Miller Electric Welder Owner's Manual
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Miller Electric Welder Owner's Manual

Operating instructions and programming instructions
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Operating Instructions and
Programming Instructions for
Auto Invision II
OM-196 188K
July 2003
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Automatic Welding
Description
Automatic Welding Interface And
Arc Welding Power Source

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Summary of Contents for Miller Electric Welder

  • Page 1 Auto Invision II Visit our website at www.MillerWelds.com Operating Instructions and Programming Instructions for OM-196 188K July 2003 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding Automatic Welding Description Automatic Welding Interface And Arc Welding Power Source...
  • Page 2 ISO 9001:2000 Quality System 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 catalog sheets.

  • Page 3: Table Of Contents

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. 1-2. 1-3. 1-4. WARNING 1-5. SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION This product, when used 1-1. for welding or cutting, 1-2. produces fumes or 1-3. gases which contain chemicals known to the 1-4.
  • Page 4 TABLE OF CONTENTS SECTION 8 – INTRODUCTION TO PROGRAMMING 8-1. Pulse MIG Programs ............8-2.
  • Page 5 TABLE OF CONTENTS SECTION 14 – SETUP ..............14-1.
  • Page 6 Declaration of Conformity For European Community (CE) Products Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W. Spencer Street Manufacturer’s Address: Appleton, WI 54914 USA Auto Invision II Declares that the product: conforms to the following Directives and Standards: Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC...

  • Page 7: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. 1-2.
  • Page 8 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit.

  • Page 10: Emf Information

    1-5. 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 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 committee’...

  • Page 11: Section 1 - Consignes De Securite - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. Signifie NOTA ;...
  • Page 12 LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

  • Page 13: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. D Ne pas placer l’appareil sur, au-dessus ou à proxi- mité de surfaces infllammables. D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique –...

  • Page 14: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

  • Page 15: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Manufacturer’s Warning Label Definitions S-179 310 Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand.
  • Page 16 = <60 OM-196 188 Page 10 > 60 s S-179 309-A Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Hazardous voltage remains on input capacitors after power is turned off.

  • Page 17: Symbols And Definitions

    2-2. Symbols And Definitions Amperage Output 2-3. Manufacturer’s Rating Label 2-4. Harmonic Data HARMONIC DATA per IEC 61000-3-12, draft 2000-9-29 PRIMARY; 400V/30.5A/60hz LOAD; R sce = 227.28 61 Amps PWHD 35 Amps Table 4, balanced three phase equipment. Positive Circuit Breaker Inductance 450A/38Vdc/390IPM/,MAXIMUM OUTPUT, GMAW.

  • Page 18: Section 3 - Installation

    SECTION 3 – INSTALLATION 3-1. Specifications Input Input Rated Welding Rated Welding Voltage Voltage Power Power Output Output Range Range 450 A @ 38 Volts DC, 450 A @ 38 Volts DC, Three Three 100% Duty Cycle; 100% Duty Cycle; 10 –...

  • Page 19: Selecting A Location

    3-3. Selecting A Location Movement Location Y Special installation may be required where gasoline or volatile liquids are present – see NEC Article 511 or CEC Section 20. 18 in (460 mm) 3-4. Connection Diagram Tipping 18 in (460 mm) Y Do not move or operate unit where it could tip.

  • Page 20: Weld Output Terminals And Selecting Cable Sizes

    3-5. Weld Output Terminals And Selecting Cable Sizes Welding Amperes Positive Positive Negative Negative (–) (–) Ref. 801 914-A Ref. 801 914-A *Weld cable size (mm ) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. 3-6.

  • Page 21: Electrical Service Guide

    3-7. Electrical Service Guide Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil Reference: 1993 National Electrical Code (NEC).

  • Page 22: Rear Panel Connections

    3-9. Rear Panel Connections Example Receptacle OM-196 188 Page 16 Receptacle Keyway 4-Pin Receptacle (Optional External Voltage Sensing Connection) To connect interconnecting cord to receptacle, align keyway, insert plug, and tighten threaded collar. Secure ring terminal on remaining end of cord to work. Peripheral Receptacle Receptacle provides connection to touch sensor, water flow switch, jog...

