Miller Electric Remote Operator Interface Owner's Manual
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Miller Electric Remote Operator Interface Owner's Manual

Miller Electric Remote Operator Interface Owner's Manual

Remote operator interface
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OM-217 834G
2006−06
Processes
MIG (GMAW) Welding
Description
Wire Feeder
ROI
(Remote Operator Interface)
File: Advanced Manufacturing Systems
Visit our website at
www.MillerWelds.com/ams

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Summary of Contents for Miller Electric Remote Operator Interface

  • Page 1 OM-217 834G 2006−06 Processes MIG (GMAW) Welding Description Wire Feeder (Remote Operator Interface) File: Advanced Manufacturing Systems Visit our website at www.MillerWelds.com/ams...
  • 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 specification sheets.

  • Page 3: Table Of Contents

    ..............4-3. Remote Operator Interface And Wire Drive Installation 4-4.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
  • Page 6 ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. D 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).

  • Page 7: 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 8: Principal Safety Standards

    1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 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 F4.1 from Global...

  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints.
  • Page 10 LES RAYONS D’ARC peuvent entraî- ner des brûlures aux yeux et à la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’installation électrique −...

  • Page 12: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : 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 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com).

  • Page 13: Section 3 − Introduction

    SECTION 3 − INTRODUCTION 3-1. Specifications Type of Input Welding Power Wire Feed Speed Range Power Source Type 40 Volts DC Axcess Series Standard: 40 To 1400 ipm (1.0 10 Amperes SECTION 4 − INSTALLATION 4-1. Mounting Plate Hole Layout (102 mm) 1-3/4 in (44 mm)

  • Page 14: Installing Insulator Kit

    4-2. Installing Insulator Kit Tools Needed: 1/2 in OM-217 834 Page 10 Y Turn Off and disconnect input power. ROI Control Insulator Plate Mounting Plate 1/4-20x3/4 in Screw (4) Nylon Shoulder Washer (4) 3/8 in Flat Washer (4) Place insulator plate between ROI base and metal mounting surface.

  • Page 15: Remote Operator Interface And Wire Drive Installation

    4-3. Remote Operator Interface And Wire Drive Installation 4-4. Connection Diagram Typical Swingarc installation shown; however, various installations are possible depending application. Remote Operator Interface Swingarc Swivel Assembly Boom AA40G Wire Drive Assembly Trigger Cable Ref. 803 697-E Welding Power Source...

  • Page 16: Rear Panel Connections

    4-5. Rear Panel Connections 4-6. 9-Pin Network Receptacle Information Capacitor C1 to ground Shield Volt sense Can low Can high +24 volts dc common + 24 volts dc Motor voltage +40 volts dc common Motor voltage +40 volts dc 4-7. Gun Recommendation Table Process GMAW −...

  • Page 17: Power Source Display At Power Up

    4-8. Power Source Display At Power Up Program Volts Process Wire Type Gas Type Process Set Up Adjust Upper Display Power Source DTEC Axcess Axcs 4-9. Dual Schedule Switch Option Time Arc Adjust Amps Arc Ctl Sequence Trigger Control Trigger Hold Feeder Set Up Voltage Range Lower Display...

  • Page 18: Section 5 − Operation

    SECTION 5 − OPERATION 5-1. Operational Terms The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder: General Terms: Arc Adjust Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases the actual arc length.

  • Page 19: Power Switch

    General Terms: Sequence Selecting Sequence will allow setting of preflow, start, crater, and postflow times and parameters. Preflow Setting a time value for gas flow prior to arc start. Start Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (which is only adjustable with the optional PDA with File Management/WaveWriter software).

  • Page 20: Front Panel Sections

    5-3. Front Panel Sections Section Program Process Wire Type Gas Type Process Set Up Section OM-217 834 Page 16 Volts Time Arc Adjust Amps Arc Ctl Sequence Trigger Control Trigger Hold Adjust Feeder Set Up Section Section Section Section...

