Miller Auto Invision 2 Owner's Manual
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Miller Auto Invision 2 Owner's Manual

Miller Auto Invision 2 Owner's Manual

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Auto Invision II
OM-196 188A
April 2001
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 Auto Invision 2

  • Page 1 OM-196 188A April 2001 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) Welding Automatic Welding Description Automatic Welding Interface And Arc Welding Power Source Auto Invision II Visit our website at www.MillerWelds.com...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1.
  • Page 4 TABLE OF CONTENTS SECTION 7 – TEACHING A PULSE WELDING PROGRAM ....... . . 7-1.
  • Page 5 TABLE OF CONTENTS SECTION 13 – MAINTENANCE & TROUBLESHOOTING (Continued) ......13-7. Diagnostic LED’s On Weld Interface Board PC12 .
  • 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: Directives 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 som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message.
  • Page 8 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense D Always ventilate confined spaces or use visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.

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

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.

  • Page 10: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields.

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

    SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 4/98 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. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
  • Page 12 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.

  • 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 DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité...

  • 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- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 15: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Manufacturer’s Warning Label Definitions 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 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. Do not touch fully charged capacitors.

  • Page 17: Symbols And Definitions

    2-2. Symbols And Definitions Amperage Positive Remote Voltage Output Circuit Breaker Negative Protective Earth Inductance Voltage Input (Ground) 2-3. Manufacturer’s Rating Label S-184 765 2-4. Harmonic Data HARMONIC DATA per IEC 61000-3-12, draft 2000-9-29 PRIMARY; 400V/30.5A/60hz LOAD; 450A/38Vdc/390IPM/,MAXIMUM OUTPUT, GMAW. R sce = 227.28 61 Amps PWHD...

  • Page 18: Section 3 - Installation

    SECTION 3 – INSTALLATION 3-1. Specifications Maximum Amperes Input Wire Input Rated Welding Voltage Wire Feed Speed Open- At Rated Load Diameter Diameter Power Output Range Range* Circuit Output 60 Hz, Range Voltage DC Three-Phase 450 A @ 38 Volts DC, 450 A @ 38 Volts DC, Standard: Three...

  • Page 19: Selecting A Location

    3-3. Selecting A Location Y Do not move or operate Movement Tipping unit where it could tip. Location Lifting Forks Y Special installation may be required where gasoline or volatile Use lifting forks to move unit. liquids are present – see NEC Article 511 or CEC Section 20. Extend forks beyond opposite side of unit.

  • Page 20: Weld Output Terminals And Selecting Cable Sizes

    3-5. Weld Output Terminals And Selecting Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding 45 m 60 m 70 m 90 m 105 m 120 m 30 m (100 ft) Or Less (150 ft) (200 ft) (250 ft) (300 ft) (350 ft) (400 ft)

  • Page 21: Electrical Service Guide

    3-7. Electrical Service Guide Three-Phase 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) 264 (80) Min Grounding Conductor Size In AWG/Kcmil Reference: 1993 National Electrical Code (NEC).

  • Page 22: Rear Panel Connections

    3-9. Rear Panel Connections 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 Example Receptacle +/–, and n/o relay contacts circuitry.

  • Page 23: Peripheral Receptacle Functions

    3-10. Peripheral Receptacle Functions Function Socket Socket Information Contact closure to B dependent upon state of programmed output (see Section 11-5). The closure between A and B can carry a maximum of 0.6 amps at 125 VAC; or a maximum of 0.6 amps at Programmable 110 VDC.

  • Page 24: Connecting Setup Pendant To Welding Power Source

    3-12. Connecting Setup Pendant To Welding Power Source 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 25: 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 26: 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 27: Upper Front Panel Controls

    4-4. Upper Front Panel Controls Setup Pendant Receptacle Jog Reverse Push Button Contactor Indicator LED Receptacle connecting pendant Retracts wire up into the gun. LED lights when welding power source interconnecting cord. Gas Indicator LED contactor is energized. Jog Forward Push Button LED lights when gas solenoid is energized.