  • Page 23: Peripheral Receptacle Functions

    3-10. Peripheral Receptacle Functions *Circuit common is same electrical reference point. **Speed of Jog + and Jog – is at setup value for Jog IPM parameter. { Socket M can be changed to 0 volts dc (common) for part touched output signal (see Section 3-12). Note: A customer supplied matching amphenol plug [Miller Part No.

  • Page 24: Touch Sensor Operation

    3-11. Touch Sensor Operation The touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source. Voltage sense leads 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.

  • Page 25: Connecting Setup Pendant To Welding Power Source

    3-13. Connecting Setup Pendant To Welding Power Source Disconnect the setup pendant from the welding power source before welding. Y Turn Off welding power source and weld control. Welding Power Source Interconnecting Cord Setup Pendant To make connections, align plug with receptacle, insert plug, and use thumb screws on receptacle to secure plug.

  • Page 26: Section 4 - Operation

    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: Adaptive Pulse Welding When the “adaptive pulse” welding process is selected, the unit will attempt to automatically regulate pulse frequency in order to maintain a constant arc length, regardless of change in welding wire stick- out.

  • Page 27: Lower Front Panel Controls

    System Reset By selecting system reset in the memory reset mode, the unit defaults to original factory settings for all programs and all set up excluding System, Arc Time, and Model Type. Voltage (Control Feedback) Allows voltage to be monitored at the output terminals by two methods. This can be selected through the internal connections of the unit, or through the unit’s external voltage sense lead.

  • Page 28: Upper Front Panel Controls

    4-4. Upper Front Panel Controls Setup Pendant Receptacle Receptacle connecting pendant interconnecting cord. Jog Forward Push Button Advances wire out of the gun. Wirefeed Indicator LED LED lights when wire feed motor is energized. OM-196 188 Page 22 Jog Reverse Push Button Retracts wire up into the gun.

  • Page 29: Duty Cycle And Overheating

    4-5. Duty Cycle And Overheating 100% Duty Cycle At 450 Amperes Continuous Welding Overheating 4-6. Volt-Ampere Curves 60% Duty Cycle At 565 Amperes 6 Minutes Welding Reduce Duty Cycle Minutes Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating.

  • Page 30: Setup Pendant Controls

    4-7. Setup Pendant Controls Increase Button Works with security feature on welding power source to allow increasing weld parameter values within the allowable range. Decrease Button Works with security feature on welding power source to allow decreasing weld parameter values within the allowable range. OM-196 188 Page 24 Parameter Select Button Press button to move indicator in right...

  • Page 31: Section 5 - Maintenance & Troubleshooting

    SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance 3 Months Replace damaged or unreadable label. Repair or replace cracked cables and cords. Clean and tighten weld terminals. 5-2. Blowing Out Inside Of Unit Y Disconnect power before maintaining. Repair or replace cracked cables.

  • Page 32: Removing Case And Measuring Input Capacitor Voltage

    5-3. Removing Case and Measuring Input Capacitor Voltage Y Significant DC voltage can remain on capacitors af- Tools Needed: 5/16 in + lead to lower right terminal, – lead to upper right terminal OM-196 188 Page 26 ter unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged be- fore working on unit.

  • Page 33: Voltmeter/Ammeter Help Displays

    5-4. Voltmeter/Ammeter Help Displays All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. Help 1 Display Indicates a malfunction in the primary power circuit. If this display is shown, contact a Factory Authorized Service Agent.

  • Page 34: Front Panel Error Displays

    5-5. Front Panel Error Displays M e m C R C E r r o r M e m R a n g e E r r V o l t S e n s e d T a c h S e n s e d A r c S t o p...

  • Page 35: Weld Interface Board Pc12 Diagnostic Led's

    5-6. Weld Interface Board PC12 Diagnostic LED’s LED2 LED4 LED6 LED7 LED5 LED3 LED1 LED10 LED8 LED11 LED9 LED12 Top View Weld Interface Board PC12 Diagnostic LED’s are visible inside unit, located on PC12 (see illustration for board location). Refer to Section 5-7 for information on diagnostic LED’s.