  • Page 21: Program Push Button

    5-4. Program Push Button 5-5. Upper Display Upper Display The upper display at idle (not welding) shows preset volts with process selection MIG or Arc Adjust for all other processes. When welding, the display shows actual voltage. The display will show actual voltage for approximately 3 seconds after welding stops before returning to preset value.

  • Page 22: Lower Display

    5-6. Lower Display Lower Display The lower display shows WFS (wire feed speed), AMPS (amperage), ARC CTL (arc control), or Time. The feeder displays only preset wire speed at idle (not welding). While welding, the average amperage is displayed. The lower display shows welding sequence time when the Time LED is illuminated.

  • Page 23: Feeder Set Up Push Button

    5-7. Feeder Set Up Push Button Sequence Trigger Control Trigger Hold Feeder Set Up Feeder Set Up Push Button LED Feeder Set Up Push Button Press button to choose Sequence. Feeder Set Up push-button LED will illuminate. Sequence LED When the Feeder Set Up button is pressed once, the Sequence LED will illuminate and the upper display will show sequence options.

  • Page 24: Process Set Up Push Button

    5-9. Process Set Up Push Button Press the Process Set Up push button the first time will illuminate the button LED and the Process LED. The upper and lower displays will be used for Accu-pulse and only the lower display for MIG, Pulse and RMD (optional) to show the current process installed in this program.

  • Page 25: Jog/Purge

    5-10. Jog/Purge The Jog/Purge switch provides the following functions: Pressing left side of the Jog/Purge switch allows the operator to feed wire without energizing the weld power or gas valve circuit. The wire will feed at a 60 ipm rate for 3 seconds, then the rate ramps up to 700 ipm until the Jog switch is released.

  • Page 26: Reset Mode

    5-11. Reset Mode 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). Program Volts Time Arc Adjust...

  • Page 27: Section 6 − Setting Sequence Parameters

    SECTION 6 − SETTING SEQUENCE PARAMETERS 6-1. Sequence Parameters In A Program Sequence 1. Preflow 2. Postflow 3. Start 4. Crater Start Time Preflow Time Start Preflow Trigger Pressed Parameters Volts/Arc Seconds Adjust Off-5.0 Off-5.0 10.0-44.0/ 40-1400 Off-5.0 0-99 10.0-44.0/ 40-1400 Off-5.0 0-99...

  • Page 28: Section 7 − Maintenance

    SECTION 7 − MAINTENANCE 7-1. Routine Maintenance n = Check Z = Change * To be done by Factory Authorized Service Agent Every Months Months l Unreadable Labels nl Cracked Parts Every Months ~ Inside Unit OM-217 834 Page 24 Y Disconnect power before maintaining.

  • Page 29: Diagnostics

    7-2. Diagnostics The following error messages are shown on the upper and lower displays to indicate specific errors. Explanations are in the text below: TACH MOTR Indicates a Indicates a motor tachometer error. error. COOL Indicates a coolant Indicates a ground flow error.
  • Page 30 7-2. Diagnostics (Continued) WELD MOTR WAIT Indicates a weld Indicates a motor cycle wait error. communication error. OVER DONE AVER Indicates an arc Indicates an over error. average current error. WELD WAIT The weld wait error indicates unit was not ready for a weld sequence.
  • Page 31 Notes OM-217 834 Page 27...

  • Page 32: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram OM-217 834 Page 28...
  • Page 33 214 842-E OM-217 834 Page 29...

  • Page 34: Section 9 − Parts List

    213 632 OM-217 834 Page 30 Hardware is common and not available unless listed. Figure 9-1. Remote Operator Interface Description Figure 9-1. Remote Operator Interface WRAPPER, feeder ..........
  • Page 35 ..... 604 224 Description Figure 9-1. Remote Operator Interface (Continued) CIRCUIT CARD ASSY, trigger filter RCPT W/SKTS, (service kit) ........
  • Page 36 Notes...
  • Page 37 Notes...
  • Page 38 Notes...
  • Page 39 Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to 1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in for your local material and workmanship at the time it is shipped by Miller.

  • Page 40: Owner's Record

    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. 2006 Miller Electric Mfg. Co. 2006−01 Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA...

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