  • Page 28: Duty Cycle And Overheating

    4-5. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.

  • Page 29: Setup Pendant Controls

    4-7. Setup Pendant Controls 802 815 Increase Button Parameter Select Button Press button to move indicator in left window display. Works with security feature on welding Press button to move indicator in right power source to allow increasing weld Interconnecting Cable Receptacle window display, and to make selections in parameter values within the allowable range.

  • Page 30: Section 5 - Introduction To Programming

    SECTION 5 – INTRODUCTION TO PROGRAMMING 5-1. Pulse MIG Programs The interface unit is designed for use in pulse MIG welding (adaptive or standard), or MIG welding. Selecting hardwire or softwire is The unit is factory-equipped with done during setup (see Section 11) eight programs for pulse MIG welding.

  • Page 31: Program 1 - .035 Steel, Argon-Oxy

    5-3. Program 1 – 1.2 mm Steel (.045”), 98-2 Argon-Oxy Wire Size/Type: 1.2 mm (.045”) Steel Gas: Ar - Oxy / 19 L/min (40 CFH) MPM / IPM PWms COMMENTS 19.1 / 750 34.5 17.8 / 700 33.9 16.5 / 650 33.3 15.2 / 600 32.7...

  • Page 32: Program 4 - .045" Steel, Argon - Co2

    5-5. Program 3 – 1.2 mm Steel (.045”), 80-20 Argon-CO Wire Size/Type: 1.2 mm (.045”) Steel Gas: Ar - CO / 19 L/min (40 CFH) MPM / IPM PWms COMMENTS 19.1 / 750 41.2 17.8 / 700 40.6 16.5 / 650 40.0 15.2 / 600 39.5...

  • Page 33: Program 6 - .045" Er 309, Argon - Co2

    5-7. Program 5 – 1.0 mm 316 (.040”), 98-2 Argon-CO Wire Size/Type: 1.0 mm (.040”) 316 Gas: Ar - CO / 19 L/min (40 CFH) MPM / IPM PWms COMMENTS 19.1 / 750 34.0 17.8 / 700 33.8 16.5 / 650 33.6 15.2 / 600 33.4...
  • Page 34 5-9. Program 7 – 1.0 mm 308L (.040”), 98-2 Argon-CO Wire Size/Type: 1.0 mm (.040”) 308L Gas: Ar - CO / 19 L/min (40 CFH) MPM / IPM PWms COMMENTS 19.1 / 750 34.2 17.8 / 700 33.7 16.5 / 650 33.2 15.2 / 600 32.7...

  • Page 35: Program 7 - .045" Metal Core, Argon - Co2

    5-11. 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 11-10). Wire Size/Type: 1.2 mm (.045”) Metal Core Gas: Ar - CO / 19 L/min (40 CFH) MPM / IPM PWms COMMENTS...

  • Page 36: Program 1 - 3/64" 4043, Argon

    5-13. Program 3 – 1.2 mm ER 4043 (.045”), Argon Wire Size/Type: 1.2 mm (.045”) ER 4043 Gas: Ar / 19 L/min (40 CFH) MPM / IPM PWms COMMENTS 17.9 / 705 31.6 17.8 / 700 31.5 16.5 / 650 30.1 15.2 / 600 28.8...

  • Page 37: Program 2 - 3/64" 5356, Argon

    5-15. Program 5 – 1.0 mm 5356 (.040”), Argon Wire Size/Type: 1.0 mm (.040”) 4043 Gas: Ar / 19 L/min (40 CFH) MPM / IPM PWms COMMENTS 18.6 / 735 27.0 18.5 / 730 27.0 17.7 / 695 26.9 16.9 / 665 26.8 16.1 / 630 26.6...