  • Page 36: Diagnostic Led's On Weld Interface Board Pc12

    5-7. Diagnostic LED’s On Weld Interface Board PC12 Status Indicates auxiliary output relay is not energized. Indicates auxiliary output relay is energized. Indicates gas valve is not energized. Indicates gas valve is energized. Indicates +24 volts dc is present for gas valve. Indicates +24 volts dc is not present for gas valve.

  • Page 37: Customer Interface Board Pc14 Diagnostic Led's

    5-8. Customer Interface Board PC14 Diagnostic LED’s LED4 LED3 LED2 LED1 LED8 LED12 LED6 LED14 LED10 LED9 LED7 LED11 LED13 LED5 Top View Customer Interface Board PC14 Diagnostic LED’s are visible inside unit, located on PC14 (see illustration for board location). Refer to Section 5-9 for information on diagnostic LED’s.

  • Page 38: Diagnostic Led's On Customer Interface Board Pc14

    5-9. Diagnostic LED’s On Customer Interface Board PC14 Status Indicates –15 volts dc RA supply is present on customer interface board PC14. Indicates –15 volts dc RA supply is not present on customer interface board PC14. Indicates +15 volts dc RA supply is present on customer interface board PC14. Indicates +15 volts dc RA supply is not present on customer interface board PC14.

  • Page 39: Motor Board Pc13 Diagnostic Led's

    Status Input signal On from peripheral for jog advance. Input signal Off from peripheral for no jog advance. Input signal On from peripheral for jog retract. Input signal Off from peripheral for no jog retract. Input signal On from peripheral for shielding gas purge. Input signal Off from peripheral for no shielding gas purge.

  • Page 40: Diagnostic Led's On Motor Board Pc13

    5-11. Diagnostic LED’s On Motor Board PC13 Status Indicates motor reverse relay is energized. Indicates motor reverse relay is not energized. LED should be On. Indicates 115 volts ac input is sufficiently charging +170 volts dc bus for motor. If LED is Off, check 115 volts ac input. LED should be On.
  • Page 41 Notes OM-196 188 Page 35...

  • Page 42: Section 6 - Electrical Diagrams

    SECTION 6 – ELECTRICAL DIAGRAMS Figure 6-1. Circuit Diagram For Welding Power Source OM-196 188 Page 36...
  • Page 43 203 505-A OM-196 188 Page 37...
  • Page 44 Figure 6-2. Circuit Diagram For Control Board PC1 (Part 1 of 3) OM-196 188 Page 38...
  • Page 45 203 311 (1 of 3) OM-196 188 Page 39...
  • Page 46 Figure 6-3. Circuit Diagram For Control Board PC1 (Part 2 of 3) OM-196 188 Page 40...
  • Page 47 203 311 (2 of 3) OM-196 188 Page 41...
  • Page 48 Figure 6-4. Circuit Diagram For Control Board PC1 (Part 3 of 3) OM-196 188 Page 42...
  • Page 49 203 311 (3 of 3) OM-196 188 Page 43...
  • Page 50 Figure 6-5. Circuit Diagram For Function/Meter Board PC3 OM-196 188 Page 44...
  • Page 51 190 696 OM-196 188 Page 45...
  • Page 52 184 183 Figure 6-6. Circuit Diagram For Interconnect Board PC2 188 015 Figure 6-7. Circuit Diagram For Gate Boards PC4 And PC5 OM-196 188 Page 46...
  • Page 53 Notes OM-196 188 Page 47...
  • Page 54 Figure 6-8. Circuit Diagram For Interface Module OM-196 188 Page 48...
  • Page 55 193 709-A OM-196 188 Page 49...
  • Page 56 Figure 6-9. Circuit Diagram For Microprocessor Board PC11 OM-196 188 Page 50...
  • Page 57 191 838 OM-196 188 Page 51...
  • Page 58 Figure 6-10. Circuit Diagram For Motor Board PC13 OM-196 188 Page 52...
  • Page 59 212 354-A OM-196 188 Page 53...
  • Page 60 182 996 Figure 6-11. Circuit Diagram For Switch Board PC15 OM-196 188 Page 54...
  • Page 61 200 739 Figure 6-12. Circuit Diagram For Junction Board PC16 OM-196 188 Page 55...
  • Page 62 Figure 6-13. Circuit Diagram For Interface Board PC12 (Part 1 of 2) OM-196 188 Page 56...
  • Page 63 191 843-A (Part 1 of 2) OM-196 188 Page 57...
  • Page 64 Figure 6-14. Circuit Diagram For Interface Board PC12 (Part 2 of 2) OM-196 188 Page 58...
  • Page 65 191 843-A (Part 2 of 2) OM-196 188 Page 59...
  • Page 66 Figure 6-15. Circuit Diagram For Customer Interface Board PC14 (Part 1 of 3) OM-196 188 Page 60...
  • Page 67 Pensar 86147s03 (Part 1 of 3) OM-196 188 Page 61...
  • Page 68 Figure 6-16. Circuit Diagram For Customer Interface Board PC14 (Part 2 of 3) OM-196 188 Page 62...
  • Page 69 Pensar 86147s03 (Part 2 of 3) OM-196 188 Page 63...
  • Page 70 Figure 6-17. Circuit Diagram For Customer Interface Board PC14 (Part 3 of 3) OM-196 188 Page 64...
  • Page 71 Pensar 86147s03 (Part 3 of 3) OM-196 188 Page 65...
  • Page 72 174 578-A Figure 6-18. Circuit Diagram For Touch Sensor Board PC18 OM-196 188 Page 66...
  • Page 73 200 739-A Figure 6-19. Circuit Diagram For Setup Pendant OM-196 188 Page 67...
  • Page 74 200 739 Figure 6-20. Circuit Diagram For Setup Pendant Centronix Junction Board PC3 OM-196 188 Page 68...
  • Page 75 191 531 Figure 6-21. Circuit Diagram For Power Distribution Board PC20 OM-196 188 Page 69...

