Miller LiveArc Owner's Manual
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Miller LiveArc Owner's Manual

Welding performance management system
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Welding Performance Management System
OM-267357H
Processes
With Optional Equipment:
Description
Arc Welding Training System
LiveArc
®
2020−03
MIG (GMAW) Welding
Gas Shielded Flux Core
(FCAW-G) Welding
Stick (SMAW) Welding
File: Accessory

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Summary of Contents for Miller LiveArc

  • Page 1 2020−03 Processes MIG (GMAW) Welding Gas Shielded Flux Core (FCAW-G) Welding With Optional Equipment: Stick (SMAW) Welding Description Arc Welding Training System LiveArc ® Welding Performance Management System For product information, File: Accessory Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • 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

    ............4-6. Naming Convention For Miller Welding Assignments − GMAW/FCAW .
  • Page 4 TABLE OF CONTENTS SECTION 8 − ADMINISTRATION TOOLS (Continued) ......... . . 8-7.

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

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING LiveArc 2020-02 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: California Proposition 65 Warnings

    HOT PARTS can burn. MOVING PARTS can injure. D Do not touch hot parts bare handed. D Keep people away from touch screen protec- tive cover when it is being opened. Keep cover D Allow cooling period before working on closed when welding.

  • Page 7: Section 2 − Mesures De Sécurité − À Lire Avant Utilisation

    SECTION 2 − MESURES DE SÉCURITÉ − À LIRE AVANT UTILISATION LiveArc_2020-02_fre 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 8: Proposition Californienne 65 Avertissements

    D Ne pas déplacer ou installer le système de formation à un endroit Risque D’INCENDIE OU où il pourrait se renverser. Installer le système de formation sur D’EXPLOSION. une surface ferme et de niveau, loin des matières inflammables. Verrouiller les roues pour maintenir la table en position. D Ne pas placer l’appareil sur, au-dessus ou D Suivre les consignes du Manuel des applications pour l’équation à...

  • Page 9: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Miscellaneous Symbols And Definitions Amperage Touchscreen Scroll Forward In Time Voltage Audio/Sound Scroll Back In Time Internal Protection Vibration Feedback Test History Rating GUIDE Panel/Local Target Multi-Pass History (Power Source Setting) Input Plug And User Profile Welding Procedure Cord Specification...
  • Page 10 Vertical Position Travel Speed CTWD T-Joint (SMAW) Flat Position Travel Angle Arc Length Index − (GMAW/FCAW) T-Joint − Flat Position Travel Angle Work Angle (SMAW) Lap Joint Horizontal Position Work Angle Work Angle (GMAW/FCAW) Butt Joint Lap Joint Horizontal Position Work Angle (SMAW) Butt Joint...

  • Page 11: Section 4 − Specifications

    4-1. Introduction The LiveArc welding training system provides the new student or the experienced welder the opportunity to develop, enhance or verify their welding abilities through an interactive, simulated or live-arc process on a variety of weld joint configurations. The microprocessor-based training system connects to nearly any Miller power source/wire feeder combination and uses a series of cameras, LEDs, and markers on the SmartGun, SmartStinger, and table to monitor the welds being performed.

  • Page 12: Serial Number And Rating Label Location

    4-4. Information About Default Weld Parameters And Settings NOTICE − Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...

  • Page 13: Environmental Specifications

    4-6. Environmental Specifications A. IP Rating IP Rating IP21 This equipment is designed for indoor use and is not intended to be used or stored outside. IP21 2014−06 B. Temperature Specifications Operating Temperature Range Storage/Transportation Temperature Range −25 to 180°F (−31 to 82°C) 32 to 104°F (0 to 40°C) Temp_2016- 07 Notes...