  • Page 38: Program 7 - 1/16" 4043, Argon

    5-17. Program 7 – .8 mm Steel (.030”), 98-2 Argon-Oxy Wire Size/Type: .8 mm (.30”) Steel Gas: Ar - Oxy / 19 L/min (40 CFH) MPM / IPM PWms COMMENTS 19.7 / 775 33.9 17.8 / 700 33.6 15.9 / 625 33.3 14.0 / 550 33.0...

  • Page 39: Setup Pendant Mode Select Button

    5-19. Setup Pendant Mode Select Button Mode Display Mode Select Button Press Mode Select button to move indicator in left window display. Go to Section 5-20. > Process > Prg 1 Process Sequence Pulse > Sequence SharpArc 035” Steel SharpArc Card Argon –...

  • Page 40: Setup Pendant Parameter Select Button

    5-20. Setup Pendant Parameter Select Button 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- dow display. Prg 1 >...

  • Page 41: Setup Pendant Parameter Increase And Decrease Buttons

    5-21. Setup Pendant Parameter Increase And Decrease Buttons Use mode select button to select mode to be changed (see 5-19). Use pulse panel parameter select button to select parameter to be changed (see 5-20). Increase Button Press button to increase value that is underlined by the moving line.

  • Page 42: Section 6 - Getting Started For Pulse Welding

    SECTION 6 – GETTING STARTED FOR PULSE WELDING 6-1. Weld Cycle For Pulse Welding The type of robot connected determines what combination of parameters are available. Start Robot Wire Weld Time Power Motion Speed Crater Time Start Speed Retract Time Weld Speed Crater...

  • Page 43: Setting Weld Sequence Display

    6-3. Setting Weld Sequence Display Weld Parameters Display Set Desired Weld Weld Parameter ranges are as follows: Sequence Trim Trim (Arc Length), 0-99 > 50 Trim Wire Feed Speed, 50-780 Inches 200 IPM Per Minute, IPM Increase/ Go to Section 6-4. Decrease Parameter Select...

  • Page 44: Setting Postflow Sequence Display

    6-5. Setting Postflow Sequence Display Postflow Parameters Display > Postflow Postflow > Postflow Postflow can be adjusted from 0.0 Sec > 0.0 Sec 1.2 Sec 0-9.9 seconds. If value set is zero (0), there is no Postflow sequence. Parameter Parameter Set Desired Time Select Select...

  • Page 45: Teach Points Explained

    7-2. Teach Points Explained Example Of A Synergic Setting For 425 IPM With All Teach Points Set At 50 IPM Increments PWms PWms 12.5 17.5 22.5 27.5 32.5 37.5 The teach mode allows the user to create of the highest teach point, the unit may limit carefully maintained.

  • Page 46: Selecting Teach Point Wire Feed Speed For Pulse Welding Program

    7-3. Selecting Teach Point Wire Feed Speed For Pulse Welding Program Process Display When unit is first turned On, Process is the default screen, at other times use mode select button to select Process. Teach Display Use parameter select button to Pulse >...

  • Page 47: Setting Teach Point Parameters For Pulse Welding Program

    7-4. Setting Teach Point Parameters For Pulse Welding Program Increase/ Decrease > Process Teach On Teach On Teach On Sequence > 450 IPM 450 IPM 450 IPM SharpArc 28.1 Vpk > 28.1 Vpk > 31.2 Vpk Card 340 Apk 340 Apk 340 Apk Parameter Select...
  • Page 48 NOTE Make copies of this chart for future use. Program # Wire Size/Type Program Name Card # Gun Model Flowrate PWms COMMENTS Preflow: Sec. Run-In Trim: IPM: Sec.: Crater Trim: IPM: Sec.: Postflow: Sec. OM-196 188 Page 42...

  • Page 49: Changing To Adaptive Pulse Welding

    7-5. Changing To Adaptive Pulse Welding Welding parameters are the same for both a Pulse and an Adaptive Pulse welding program. While welding adaptively, the unit uses feedback to attempt to maintain a Mode constant arc length. To change to Select Adaptive Pulse welding, proceed as shown:...