  • Page 76: Section 7 - Parts List

    SECTION 7 – PARTS LIST Hardware is common and not available unless listed. 802 872-D Figure 7-1. Complete Assembly OM-196 188 Page 70...
  • Page 77 Item Dia. Part Mkgs....185 970 ..... . 195 585 .
  • Page 78 Item Dia. Part Mkgs....185 231 ... . . RC10 ..166 679 .
  • Page 79 Item Dia. Part Mkgs..... . . 144 844 ..... . 091 772 .
  • Page 80 Notes OM-196 188 Page 74...
  • Page 81 OM-196 188K July 2003 Programming Instructions for Auto Invision II...

  • Page 82: Section 8 - Introduction To Programming

    SECTION 8 – INTRODUCTION TO PROGRAMMING 8-1. Pulse MIG Programs Selecting hardwire or softwire is done during setup (see Section 14) Program Hardwire Selected .035” Steel, Argon – Oxy .045” Steel, Argon – Oxy .035” Steel, Argon – CO2 .045” Steel, Argon – CO2 .035”...

  • Page 83: Program 1 - 1.2 Mm Steel (.045"), 98-2 Argon-Oxy

    8-3. Program 1 – 1.2 mm Steel (.045”), 98-2 Argon-Oxy Wire Size/Type: 1.2 mm (.045”) Steel MPM / IPM 19.1 / 750 17.8 / 700 16.5 / 650 15.2 / 600 14.0 / 550 12.7 / 500 11.4 / 450 10.2 / 400 8.9 / 350 7.6 / 300...

  • Page 84: Program 3 - 1.2 Mm Steel (.045"), 80-20 Argon-Co2

    8-5. Program 3 – 1.2 mm Steel (.045”), 80-20 Argon-CO Wire Size/Type: 1.2 mm (.045”) Steel MPM / IPM 19.1 / 750 17.8 / 700 16.5 / 650 15.2 / 600 14.0 / 550 12.7 / 500 11.4 / 450 10.2 / 400 8.9 / 350 7.6 / 300...

  • Page 85: Program 5 - 1.0 Mm 316 (.040"), 98-2 Argon-Co2

    8-7. Program 5 – 1.0 mm 316 (.040”), 98-2 Argon-CO Wire Size/Type: 1.0 mm (.040”) 316 MPM / IPM 19.1 / 750 17.8 / 700 16.5 / 650 15.2 / 600 14.0 / 550 12.7 / 500 11.4 / 450 10.2 / 400 8.9 / 350 7.6 / 300...