  • Page 14: Naming Convention For Miller Welding Assignments − Gmaw/Fcaw

    4-7. Naming Convention For Miller Welding Assignments − GMAW/FCAW -GMAWS MATERIAL THICKNESS Inch Fraction JOINT TYPE T=T-Joint L=Lap Joint B=Butt Joint WELD POSITION 1F/1G=Flat 2F/2G=Horizontal 3F/3G=Vertical 4F/4G=Overhead WELDING PROGRESSION P=Push D=Drag Up=Uphill Dwn=Downhill WELDING PROCESS GMAW=GMAW GMAWS=GMAW-S GMAWP=GMAW-P FCAWG=FCAW-G NUMBER OF PASSES Integer 4-8.

  • Page 15: Section 5 − Installation

    SECTION 5 − INSTALLATION Welding-related hazards are present when using the welding training system. Read the welding power source and wire feeder Owner’s Manuals and labels carefully for more information on arc welding hazards. Also read American National Standard Z49.1, Safety in Welding, Cutting, and Allied Processes, from American Welding Society (www.aws.org).

  • Page 16: Installing Monitor Stand On Weld Table

    5-2. Installing Monitor Stand On Weld Table Use equipment of adequate capacity to lift and support monitor stand. Stabilize weld table by adjusting leveling feet. Casters Leveling Foot Monitor Stand Weld Table 3/8 x 1-1/2 in. Screw 3/8 in. Flat Washer 3/8 in.

  • Page 17: Positioning Arm

    5-3. Positioning Arm Keep fingers away from pinch points on positioning arm. Before removing positioning arm extension: w Remove weld coupon from clamp assembly. w Remove clamp assembly. w Place clamp assembly in storage holster. Stabilize weld table by adjusting leveling feet.

  • Page 18: Extension Arm And Clamp Assembly

    5-4. Extension Arm And Clamp Assembly Keep fingers away from pinch points on position- ing arm. Do not use extension arm and clamp to support ob- jects weighing more than 25 lb (11 kg). Before removing position- ing arm extension: w Remove weld coupon from clamp assembly.

  • Page 19: Clamp Assembly Height Limits By Weld Position (Gmaw/Fcaw)

    5-5. Clamp Assembly Height Limits By Weld Position (GMAW/FCAW) Position Height* Max. Coupon Length* Notes Table 36 in. (0.91 m) 24 in. (610 mm) Minimum 4 ft. 9 in. (1.45 m) 12 in. (305 mm) Height measured from top of coupon. Average 5 ft.

  • Page 20: Grounding The Work Table

    5-6. Grounding The Work Table Connect welding table to a good electrical ground (independent of the welding leads) unless qualified person assures it is safe to work an ungrounded workpiece. Ground Bolt Tapped Hole For Ground Bolt Use ground bolt (customer sup- plied) to connect the welding table good electrical...

  • Page 21: Installing Power Source Work Clamp

    5-8. Installing Power Source Work Clamp Keep fingers away from pinch points on positioning arm. Work Clamp Connection Plate For Weld Connect clamp Table Work Clamp to surface. Work Clamp Connection On Clamp Assembly Work clamp plates are located on both sides of weld table. Connect work clamp from welding power source to connection plate on weld table.

  • Page 22: Installing Gmaw Smartgun

    5-9. Installing GMAW SmartGun The SmartGun is compatible with Miller wire feeders that use a power pin connection and four−pin trigger receptacle. GMAW SmartGun Gun Power Pin Gun Trigger Plug SmartGun Power Plug SmartGun Power Cable Install SmartGun power pin and thread wire according to wire feeder Owner’s Manual.

  • Page 23: Making Connections To Touchscreen Monitor

    5-10. Making Connections To Touchscreen Monitor See Section 12 for making connections to monitor for units equipped with optional SMAW module. SmartGun Power Receptacle RJ45 Ethernet Receptacle HDMI Receptacle USB Receptacle Connect data cable from Smart- Gun to receptacle on back of moni- tor.