  • Page 50: Changing To Mig Welding

    8-2. Changing To Mig Welding Mode Setup Pendant Display Select Default display when unit is first turned On, at other times use mode select button to select Process. Go to Section 8-3. > Process > Prg 1 Sequence AdaptPulse SharpArc 035”...

  • Page 51: Setting Start Sequence Display

    8-4. Setting Start Sequence Display Start Parameters Display Parameter ranges are as follows: > Start Seconds, 0-2.5 Sec. If value set is Start Start zero (0), there is no Run-In se- 24.0 Volt > 18.0 Volt 18.0 Volt quence. With zero (0) time value, 90 IPM 90 IPM >...

  • Page 52: Setting Crater Sequence Display

    8-6. Setting Crater Sequence Display Crater Parameters Display > Crater Parameter ranges are as follows: 0.02 Sec Seconds, 0-2.50 Sec. If value set is 24.0 Volt zero (0), there is no Crater 90 IPM sequence. Volts, 10.0-38.0 Volts. Parameter Wire Feed Speed, 50 to 780 inches Select per minute, IPM.

  • Page 53: Setting Postflow Sequence Display

    8-8. Setting Postflow Sequence Display Postflow Parameters Display Postflow can be adjusted from 0-9.9 seconds. If value set is zero > Postflow Postflow > Postflow (0), there is no Postflow sequence. 0.0 Sec > 0.0 Sec 1.2 Sec Parameter Set Desired Time Parameter Select Select...

  • Page 54: Section 9 - Setting Sharparce Control

    SECTION 9 – SETTING SharpArcE CONTROL 9-1. Selecting And Adjusting SharpArcE Control SharpArc SharpArc is used to adjust arc cone width and arc characteristics. Use mode select button to move > to select SharpArc. Use Display Control to adjust Arc setting. >...

  • Page 55: Section 10 - Using The Optional Data Card

    SECTION 10 – USING THE OPTIONAL DATA CARD 10-1. Installing Data Card 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 56: Using The Data Card

    10-2. Using The Data Card Use Mode Select button to select Card. Card Display Write Used to transfer program data from unit to card. The program card can Process hold up to 32 programs. When Sequence writing to the card, the next available program number SharpArc...

  • Page 57: Naming Programs And Writing To Card

    10-3. Naming Programs And Writing To Card NOTE All program types (Pulse, Adaptive Pulse, and MIG) can be stored on a data card and retrieved. Process Sequence SharpArc Press > Card Below Parameter Select > Write #1 Pulse Read 035” Steel Delete Argon –...

  • Page 58: Reading From Card

    10-4. Reading From Card Process Sequence SharpArc Press > Card Below Mode Parameter Select Select Once Twice Write # 1 Pulse Read Card > Read 035” Steel to Feeder Delete Argon – Oxy Prg 1 Done Press Press Parameter Select Parameter Select WARNING:...

  • Page 59: Reading (Or Deleting) From An Empty Card

    10-5. Reading (Or Deleting) From An Empty Card Warning Display If there are no programs on the Write WARNING: card, this series of displays appear. > Read Card Empty Delete Press Done Below Parameter Select Once >Process > Prg 2 Write Sequence Read...

  • Page 60: Selecting Security Lock

    10-7. Selecting Security Lock NOTE Security lock works only when a data card is inserted. Security Display Use this display to lock a program’s weld parameters so that changes Access can not be made using pulse panel Setup controls. Display Program Number Choose the program number (1 through 8) to be locked.

  • Page 61: Section 11 - Setup

    SECTION 11 – SETUP 11-1. Setup Flow Chart Display Selections Access > Volt Min Features Mig Type 10.0 Volt Example Setup Settings Aux Out Pendant Display To set up features that customize operation, use the setup Voltage displays. Features that can be customized are as follows: Display Features Settings...