  • Page 86: Program 7 - 1.0 Mm 308L (.040"), 98-2 Argon-Co2

    8-9. Program 7 – 1.0 mm 308L (.040”), 98-2 Argon-CO Wire Size/Type: 1.0 mm (.040”) 308L MPM / IPM 19.1 / 750 17.8 / 700 16.5 / 650 15.2 / 600 14.0 / 550 12.7 / 500 11.4 / 450 10.2 / 400 8.9 / 350 7.6 / 300...

  • Page 87: Program 1 - 1.2 Mm Metal Core (.045"), 95-5 Argon-Co2

    8-11. Program 1 – 1.2 mm Metal Core (.045”), 95-5 Argon-CO Note The next 8 programs are available after changing software wiretype (see Section 14-10). Wire Size/Type: 1.2 mm (.045”) Metal Core MPM / IPM 19.1 / 750 17.8 / 700 16.5 / 650 15.2 / 600 14.0 / 550...

  • Page 88: Program 3 - 1.2 Mm Er 4043 (.045"), Argon

    8-13. Program 3 – 1.2 mm ER 4043 (.045”), Argon Wire Size/Type: 1.2 mm (.045”) ER 4043 MPM / IPM 17.9 / 705 17.8 / 700 16.5 / 650 15.2 / 600 14.0 / 550 12.7 / 500 11.4 / 450 10.2 / 400 8.9 / 350 7.6 / 300...

  • Page 89: Program 5 - 1.0 Mm 5356 (.040"), Argon

    8-15. Program 5 – 1.0 mm 5356 (.040”), Argon Wire Size/Type: 1.0 mm (.040”) 4043 MPM / IPM 18.6 / 735 18.5 / 730 17.7 / 695 16.9 / 665 16.1 / 630 15.2 / 600 13.8 / 540 12.4 / 485 11.0 / 430 9.7 / 380 8.3 / 325...

  • Page 90: Program 7 - .8 Mm Steel (.030"), 98-2 Argon-Oxy

    8-17. Program 7 – .8 mm Steel (.030”), 98-2 Argon-Oxy Wire Size/Type: .8 mm (.30”) Steel MPM / IPM 19.7 / 775 17.8 / 700 15.9 / 625 14.0 / 550 12.1 / 475 10.2 / 400 8.9 / 350 7.6 / 300 6.4 / 250 5.1 / 200...

  • Page 91: Setup Pendant Mode Select Button

    8-19. Setup Pendant Mode Select Button Process > Sequence SharpArc Card > Process > Prg 1 Sequence Pulse SharpArc 035” Steel Card Argon – Oxy Mode Display Mode Select Button Press Mode Select button to move indicator in left window display. Go to Section 8-20.

  • Page 92: Setup Pendant Parameter Select Button

    8-20. Setup Pendant Parameter Select Button > Process Sequence SharpArc Card OM-196 188 Page 86 > Prg 1 Pulse 035” Steel Argon – Oxy Parameter Display Moving Line Moving line is under value that can be changed. Pulse Panel Parameter Select Button Press pulse panel parameter select button to move indicator in right win-...

  • Page 93: Setup Pendant Parameter Increase And Decrease Buttons

    8-21. Setup Pendant Parameter Increase And Decrease Buttons > Prg 1 Pulse 035” Steel Argon – Oxy Use mode select button to select mode to be changed (see 8-19). Use pulse panel parameter select button to select parameter to be changed (see 8-20).

  • Page 94: Section 9 - Getting Started For Pulse Welding

    SECTION 9 – GETTING STARTED FOR PULSE WELDING 9-1. Weld Cycle For Pulse Welding Start Wire Power Speed Start Speed Preflow Run-In Time Weld Run-In Start Setting Strike 9-2. Setting Preflow Sequence Display Process > Sequence SharpArc Card Mode Select >...