  • Page 24: Connecting Input Power To Monitor

    GFCI receptacle to power the training system. If a GFCI re- ceptacle must be used, do not use an extension cord. Ref. 268609-C Notes Register to Receive IMPORTANT Alerts for FREE LiveArc Software Upgrades MillerWelds.com/register Serial Number Sticker OM-267357 Page 20...

  • Page 25: Section 6 − System Controls And Components

    On-Off switch (Section 8-2). Close cover before beginning weld assignment. The LiveArc system will not permit live welding with cover open. The monitor screensaver dis- plays after four hours of inac-...

  • Page 26: Training System Cameras And Markers

    6-2. Training System Cameras And Markers Keep cameras, markers, and LEDs free of tools, coupons, weld spatter and other debris. If table is clear and cameras cannot locate table markers, clean marker tubes with a damp cloth. (Do not use chemicals, solvents, or abra- sives to clean markers.) Table markers can be covered af- ter completion of table calibration...

  • Page 27: Smartgun Controls

    6-3. SmartGun Controls Keep cameras and sensors free of weld spatter and other debris. The SmartGun LEDs may cause auto-darkening welding helmets to turn on (darken) before weld- ing starts. Set lens sensitivity to a level that prevents premature darkening of the lens (see hel- met owner’s manual).

  • Page 28: Using The Joint Calibration Tool

    6-4. Using The Joint Calibration Tool Clamp workpiece to table before calibrating. Joint Calibration Tool Workpiece Weld Joint At the beginning of each weld assign- ment you will be asked to use the joint calibration tool to establish setpoints on the workpiece joint. Setpoints are necessary for the training system cameras to learn the precise location of the joint.

  • Page 29: Section 7 − Operation

    Nothing is shown on the SmartGun display during SMAW welding. There is no SIM (Simulation) mode for SMAW welding. 7-1. Equipment Setup 1. Assemble LiveArc training system. Install in proper location and near welding power source (see Section 5-1). 2. Ground weld table as specified in Section 5-6.
  • Page 30 Add an input method. Scroll down to the United States-International Touch keyboard layout (in most cases, this should be the ninth option on the list). Select it to highlight it, then select Add. In the Language Options window, select Save. After logging into the LiveArc software as an instruc- tor, select System Admin, then Settings.

  • Page 31: Select Assignment

    7-2B. Select Assignment 1. Select desired assignment (Figure 7-4). Note the corresponding weld process, joint type, and position (flat or horizontal). View more assignments by touching link at bottom of screen. Screen also displays history of previous tests. Select Filters to narrow your search for specific assignments. Corresponding SmartGun Display Select Filters to help locate...
  • Page 32 2. Review weld assignment specifications. See Figure 7-5. Corresponding SmartGun Display Use button to navigate LiveArc screens. Screen shown is representative. Specific options may vary with weld process. Figure 7-5. Welding Assignment Specifications 3. Select Next (to continue with assignment), Back (previous page), or Change Assignment (to select a new assignment). See Figure 7-6.

  • Page 33: 7-2C

    7-2C. Table Calibration 1. Close touchscreen cover to enable table calibration process. Remove any objects blocking markers on table. See Figure 7-7, Figure 7-8, and Figure 7-9. Corresponding SmartGun Display Figure 7-7. Close Cover To Begin Table Calibration Corresponding SmartGun Display 161-049 Figure 7-8.

  • Page 34: Preparing To Weld

    Corresponding SmartGun Display 161-049 Figure 7-9. Successful Table Calibration 7-2D. Preparing To Weld 1. To tack weld coupons, press and hold Weld button on SmartGun until system enters Weld mode (about two seconds). (Monitor displays warning message.) Tack weld coupons on both ends. (See Figure 7-10 and Figure 7-11). Press Done button on SmartGun when finished. For tacking with the SMAW process, see Section 12-5.
  • Page 35 Corresponding SmartGun Display Figure 7-11. Warning Message Displayed When Welding 2. Clean table of spatter and clamp coupons to table on both ends (Figure 7-12). Press Weld button if additional tacking is needed or Next button if finished clamping. Corresponding SmartGun Display Clamp both ends of weld joint to prevent coupon from moving during...
  • Page 36 3. Calibrate both ends of weld joint. System chimes and touchscreen displays checkmark to indicate successful calibration. See Section 6-4 and Figure 7-13. Clamp weld coupons before calibrating. (Weld clamps are not shown.) Calibrate at both ends of weld joint. See Section 4-1 for joint cali- Avoid tack points.