  • Page 62: Using Setup Displays

    11-2. Using Setup Displays Front Panel Setup Display Front panel display during setup. Mode Parameter Pulse Panel Mode And Select Select Parameter Select Buttons Power Switch On Rear Panel Press and hold down both buttons while turning On unit. Setup Pendant Display Follow this procedure any time access is required.

  • Page 63: Selecting Or Changing Access Code

    11-3. Selecting Or Changing Access Code NOTE Access code works only when a data card is inserted (see Section 10). Code Display Access With code off, access to the setup Setup displays is not restricted. Display With code on, the operator must know and enter the access code to access or change any of the setup displays.

  • Page 64: Selecting Voltage Correction

    11-4. Selecting Voltage Correction Mig Type Display With DVC Voltage Correction On, Access Access the unit uses closed-loop feedback > Mig Type Voltage Setup or voltage sensing leads Display Aux Out Correction maintain set voltage parameters. Voltage > DVC Off With DVC Voltage Correction Off, feedback from the arc is not used Press Mode...

  • Page 65: Selecting Arc Start Method

    11-7. 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. Standard Start Access Welding operation is performed at Setup set values for welding parameters.

  • Page 66: Selecting Units For Wire Feed Speed And Motor Type

    11-9. Selecting Units For Wire Feed Speed And Motor Type Wire Feed Display The displayed unit of wire speed (IPM or MPM) can be changed along with the wire feed motor type Access (Standard, Low Speed, or High Setup Speed). Display Press Mode Select...

  • Page 67: Selecting Wire Type

    11-10. Selecting Wire Type NOTE If wire type is changed, perform a system reset (see Section 11-12) immediately after selecting wire type to bring up the correct welding programs. Wire Type Display After using system reset to store wire type selection into memory, all other setup parameters return to factory default Select soft wire when using Access...

  • Page 68: Resetting Memory

    11-12. Resetting Memory No Reset Press Parameter Select button to exit memory reset parameter with- Press Mode out resetting any data. Wiretype > No Reset Access Select Program Reset Display Setup Display > Memory Press Parameter Select button to reset last active program to original Shutdown factory program settings.

  • Page 69: Selecting Program Name Feature

    11-14. Selecting Program Name Feature Name Display Access When a data card is used, the pro- Setup grams written from the unit to the Display card can be named. Press Mode Select Memory Card Card Shutdown Programs Programs > Name >...

  • Page 70: Jog Wire Feed Speed Selection

    11-17. Jog Wire Feed Speed Selection Jog IPM Display Jog wire feed speed can be varied between 50 and 780 inches per Access minute, IPM. Setup Display When not welding, a Robot Jog local setting will jog wire at the Local Jog ipm setting, even if robot pro- Press Mode vides wire jog signal.

  • Page 71: Arc Voltage Error Selection

    11-19. Arc Voltage Error Selection Monitor Display Access Provides a means to enable/dis- Setup able the arc voltage error feature Display When a system reset is and to set an acceptable range of done, Monitor is set to Off. deviation from set arc voltage or arc length (trim) before the error will ac- Press Mode tuate.

  • Page 72: Setting Ramps Function

    11-21. Setting Ramps Function Ramps Display Access The ramps function allows output Setup power to be tapered from start to Display weld and/or from weld to crater. Program Number Choose the desired program num- ber (1 through 8). Turns start and/or Monitor >...

  • Page 73: Section 12 - Control Menu

    SECTION 12 – 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 74: Setting Rise Time Parameter

    12-2. 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). Rise Time Display Setting is depend on desired arc characteristics.

  • Page 75: Setting Auto Configure Parameter

    12-4. Setting Auto Configure Parameter Auto Configure Display Setting allows user to do manual configuration automatic configuration by welding power Rise Time > On Access source/interface. Adaptive None Control > AutoConfig Use Increase or Decrease button to Display change setting. Retract Press Mode Select button to go to Press Mode...