  • Page 95: Setting Weld Sequence Display

    9-3. Setting Weld Sequence Display Set Desired Weld Weld Sequence Trim > 50 Trim 200 IPM Increase/ Decrease Set Desired Weld Sequence Weld Wire Feed Speed 60 Trim > 200 IPM Increase/ Decrease > Weld 60 Trim 300 IPM 9-4. Setting Crater Sequence Display >Cratr 0.00 Sec 50 Trim...

  • Page 96: Setting Postflow Sequence Display

    9-5. Setting Postflow Sequence Display > Poflw 0.0 Sec Parameter Select SECTION 10 – TEACHING A PULSE WELDING PROGRAM NOTE See GMAW-P (Pulsed MIG) Process Guide supplied with unit for more information. 10-1. Pulse Waveform Explained Amps (Current) OM-196 188 Page 90 Poflw >...

  • Page 97: Teach Points Explained

    10-2. Teach Points Explained The teach mode allows the user to create custom pulse MIG welding programs. The teach mode has 15 teach points. At each teach point, the user can adjust five parameters: peak amperage (Apk), back- ground amperage (Abk), pulses per second (PPS), pulse width in milliseconds (PWms), and peak voltage (Vpk) to shape the pulse waveform of the weld output.

  • Page 98: Selecting Teach Point Wire Feed Speed For Pulse Welding Program

    10-3. Selecting Teach Point Wire Feed Speed For Pulse Welding Program > Process Sequence SharpArc Card Mode Select OM-196 188 Page 92 Pulse > Prg 1 035” Steel Pulse 035” Steel > Teach Off Argon – Oxy Parameter Select Increase/ Decrease Teach On >...

  • Page 99: Setting Teach Point Parameters For Pulse Welding Program

    10-4. Setting Teach Point Parameters For Pulse Welding Program > Process Teach On Sequence > 450 IPM SharpArc 28.1 Vpk Card 340 Apk Increase/ Decrease 31.2 Vpk 343 Apk > 92 Abk 160 PPS Parameter Select Increase/ Decrease 31.2 Vpk 343 Apk 92 Abk >...
  • Page 100 NOTE Make copies of this chart for future use. Program # Wire Size/Type Program Name Gun Model Preflow: Sec. Run-In Trim: Crater Trim: Postflow: Sec. OM-196 188 Page 94 PWms IPM: IPM: Card # Flowrate COMMENTS Sec.: Sec.:...

  • Page 101: Changing To Adaptive Pulse Welding

    10-5. Changing To Adaptive Pulse Welding Mode Select > Process > Prg 1 Sequence SharpArc 035” Steel Card Argon – Oxy > Process Prg 1 Sequence > MIG SharpArc 035” Steel Card Argon – Oxy SECTION 11 – TEACHING A MIG WELDING PROGRAM 11-1.

  • Page 102: Changing To Mig Welding

    11-2. Changing To Mig Welding Mode Select > Process > Prg 1 Sequence AdaptPulse SharpArc 035” Steel Card Argon – Oxy > Process Sequence SharpArc Card 11-3. Setting Preflow Sequence Display >Process > Prg 1 Sequence SharpArc Card Mode Select >Preflow Process 0.0 Sec...

  • Page 103: Setting Start Sequence Display

    11-4. Setting Start Sequence Display > Start Start 24.0 Volt > 18.0 Volt 90 IPM 90 IPM 0.2 Sec 0.2 Sec Parameter Set Desired Voltage Select Start 18.0 Volt 200 IPM 0.5 Sec Increase Proceed to next Section. 11-5. Setting Weld Sequence Display >...

  • Page 104: Setting Crater Sequence Display

    11-6. Setting Crater Sequence Display > Cratr 0.02 Sec 24.0 Volt 90 IPM Parameter Select Cratr > 0.12 Sec 24.0 Volt > 18.0 Volt 90 IPM Set Desired Time Parameter Select Increase/ Decrease 11-7. Setting Retract Sequence Display > Rtrct >...

  • Page 105: Setting Postflow Sequence Display

    11-8. Setting Postflow Sequence Display > Poflw 0.0 Sec > 0.0 Sec Parameter Set Desired Time Select 11-9. Setting Run-in Sequence Display > Runin Runin > ON 100 IPM 100 IPM Parameter Set ON or OFF Select Poflw > Poflw 1.2 Sec Parameter Select...