  • Page 37: 7-2E. Practicing In Sim (Simulation) Mode (Gmaw/Fcaw Only)

    7-2E. Practicing In SIM (Simulation) Mode (GMAW/FCAW Only) 5. System is now in the SIM (simulation) mode (as indicated on SmartGun display screen) (Figure 7-15 and Figure 7-16). Move SmartGun near the weld joint; gun positioning recommendations are displayed on the touchscreen and the SmartGun display screen. (If you wish to relocate the weld coupons on the weld table, touch Move Part on the touchscreen.) Press Guide button to cycle through the parameters (work angle, travel angle, travel speed, aim, CTWD, and Guide Disabled).
  • Page 38 6. Position SmartGun near weld joint. Pull trigger and move gun along entire length of weld joint (4 in. [101 mm] for Miller assignments) in the correct orientation and speed as specified on the touchscreen. Release trigger and check score (Figure 7-17). If you fail the simulated test (score less than 90 for Miller assignments), examine scores in individual categories (gun angle, gun speed, contact tip to work distance [CTWD], etc.) to determine...
  • Page 39 Corresponding SmartGun Display History of total scores. Test dates are shown at top and weld test serial numbers at bottom. Corresponding SmartGun Display Touch screen to select other test histories. History of results in travel speed category. Touch histogram bar to view associated test graphs.

  • Page 40: Testing In Weld Mode

    The warning screen is displayed when SmartGun nears weld joint. Figure 7-19. Selecting LiveArc Mode 3. With SmartGun more than 3 in. (76 mm) from weld joint and SmartGun LEDs in view of camera, pull trigger to jog wire. Cut wire to length appropriate for the weld process (Figure 7-20).
  • Page 41 4. Pull trigger to begin welding. Weld must be a minimum 4 in. (101 mm) in length to satisfy Miller weld test. You must achieve a passing score (90 and above for Miller assignments) three times to advance to the next assignment (Figure 7-21). Select another assignment or touch to logout.

  • Page 42: Section 8 − Administration Tools

    • Options for who can turn off the system: Instructor and students, or Instructors only. • Option for saving tests to USB or for printing. To print directly from the LiveArc system, the printer must be installed on the LiveArc PC through the Windows 8 OS and configured as the default printer.

  • Page 43: Weld Tool Calibration

    Backups made with an earlier software version cannot be restored directly on a LiveArc system running a later software version. However, such backups can be restored on a computer running the later version of LiveArc software. After doing so, a new backup can be created on the computer and then restored onto the LiveArc system.

  • Page 44: Section 9 − Assignment Management

    Name, Joint Design, Base Metals, Filler Metals/Shielding, Position/Electrical Characteristics, Technique, Preheat/Postweld Heat Treatment, Welding Procedure, and Completion Criteria. Figure 9-1. Administration Mode Screen Notes Register to Receive IMPORTANT Alerts for FREE LiveArc Software Upgrades MillerWelds.com/register Serial Number Sticker OM-267357 Page 40...

  • Page 45: Creating New Assignments

    Assignments with incomplete Data Completion will remain hidden until all required fields are completed with valid data. Assignments can be imported from or exported to a USB drive to transfer between LiveArc systems or between a computer and a LiveArc system.
  • Page 46 3. Ensure each required parameter is filled out. Parameters may differ based on welding process. It is not necessary to save settings before proceeding to the next parameter screen. 4. To modify the Welding Procedure parameters of the new assignment, touch Welding Procedures/1 Pass (Figure 9-4). All applicable parameters can be changed;...