  • Page 76: Setting Retract On/Off

    12-5. Setting Retract On/Off Retract Display Settings allow user to turn the re- tract feature On or Off. The retract Adaptive > Retract feature allows the user to set a time Access AutoConfig and wire feed speed to pull wire Control away from work when the weld is >...

  • Page 77: Exiting The Control Menu

    12-7. Exiting The Control Menu Exit Control Menu Display Allows the user to leave the control menu. AutoConfig Exit Cntrl Access Retract Menu Now Control ShrpStrt Display > Exit Press Press Mode Select SECTION 13 – MAINTENANCE & TROUBLESHOOTING 13-1. Routine Maintenance Y Disconnect power Maintain more often before maintaining.

  • Page 78: Removing Case And Measuring Input Capacitor Voltage

    13-3. Removing Case and Measuring Input Capacitor Voltage Turn Off welding power source, and Y Significant DC voltage can remain on capacitors af- disconnect input power. ter unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged be- Outside Handle Screws fore working on unit.

  • Page 79: Voltmeter/Ammeter Help Displays

    13-4. Voltmeter/Ammeter Help Displays All directions are in reference to the front of the unit. All circuitry referred to is located inside the unit. HE.L P–1 Help 1 Display Indicates a malfunction in the primary power circuit. If this display is shown, contact a Factory Authorized Service Agent.

  • Page 80: Front Panel Error Displays

    13-5. Front Panel Error Displays M e m C R C E r r o r E r r o r C a r d R e a d M e m R a n g e E r r F l o w D e t e c t e d V o l t...

  • Page 81: Weld Interface Board Pc12 Diagnostic Led's

    13-6. Weld Interface Board PC12 Diagnostic LED’s Weld Interface Board PC12 LED10 LED8 Diagnostic LED’s are visible inside LED2 LED4 LED11 unit, located on PC12 (see illustration LED6 for board location). LED7 LED9 LED5 LED3 LED12 LED1 Refer to Section 13-7 for information on diagnostic LED’s.

  • Page 82: Diagnostic Led's On Weld Interface Board Pc12

    13-7. Diagnostic LED’s On Weld Interface Board PC12 Status Diagnosis 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 83: Customer Interface Board Pc14 Diagnostic Led's

    13-8. Customer Interface Board PC14 Diagnostic LED’s Customer Interface Board PC14 Diagnostic LED’s are visible inside unit, located on PC14 (see illustration for board location). Refer to Section 13-9 for information on diagnostic LED’s. Reinstall top cover after checking diagnostic LED’s. LED8 LED12 LED16...

  • Page 84: Diagnostic Led's On Customer Interface Board Pc14

    13-9. Diagnostic LED’s On Customer Interface Board PC14 Status Diagnosis 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 85: Motor Board Pc13 Diagnostic Led's

    Status Diagnosis 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 86: Diagnostic Led's On Motor Board Pc13

    13-11. Diagnostic LED’s On Motor Board PC13 Status Diagnosis Indicates motor reverse relay is energized. Indicates motor reverse relay is not energized. Indicates bus voltage is present. Indicates bus voltage is not present. Indicates microprocessor is operational. Indicates microprocessor is not operational. Indicates tachometer feedback signal is present.
  • Page 87 Notes OM-196 188 Page 81...