  • Page 106: Section 12 - Setting Sharparce Control

    SECTION 12 – SETTING SharpArcE CONTROL 12-1. Selecting And Adjusting SharpArcE Control > Process Sequence SharpArc Card Process Sequence > SharpArc Card OM-196 188 Page 100 > Prg 1 Pulse 035” Steel Argon – Oxy Mode Select >SharpArc Parameter Select SharpArc >...

  • Page 107: Section 13 - Using The Optional Data Card

    SECTION 13 – USING THE OPTIONAL DATA CARD 13-1. Installing Data Card Card Data 60-M Label Peel backing from label and apply to data card with THIS SIDE UP by metal pins. Write the names of the programs stored on the card on the label. Write the name of the piece of equipment the card is used with on the label.

  • Page 108: Using The Data Card

    13-2. Using The Data Card Process Sequence SharpArc > Card > Write Read Delete Done OM-196 188 Page 102 Press Below Parameter Select Once # 1 Pulse 035” Steel Argon – Oxy Press Use Mode Select button to select Card. Card Display Write Used to transfer program data from...

  • Page 109: Naming Programs And Writing To Card

    13-3. Naming Programs And Writing To Card NOTE All program types (Pulse, Adaptive Pulse, and MIG) can be stored on a data card and retrieved. Setup and Control menus do not save to the card. Parameter Select Name? No 035” Steel Argon –...

  • Page 110: Reading From Card

    13-4. Reading From Card NOTE Programs developed on the Auto Invision will not run the same on Auto Invision II. WARNING: Prg1 Will Be Lost Lose? Yes Press Use Mode Select button to select Card. Card Display Moving Line Moving line is under value that can be OM-196 188 Page 104 Process Sequence...

  • Page 111: Reading (Or Deleting) From An Empty Card

    13-5. Reading (Or Deleting) From An Empty Card Write WARNING: > Read Card Empty Delete Press Done Below Write Read Delete > Done Press 13-6. Deleting Programs From Card Process Sequence SharpArc > Card Mode Select Twice Write Read > Delete Done Delete Card Prg2...

  • Page 112: Selecting Security Lock

    13-7. Selecting Security Lock NOTE Security lock works only when a data card is inserted. Access Setup Display Sequence SharpArc Card > Security Press Mode Select Prog 2 > Lock On Increase Parameter Select > Prog 2 Lock On Increase OM-196 188 Page 106 >...

  • Page 113: Section 14 - Setup

    14-1. Setup Flow Chart Access Mig Type Example Setup Aux Out Pendant Display Voltage Display Features Settings Selection >Access Code Off/On Press Mode Select To Go To Next Setup Dis- play >Mig Type Voltage DVC On/Off Correction >Aux Output Auxiliary Output On Output w/Feeder...

  • Page 114: Using Setup Displays

    14-2. Using Setup Displays Mode Parameter Select Select S e t u p Front Panel Display OM-196 188 Page 108 Access > Volt Min Mig Type 10.0 Volt Aux Out Voltage Setup Pendant Display Front Panel Setup Display Front panel display during setup. Pulse Panel Mode And Parameter Select Buttons Power Switch On Rear Panel...

  • Page 115: Selecting Or Changing Access Code

    14-3. Selecting Or Changing Access Code NOTE Access code works only when a data card is inserted (see Section 13). Access Setup Display >Access Mig Type Aux Out Voltage Press Mode Select Turn Power Off And Back On And Access Security Display Enter Access Code...

  • Page 116: Selecting Voltage Correction

    14-4. Selecting Voltage Correction Access Setup Display Press Mode Select 14-5. Selecting Auxiliary Output Access Setup Display Press Mode Select Turn On > w/Weld Cyc > w/Arc Increase 14-6. Selecting Voltage Sensing Method Access Setup Display Press Mode Select Mig Type Control Aux Out Feedback...

  • Page 117: Selecting Arc Start Method

    14-7. Selecting Arc Start Method NOTE Arc Start selection is not used when welding in non-pulsed MIG. Do not use the Hot Start setting for .035 in (9 mm) or smaller wire. Access Setup Display Press Mode Select Aux Output Pulse Voltage ArcStart...