  • Page 47: Section 10 − User Management

    SECTION 10 − USER MANAGEMENT Welding-related hazards are present when using the welding training system. Read the welding power source and wire feeder Owner’s Manuals and labels carefully for more information on arc welding hazards. Also read American National Standard Z49.1, Safety in Welding, Cutting, and Allied Processes, from American Welding Society (www.aws.org).

  • Page 48: Editing User Information

    2. Enter first name, last name, user name, and user/student ID number. Designate whether the user is left-handed or right-handed and if the user is a student or an instructor. Touch Add when finished. Figure 10-3. Entering New User Information 10-3.

  • Page 49: Searching For Weld Serial Number

    2. Revise first name, last name, user name, user/student ID number, left-handed or right-handed status, and if the user is a student or an instructor. Touch Update when finished. Figure 10-5. Editing User Information 10-4. Searching For Weld Serial Number If the serial number of a weld is written on the weld coupons, an instructor can retrieve the test data associated with that weld by searching for the weld serial number.

  • Page 50: Section 11 − Viewing Dashboard

    Administration mode is only available to users designated as instructors. User Management records are password protected and can only be accessed by the user and the administrator/instructor. Touch Dashboard. Use Dashboard screen to review total usage of the LiveArc system, including number of tests and duration of tests (in Weld and Sim modes). Touch Home when finished.

  • Page 51: Section 12 − Optional Smaw Module Operation

    SECTION 12 − OPTIONAL SMAW MODULE OPERATION 12-1. SMAW Router Box Connection Points LiveArc Monitor Communication Receptacle Router Box To LiveArc SmartGun Receptacle Router Box Connection To Wire Feeder Monitor Back See Section 5-9 to connect Smart- Gun to wire feeder.

  • Page 52: Connecting Training System With Optional Smaw Module

    12-2. Connecting Training System With Optional SMAW Module Bottom of Router Box OM-267357 Page 48...
  • Page 53 SMAW Work Clamp To Weld Table that was originally made to the back fo the for disconnection from the electrical LiveArc monitor. Communication Cable To LiveArc supply source and the cord must be Positive Cable To SMAW Power Communication Cable To Router Box readily available.

  • Page 54: Connecting Smaw Router Box Input Power

    Be sure the training system does not block access to the input power cord. Monitor Back Connect LiveArc input power ac- cording to Section 5-11. SMAW Router Box Router Box Input Power Connection A 120 volt AC, 15 amp individual branch circuit protected by fuses or circuit breaker is required.

  • Page 55: Smartstinger Controls

    ★ Star ( ) Button Left And Right Arrow Naviga- tion Buttons The main LiveArc display screen helps the user navigate through the user interface. The screen displays warning statements, indicates the training mode (SETUP or WELD) and helps the user position the stinger properly.

  • Page 56: Tacking Weld Coupons

    Press Star ★ ) button on SmartStinger when finished. The LiveArc system can detect when a stick electrode becomes stuck to the workpiece. If stick stuck is detect- ed, the welding power turns off and a message is displayed below the warning.

  • Page 57: Stick Electrode Slot Confirmation

    12-6. Stick Electrode Slot Confirmation Stick electrode must be firmly seated in one of the two slots in the electrode holder. Incorrect electrode place- ment prevents accurate tracking of the SmartStinger. The stick electrode can be inserted in either side of SmartStinger for 1G and 2F positions.

  • Page 58: Using Smartstinger Position Guides

    WELD Mode 12-8. Equipment Setup 1. Assemble LiveArc training system. Install in proper location and near welding power source (see Section 5-1). 2. Ground weld table as specified in Section 5-6. 3. Connect welding power source work clamp(s) to welding table and positioning arm (if applicable). See Section 5-8.