  • Page 88: Section 14 - Electrical Diagrams

    SECTION 14 – ELECTRICAL DIAGRAMS Figure 14-1. Circuit Diagram For Welding Power Source OM-196 188 Page 82...
  • Page 89 203 505 OM-196 188 Page 83...
  • Page 90 Figure 14-2. Circuit Diagram For Control Board PC1 (Part 1 of 3) OM-196 188 Page 84...
  • Page 91 188 814 (1 of 3) OM-196 188 Page 85...
  • Page 92 Figure 14-3. Circuit Diagram For Control Board PC1 (Part 2 of 3) OM-196 188 Page 86...
  • Page 93 188 814 (2 of 3) OM-196 188 Page 87...
  • Page 94 Figure 14-4. Circuit Diagram For Control Board PC1 (Part 3 of 3) OM-196 188 Page 88...
  • Page 95 188 814 (3 of 3) OM-196 188 Page 89...
  • Page 96 Figure 14-5. Circuit Diagram For Function/Meter Board PC3 OM-196 188 Page 90...
  • Page 97 190 696 OM-196 188 Page 91...
  • Page 98 184 183 Figure 14-6. Circuit Diagram For Interconnect Board PC2 188 015 Figure 14-7. Circuit Diagram For Gate Boards PC4 And PC5 OM-196 188 Page 92...
  • Page 99 Notes OM-196 188 Page 93...
  • Page 100 Figure 13-8. Circuit Diagram For Interface Module OM-196 188 Page 94...
  • Page 101 193 709 OM-196 188 Page 95...
  • Page 102 Figure 13-9. Circuit Diagram For Microprocessor Board PC11 OM-196 188 Page 96...
  • Page 103 191 838 OM-196 188 Page 97...
  • Page 104 Figure 13-10. Circuit Diagram For Motor Board PC13 OM-196 188 Page 98...
  • Page 105 177 289-A OM-196 188 Page 99...
  • Page 106 182 996 Figure 13-11. Circuit Diagram For Switch Board PC15 OM-196 188 Page 100...
  • Page 107 200 739 Figure 13-12. Circuit Diagram For Junction Board PC16 OM-196 188 Page 101...
  • Page 108 Figure 13-13. Circuit Diagram For Interface Board PC12 (Part 1 of 2) OM-196 188 Page 102...
  • Page 109 191 843-A (Part 1 of 2) OM-196 188 Page 103...
  • Page 110 Figure 13-14. Circuit Diagram For Interface Board PC12 (Part 2 of 2) OM-196 188 Page 104...
  • Page 111 191 843-A (Part 2 of 2) OM-196 188 Page 105...
  • Page 112 Figure 13-15. Circuit Diagram For Customer Interface Board PC14 (Part 1 of 3) OM-196 188 Page 106...
  • Page 113 Pensar 86147s03 (Part 1 of 3) OM-196 188 Page 107...
  • Page 114 Figure 13-16. Circuit Diagram For Customer Interface Board PC14 (Part 2 of 3) OM-196 188 Page 108...
  • Page 115 Pensar 86147s03 (Part 2 of 3) OM-196 188 Page 109...
  • Page 116 Figure 13-17. Circuit Diagram For Customer Interface Board PC14 (Part 3 of 3) OM-196 188 Page 110...
  • Page 117 Pensar 86147s03 (Part 3 of 3) OM-196 188 Page 111...
  • Page 118 174 578-A Figure 13-18. Circuit Diagram For Touch Sensor Board PC18 OM-196 188 Page 112...
  • Page 119 200 739-A Figure 13-19. Circuit Diagram For Setup Pendant OM-196 188 Page 113...
  • Page 120 200 739 Figure 13-20. Circuit Diagram For Setup Pendant Centronix Junction Board PC3 OM-196 188 Page 114...
  • Page 121 Notes OM-196 188 Page 115...

  • Page 122: Section 15 - Parts List

    SECTION 15 – PARTS LIST Hardware is common and not available unless listed. 802 872-A Figure 15-1. Complete Assembly OM-196 188 Page 116...
  • Page 123 Item Dia. Part Mkgs. Description Quantity Figure 15-1. Complete Assembly ....185 970 . . . COVER, top ...........
  • Page 124 Item Dia. Part Mkgs. Description Quantity Figure 15-1. Complete Assembly (Continued) ....183 192 . . . TRANSFORMER, control 230/460 VAC ......
  • Page 125 Item Dia. Part Mkgs. Description Quantity Figure 15-1. Complete Assembly (Continued) ..... . 144 844 . . . STAND-OFF, No. 6-32 x .875 .
  • Page 126 Notes OM-196 188 Page 120...
  • Page 127 Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...
  • Page 128 Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate 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...

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