  • Page 118: Selecting Units For Wire Feed Speed And Motor Type

    14-9. Selecting Units For Wire Feed Speed And Motor Type ArcStart Arc Time > Wirefeed Wiretype Display Display Motor Type Motor Type > Low Spd > High Spd Increase OM-196 188 Page 112 Access Setup Display Press Mode Select Display >...

  • Page 119: Selecting Wire Type

    14-10. Selecting Wire Type NOTE If wire type is changed, perform a system reset (see Section 14-12) immediately after selecting wire type to bring up the correct welding programs. After using system reset to store wire type selection into memory, all other setup parameters return to factory default Access settings.

  • Page 120: Resetting Memory

    14-12. Resetting Memory Press Mode Wiretype Access Select Display Setup Display > Memory Shutdown > Process > Prg 1 Sequence Pulse SharpArc 035” Steel Card Argon – Oxy 14-13. Selecting Arc Start/Volt Sense Error Shutdown Access Setup Display Press Mode Select Display Arc Start/...

  • Page 121: Selecting Program Name Feature

    14-14. Selecting Program Name Feature Access Setup Display Press Mode Select Memory Card Shutdown Programs > Name > On Program 14-15. Remote Program Select Access Setup Display Press Mode Select Shutdown Remote Name Select > Program > Off Jog IPM 14-16.

  • Page 122: Jog Wire Feed Speed Selection

    14-17. Jog Wire Feed Speed Selection Access Setup Display Press Mode Select Name Robot Jog Program > Remote > Jog IPM Local Jog Flow 200 ipm Parameter Select Robot Jog local Local Jog > 425 ipm 14-18. Flow Selection Access Setup Display When a system reset is...

  • Page 123: Arc Voltage Error Selection

    14-19. Arc Voltage Error Selection Access Setup Display When a system reset is done, Monitor is set to Off. Press Mode Select Jog IPM Arc Volts Flow > On > Monitor 2.0 Volts Stick 1.0 Sec 14-20. Stick Check Selection Access Setup Display...

  • Page 124: Setting Ramps Function

    14-21. Setting Ramps Function Access Setup Display Monitor Stick > Ramps Exit Press Mode Select Prog 2 > Start Crater Increase Parameter Select Prog 2 Start > Crater Increase 14-22. Software Version Number Press Mode Stick Select Access Ramps Setup >...

  • Page 125: Section 15 - Control Menu

    SECTION 15 – CONTROL MENU The control menu allows the user access to rise time setting that controls rise and fall time of the pulse square wave. Changing the rise time setting changes the square wave shape by rounding off the corners, and makes it possible to quiet the pulse arc by just changing the rise time.

  • Page 126: Setting Rise Time Parameter

    15-2. Setting Rise Time Parameter NOTE Maximum Rise Time setting will make the welding power source go to its maximum output in the maximum amount of time (1250 amperes per millisecond). Access Control Display > Process > Prg 1 Sequence Pulse SharpArc 035”...

  • Page 127: Setting Auto Configure Parameter

    15-4. Setting Auto Configure Parameter Access Control Display Press Mode Select >Process > Prg 1 Sequence Pulse SharpArc 035” Steel Card Argon – Oxy Rise Time > On Adaptive None > AutoConfig Retract Increase/Decrease Arc On No Analog Inputs Increase/Decrease Arc On &...

  • Page 128: Setting Retract On/Off

    15-5. Setting Retract On/Off Access Control Display Press Mode Select >Process > Prg 1 Sequence Pulse SharpArc 035” Steel Card Argon – Oxy 15-6. Setting Sharp Start On/Off Access Control Display Press Mode Select >Process > Prg 1 Sequence Pulse SharpArc 035”...

  • Page 129: Exiting The Control Menu

    15-7. Exiting The Control Menu AutoConfig Access Retract Control ShrpStrt Display > Exit Press Mode Select Exit Control Menu Display Allows the user to leave the control menu. Exit Cntrl Menu Now Press OM-196 188 Page 123...
  • Page 131 Warranty Questions? Call LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold for your local after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller.

  • Page 132: Options And Accessories

    File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2003 Miller Electric Mfg. Co. 1/03 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters–USA...

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