  • Page 59: Section 13 − Maintenance

    SECTION 13 − MAINTENANCE Welding-related hazards are present when using the welding training system. Read the welding power source and wire feeder Owner’s Manuals and labels carefully for more information on arc welding hazards. Also read American National Standard Z49.1, Safety in Welding, Cutting, and Allied Processes, from American Welding Society (www.aws.org).

  • Page 60: Emptying Work Table Particle Tray

    13-2. Emptying Work Table Particle Tray Before each use, check tray and empty the particles into a fire- proof container. Do not operate unit without parti- cle tray. Hand Knobs After emptying particle tray, reinstall and tighten hand knobs. Tools Needed: Ref.

  • Page 61: Smartgun Consumable Removal And Replacement

    13-4. SmartGun Consumable Removal And Replacement Tools Needed: 5/8 in. (16 mm) Ref. Bernard 156 203 Tregaskiss tip tool (part no. 450−18 for NOTICE − The heavy duty retaining head See Section 16 for lists of consumable heavy duty tips) or a pair of weld pliers for must be tightened with a 5/8 in.

  • Page 62: Smartgun Quick Load Liner Replacement

    13-5. SmartGun Quick Load Liner Replacement Tools Needed: Turn Off welding power source and wire feeder. Quick Load liners feed from the front of the GMAW gun. There is no need to disconnect the SmartGun from the welding power source when changing liners. See Section 16 for lists of liner part numbers.

  • Page 63: Section 14 − Troubleshooting

    SECTION 14 − TROUBLESHOOTING Welding-related hazards are present when using the welding training system. Read the welding power source and wire feeder Owner’s Manuals and labels carefully for more information on arc welding hazards. Also read American National Standard Z49.1, Safety in Welding, Cutting, and Allied Processes, from American Welding Society (www.aws.org).
  • Page 64 Redo Camera-to-Arms Linkage Adjustment (see Section 8-8). SmartGun displays “Connection not High frequency interferes with SmartGun function. Do not connect LiveArc to a circuit used by equip- established.” ment producing high frequency. Do not connect work cable to a common ground used by welding equipment producing high frequency.

  • Page 65: Section 15 − Electrical Diagrams

    SECTION 15 − ELECTRICAL DIAGRAMS 272 833-A Figure 15-1. Circuit Diagram OM-267 357 Page 61...
  • Page 66 276650-B Figure 15-2. Circuit Diagram For Unit With Optional SMAW Module OM-267357 Page 62...

  • Page 67: Section 16 − Parts List

    267504 Power Cord, LiveArc No 16/3 15 ft ........
  • Page 68 ... . . 277826 Kit, LiveArc SmartGun Replacement (See Figure 16-2) .....
  • Page 69 Replacement Parts. Model and serial number required when ordering parts from your local distributor. The consumables on this page are included with every LiveArc system. They are available from Miller parts. See Section 13-4 for instructions on removing and replacing SmartGun consumables. See Section 13-5 for instructions on removing and replacing the SmartGun liner.
  • Page 70 Table 16-1 through Table 16-4 list all consumables compatible with the SmartGun. These parts are available from Bernard/Tregaskiss at 1-855−MIGWELD (1-855-644-9353). *Parts included with every LiveArc system. Table 16-1. Quick Load Liners Wire Size Liner Part Number 0.023 in. 415−23−15Q 0.030 in.
  • Page 71 *Parts included with every LiveArc system. Table 16-3. Nozzles Part No. Nozzle Type Bore Type** Material O.D. Length Tip Placement 401−6−50 Heavy Duty 1/2 in. Copper 1.062 in. 2.88 in. 1/8 in. Recess 401−48−62* Heavy Duty 5/8 in. Copper 1.062 in. 2.76 in.
  • Page 75 Effective January 1, 2020 (Equipment with a serial number preface of NA or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions Supplied Air Respirator (SAR) Boxes and Panels below, Miller Electric Mfg.
  • Page 76 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 2020 Miller Electric Mfg. LLC 2020−01...

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