage arc adjust wire feed rate and time value for modified arc starts only available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes and can only be set with the optional PDA with File Management software Sequence function that allows for a timed weld operation 0 to 999 seconds only available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes and can only be set with the optional PDA with File Management software Allows setting of voltage arc adjust wire feed rate and time value for arc ends only available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes and can only be set with the optional PDA with File Management software Setting a time value for gas flow after arc end only available on Auto Axcess models in the Arc On and Analog input or the Arc On and No Analog input modes and can only b
105. ts dc is present on automation interface module PC9 Off Indicates 15 volts dc is not present on automation interface module PCY 29 On Input signal on from relay K6 for arc detected Off Input signal off from relay K6 for no arc detected 30 31 On See Network Status Table in Section 7 12 Off See Network Status Table in Section 7 12 32 On Input signal on for aux relay energized Off Input signal off for aux relay energized 33 On Input signal on touch sensor touch detected Off Input signal off touch sensor touch not detected OM 210 540 Page 44 7 12 Network And Module Status LED s A Network Status LED s The following are network status LED s LED1 on the UIM circuit board LED4 on the WFM and PCM circuit boards LED30 on the AIM circuit board Status Diagnosis Off The circuit board is not on line with the network or there is no power applied to the circuit board Green The circuit board is operating normally and the on line connection is made with the network Flashing Green The circuit board is waiting for an on line connection to be made with the network Red The circuit board has encountered a communication link failure with the network Check DeviceNet cable connections Verify dip switch positions according to Sections 1 2 and 1 3 Replace circuit board if necessary B Module Status LED s The following are module status LED s LED2 on the UIM circuit board LED3 on the WFM and PCM circuit
106. une torche de soudage sur une bouteille gaz e Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille 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 D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille e Le couvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur e Utiliser les quipements corrects les bonnes proc dures et suffi samment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s cu rit 2 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU D EXPLO SION e Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Nepasinstaller l appareil proximit de pro duits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimentationest correctement dimensionn e et prot g e avant de mettre l appareil en service LA
107. urves CV MODE Volt ampere curves show minimum and maximum voltage amperage output capabilities of unit Curves of other settings fall between curves shown 7 This volt ampere curve represents the dynamic output of the unit with a static load va curvel 4 95 220 486 OM 210 540 Page 12 3 5 Selecting A Location Tipping A Do not move or operate unit where it could tip Location A Do not stack units Beware of A Special installation may be required where gasoline or volatile tipping liquids are present see NEC Article 511 or CEC Section 20 1 Lifting Forks Use lifting forks to move unit Extend forks beyond opposite side of unit 2 Hand Cart Use cart or similar device to move INPUT SERIAL NO S 6 unit p Mus 4 3 Rating Label VOLTS Use rating label to determine input AMPERES KW S power needs PHASE SEN 1 4 Line Disconnect Device Locate unit near correct input power supply loc 2 3 96 Ref 803 244 B gt The proper interface kit must be installed in the welding power source interface unit to allow it to be connected to the robot Robot Will Vary According To Application Motor Drive Assembly Gas Cylinder Gas Hose Robot Control Robot Input Output Cable Gas And Motor Control Cable Welding Power Source Interface Unit 9 Negative Weld Cable 10 Workpiece 11 Voltage Sensing Lead Recommended for Accu pulse and RMD optional gt Pos
108. utton to clear error OM 210 540 Page 36 average current error Indicates a CRC PCM bus error Indicates an overcurrent error ROBT MEM e The robot memory error indicates robot lost memory data Press Jog Purge button to clear error E STOP e The emergency stop error occurs if the user presses an emergency stop button Reset the emergency stop button and press Jog Purge button to clear error Only applies to units equipped with E stop option RMD DONE e The RMD done message indicates the RMD demo is completed Pressing Jog Purge button will change the screen to CYCL PWR on the display Turn unit power off and back on again OVER AVG e The over average error indicates that current is outside the average range for the set program parameters Check and correct program parameters Press Jog Purge button to clear error UNIT COMM e The unit communication error indicates the data bus on the PCM board is not functioning properly Press Jog Purge button to clear error OVER CRNT e The over current error indicates welding power source primary current of the inverter 15 too high Turn welding power source off and disconnect unit for servicing Attempting to reset the display to continue welding may further damage internal components complete prepower check of the unit is needed including resistance measurements of R1 and R8 resistors on welding power source Interconnect board Resistors should measure 30K
109. wire drive systems Press Jog Purge button to clear error ERR FLOW e The flow error indicates no gas flow to the gun The error may be reset by reestablishing gas flow to the gun and then pressing the Jog Purge button ERR COOL e The cool error indicates no coolant flow in water flow switch option The error may be reset by reestablishing coolant flow to the gun and then pressing the Jog Purge button ERR GND e The ground current error occurs if weld current is detected in the earth ground connection May be caused by a conductor making contact with unit chassis Check and repair feeder weld connections Turn power off and back on to clear error Indicates an arc stop error Indicates a gas flow error ARC Indicates an arc error Indicates a line error ERR STUK e The stuck error occurs if the welding wire sticks to the workpiece at the end of a weld May be caused by poor weld conditions The error may be cleared by cutting wire from workpiece and pressing the Jog Purge button ERR TEMP e The temperature error indicates welding power source has overheated and shutdown The error may be cleared by allowing unit to cool down and pressing the Jog Purge button If problem persists check fan motors and thermistors for proper operation If unit is not overheated check in put line voltage If input line voltage is okay contact nearest factory authorized Service Agent ERR LINE e The line err
110. xer d abord le conduc teur de mise la terre appropri et contre v rifier les connexions e les cables doivent tre exempts d humidit d huile et de graisse prot gez les contre les tincelles et les pi ces m talliques chaudes e V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou nu le remplacer imm diatement s il l est Un fil nu peut entrainer la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des cables us s endommag s de grosseur insuffi sante ou mal piss s e Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine e Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide dou bl e e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si l on doit travailler au dessus du sol S assurer que tous les panneaux et couvercles sont correctement en place e Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de
111. ys Parts MIG Guns TIG Torches and Subarc SAW Guns Induction Heating Coils and Blankets Cables and Non Electronic Controls APT amp SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Millers True Blue Limited 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 ap

Download Pdf Manuals

Related Search

Related Contents

KEETEC bS 400, bS 400 LED PARKING SENSOR USER MANUAL  FORD FOCUS Guia rápido  PDF  12-MAI 2014 fiche engrais Universel Bleu 12-10-15  MEGA - Profibus-DP  Convecto v3.0 User Manual    HP R847 Quick Start Manual  Soleus Air WA1-02-21 User's Manual  User`s Manual  

Copyright © All rights reserved. Failed to retrieve file