Miller ROI BOX CE Owner's Manual
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Miller ROI BOX CE Owner's Manual

Miller ROI BOX CE Owner's Manual

Remote operator interface
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OM-220979S
2016−02
Processes
MIG (GMAW) Welding
Description
Wire Feeder
ROI
(Remote Operator Interface)
CE
Visit our website at
File: Advanced Manufacturing Systems
www.MillerWelds.com/ams

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  • Page 1 OM-220979S 2016−02 Processes MIG (GMAW) Welding Description Wire Feeder (Remote Operator Interface) Visit our website at File: Advanced Manufacturing Systems www.MillerWelds.com/ams...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 DECLARATION OF CONFORMITY for European Community (CE marked) products. MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s).

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

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear body protection made from durable, flame−resistant material Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high health.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. 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 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer.

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

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2015−09 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 10 chauffement ou un incendie. Avant de commencer le soudage, vérifier LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger. provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage.

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

    D Tenir les bouteilles éloignées des circuits de soudage ou autres LE BRUIT peut endommager l’ouïe. circuits électriques. D Ne jamais placer une torche de soudage sur une bouteille à gaz. Le bruit des processus et des équipements peut affecter l’ouïe. D Une électrode de soudage ne doit jamais entrer en contact avec D Porter des protections approuvées pour les une bouteille.

  • Page 12: Proposition Californienne 65 Avertissements

    RAYONNEMENT HAUTE LE SOUDAGE À L’ARC risque de FRÉQUENCE (H.F.) risque provoquer des interférences. provoquer des interférences. D L’énergie électromagnétique risque D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences pour l’équipement provoquer des interférences avec les équi- électronique sensible tel que les ordinateurs et l’équipement commandé...

  • Page 13: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not discard product (where applicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection facility.
  • Page 14 Do not weld on drums or any closed containers. Safe16 2012−05 Do not remove or paint over (cover) the label. Safe20 2012−05 Disconnect input plug or power before working on machine. Safe30 2012−05 Drive rolls can injure fingers. Safe32 2012−05 Welding wire and drive parts are at welding voltage during operation −...

  • Page 15: Miscellaneous Symbols And Definitions

    3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Direct Current Output Amperes Volts (DC) Degree Of Duty Cycle Wire Feed Percent Protection Cold Jog (Inch) Towards Input Purge By Gas Fast Workpiece Constant Current Circuit Breaker Constant Voltage Slow Rated Welding...

  • Page 16: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2.

  • Page 17: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Mounting Plate Hole Layout 102 mm (4 in.) 5.6 mm (7/32 in.) Dia. (4 holes) 44 mm 76 mm 44 mm (1-3/4 in.) (3 in.) (1-3/4 in.) Ref. 200 553-A 5-2. Installing Insulator Kit Turn Off and disconnect input power.

  • Page 18: Remote Operator Interface And Wire Drive Installation

    5-3. Remote Operator Interface And Wire Drive Installation 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 5-4. Connection Diagram Welding Power Source Wire Feeder Gas Cylinder Gas Hose...

  • Page 19: Rear Panel Connections

    5-5. Rear Panel Connections 9-Pin Network Receptacle Motor Control/Shielding Gas Valve Receptacle Ref. 803 503-A 5-6. 9-Pin Network Receptacle Information Pin 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 5-7.

  • Page 20: Power Source Display At Power Up

    5-8. Power Source Display At Power Up Upper Display Lower Display Process Setup Adjust Feeder Setup Power Source Upper Display Lower Display Voltage Range Wait DTEC Axcess Axcs 300/450/675 219 711-A 5-9. Dual Schedule Switch Option Maint 2P (Maintained-Contact 2-Pole Switch) DSS-9M Part# 041793 DSS-9M OM-220979 Page 16...

  • Page 21: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. 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: AccuCurve CV Pulse process using a pulse waveform with modified curves at particular locations within the wa- veform.

  • Page 22: Power Switch

    General Terms: Time 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). TPS (Trigger Program Schedule) TPS allows the operator to select weld programs by using the gun trigger. In TPS mode, momentarily pressing the gun trigger allows the operator to cycle through preselected weld programs up to a total of 8 programs.

  • Page 23: Front Panel Sections

    6-3. Front Panel Sections Section 6-5 Section 6-4 Section 6-6 Process Setup Adjust Feeder Setup Section 6-8 Section 6-7 Section 6-9 OM-220979 Page 19...

  • Page 24: Program Push Button

    6-4. Program Push Button Program Display The number of the active program is displayed. Program Push Button Program Push Button LED The LED lights to indicate that programs can be changed using the Adjust knob. Momentarily press button illuminate LED. To change the program number, rotate Adjust knob to select one of eight programs.

  • Page 25: Lower Display

    6-6. Lower Display Lower Display Arc Ctl (Arc Control) LED When the lower display push-button LED and the WFS LED are both illuminated, it is LED illuminates to indicate that inductance The lower display shows WFS (wire feed possible to change WFS while welding by (MIG) or ARC [Pulse, Accu-pulse, or RMD speed), AMPS (amperage), ARC CTL (arc using the Adjust knob.

  • Page 26: Feeder Set Up Push Button

    6-7. Feeder Set Up Push Button Start Crater Time Time Preflow Postflow Time Time Sequence Diagram Feeder Setup Feeder Set Up Push Button LED pushing the Lower Display push button a trigger control methods are compatible with second time, while STRT or CRTR appear each other, therefore, turning on certain trig- Feeder Set Up Push Button in the upper display, allows entering voltage...

  • Page 27: Process Set Up Push Button

    6-9. Process Set Up Push Button Process Set Up Push Button Process Set Up LED Program Selection LEDs Process Setup • Press the Process Set Up push button the • Pressing the Process Set Up push button a • If a custom program is loaded using an first time will illuminate the button LED and fourth time will keep Wire Type LED lit and optional PDA with File Management...

  • Page 28: Jog/Purge

    6-10. Jog/Purge Jog/Purge Push Button Adjust Control Gun Trigger Receptacle The Jog/Purge switch provides the following ent as indicated on feeder upper display. Af- the first 3 seconds of run in and jogging functions: ter 3 seconds the weld output turns off and from the trigger is not possible.

  • Page 29: Reset Mode

    6-11. Reset Mode 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. System configuration data will be lost during the Reset operation. Setup Adjust Arc Control...

  • Page 30: Section 7 − Setting Sequence Parameters

    SECTION 7 − SETTING SEQUENCE PARAMETERS 7-1. Sequence Parameters In A Program For more information on Sequence mode, see Feeder Set Up Push Button in Section 6-7. Weld Time can only be set by using Sequence Parameters optional with File Management/WaveWriter software.

  • Page 31: Section 8 − Maintenance And Troubleshooting

    SECTION 8 − MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance Maintain more often Disconnect power before maintaining. during severe conditions. n = Check Z = Change ~ = Clean l = Replace Reference * To be done by Factory Authorized Service Agent Every Months l Unreadable Labels...

  • Page 32: Error Code Troubleshooting Tables

    8-2. Error Code Troubleshooting Tables Display Example TACH The following error codes may appear on the upper and lower displays of the User Interface Module to indicate specific errors. Explanations of the error codes are provided in the sections referenced. User Interface Module User Interface Module Error Type...
  • Page 33 A. Emergency Stop Error Indicates an emergency stop error. Receptacle RC5-1 connects to receptacle RC1-4 and receptacle RC5-2 connects to receptacle RC4-2 on E-Stop board PC12. A closure between RC4-1 and RC4-2 allows +24 volts DC to be supplied to the four relays on E-Stop board PC12. In an E-Stop situation (relays open), all four relays on the E-Stop board de-energize and cut power to the control boards.
  • Page 34 G. Arc Start Error Indicates the contactor either is or was active, but the system failed to start an arc. Conditions for a valid arc start are at least 50% of arc start current, voltage less than 60 volts, and voltage greater than min. valid arc voltage (default is 22.5 volts).
  • Page 35 K. Motor Communications Error The motor board has lost communication with the PCM board PC4. Check cabling and cable routing for boom system motor cable and secondary cables. Separate cable as much as possible. Check if WFM board PC6 code is installed and if microprocessor is running. Check LED3 and LED4 on WFM board PC6. Depending on the wire feed speed, check for 0-40 volts DC on J17-3 to J17-1.
  • Page 36 M. Over Current Error Indicates one or more of the inverter engines has latched with an over-current. Signal is sent from engine module(s) (RC6, Pin 11, on inverter control board PC1) to process control module PC4 (J2, Pin 6). The over-current circuit monitors the inverter high frequency transformer primary current. Normal welding will never trip this circuit, only a fault will cause an over-current condition.
  • Page 37 S. Stuck Error Indicates a wire stuck error. Press Jog/Purge button to clear error. This error occurs if the welding wire sticks to the workpiece at the end of a weld. This fault may be caused by poor welding conditions. Cut the welding wire from the workpiece. STUK T.

  • Page 38: Section 9 − Electrical Diagram

    SECTION 9 − ELECTRICAL DIAGRAM Figure 9-1. Circuit Diagram OM-220979 Page 34...
  • Page 39 214 842-F OM-220979 Page 35...

  • Page 40: Section 10 − Parts List

    SECTION 10 − PARTS LIST Hardware is common and not available unless listed. 803 696-D Figure 10-1. Remote Operator Interface Item Dia. Part Mkgs. Description Quantity Figure 10-1. Remote Operator Interface ....214839 WRAPPER, feeder .
  • Page 41 Item Dia. Part Mkgs. Description Quantity Figure 10-1. Remote Operator Interface (Continued) ... . 242360 CIRCUIT CARD ASSY, trigger filter ....... .
  • Page 42 Notes...
  • Page 43 Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? LIMITED WARRANTY − Subject to the terms and conditions below, 6 Months —...
  • Page 44 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 manufacturer’s Transportation Department. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2016 Miller Electric Mfg. Co. 2016−01...

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