Miller Electric Welder operating instructions

Contents

Main Auto Invision II Operating Instructions and Programming Instructions for From Miller to You WARNING Page Page Declaration of Conformity For European Community (CE) Products Appleton, WI 54914 USA SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage . 1-2. Arc Welding Hazards ELECTRIC SHOCK can kill. ARC RAYS can burn eyes and skin. WELDING can cause fire or explo- sion. FLYING METAL can injure eyes. BUILDUP OF GAS can injure or kill. HOT PARTS can cause severe burns. 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. FALLING UNIT can cause injury. OVERUSE can cause OVERHEATING STA TIC (ESD) can damage PC boards. 1-5. EMF Information OM-196 188 Page 5 SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 1-1. Signification des symboles . 1-2. Dangers relatifs au soudage larc UN CHOC LECTRIQUE peut tuer. LES RAYONS DE LARC peuvent pro- voquer des brlures dans les yeux et sur la peau. LE SOUDAGE peut provoquer un incendie ou une explosion. DES PARTICULES VOLANTES peuvent blesser les yeux. LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou mme la mort. DES PICES CHAUDES peuvent pro- voquer des brlures graves. 1-3. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance 1-4. Principales normes de scurit 1-5. Information sur les champs lectromagntiques SECTION 2 DEFINITIONS 2-1. Manufacturers Warning Label Definitions = <60 2-2. Symbols And Definitions A Amperage Positive Remote V 2-3. Manufacturers Rating Label 2-4. Harmonic Data SECTION 3 INSTALLATION 3-1. Specifications 3-2. Dimensions And Weight 3-3. Selecting A Location 3-4. Connection Diagram . 3-5. Weld Output Terminals And Selecting Cable Sizes 3-6. 115 Volts AC Duplex Receptacle And Circuit Breakers 3-7. Electrical Service Guide 3-8. Connecting Input Power 3-9. Rear Panel Connections 3-10. Peripheral Receptacle Functions 3-11. Touch Sensor Operation 3-12. Touch Sensor Board PC18 Switch S1 Settings 3-13. Connecting Setup Pendant To Welding Power Source . SECTION 4 OPERATION 4-1. Operational Terms The following is a list of terms and their definitions as they apply to this interface unit: 4-2. Lower Front Panel Controls . CE 4-3. Meter Functions 24.5 250 24.5 24.5 250 4-4. Upper Front Panel Controls 4-5. Duty Cycle And Overheating A/V 4-6. Volt-Ampere Curves 4-7. Setup Pendant Controls SECTION 5 MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance 5-2. Blowing Out Inside Of Unit 3 Months 6 Months 5-3. Removing Case and Measuring Input Capacitor Voltage 5-4. Voltmeter/Ammeter Help Displays . HE.L P1 HE.L P2 HE.L P3 HE.L P4 HE.L P8 HE.L P5 HE.L P6 5-5. Front Panel Error Displays Mem CRC E r r o r No I nput IPM Stop Weld Cycle Err Mem Range Er r 5-6. Weld Interface Board PC12 Diagnostic LEDs 5-7. Diagnostic LEDs On Weld Interface Board PC12 5-8. Customer Interface Board PC14 Diagnostic LEDs 5-9. Diagnostic LEDs On Customer Interface Board PC14 5-10. Motor Board PC13 Diagnostic LEDs 5-11. Diagnostic LEDs On Motor Board PC13 5-12. Troubleshooting Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page SECTION 7 PARTS LIST . Figure 7-1. Complete Assembly Page Page Page Page Page SECTION 8 INTRODUCTION TO PROGRAMMING 8-1. Pulse MIG Programs . 8-2. Standard Pulse Welding Programs 8-3. Program 1 1.2 mm Steel (.045), 98-2 Argon-Oxy 8-4. Program 2 1.0 mm Steel (.040), 80-20 Argon-CO 8-5. Program 3 1.2 mm Steel (.045), 80-20 Argon-CO 8-6. Program 4 .8 mm 316 (.030), 98-2 Argon-CO 8-7. Program 5 1.0 mm 316 (.040), 98-2 Argon-CO 8-8. Program 6 1.2 mm 316 (.045), 98-2 Argon-CO 8-9. Program 7 1.0 mm 308L (.040), 98-2 Argon-CO 8-10. Program 8 1.2 mm 308L (.045), 98-2 Argon-CO 8-1 1. Program 1 1.2 mm Metal Core (.045), 95-5 Argon-CO The next 8 programs are available after changing software wiretype (see Section 14-10). 8-12. Program 2 1.4 mm Metal Core (.052), 95-5 Argon-CO 8-13. Program 3 1.2 mm ER 4043 (.045), Argon 8-14. Program 4 1.0 mm ER 4043 (.040), Argon 8-15. Program 5 1.0 mm 5356 (.040), Argon 8-16. Program 6 1.2 mm ER 5356 (.045), Argon 8-17. Program 7 .8 mm Steel (.030), 98-2 Argon-Oxy 8-18. Program 8 1.0 mm Steel (.040), 98-2 Argon-Oxy 8-19. Setup Pendant Mode Select Button 8-20. Setup Pendant Parameter Select Button 8-21. Setup Pendant Parameter Increase And Decrease Buttons SECTION 9 GETTING STARTED FOR PULSE WELDING 9-1. Weld Cycle For Pulse Welding . 9-2. Setting Preflow Sequence Display 9-3. Setting Weld Sequence Display 9-4. Setting Crater Sequence Display 9-5. Setting Postflow Sequence Display SECTION 10 TEACHING A PULSE WELDING PROGRAM See GMAW-P (Pulsed MIG) Process Guide supplied with unit for more information. 10-1. Pulse Waveform Explained 10-2. Teach Points Explained 10-3. Selecting Teach Point Wire Feed Speed For Pulse Welding Program 10-4. Setting Teach Point Parameters For Pulse Welding Program Make copies of this chart for future use. 10-5. Changing To Adaptive Pulse Welding SECTION 11 TEACHING A MIG WELDING PROGRAM 11-1. Weld Cycle For Mig Welding . 11-2. Changing To Mig Welding 11-3. Setting Preflow Sequence Display 11-4. Setting Start Sequence Display 11-5. Setting Weld Sequence Display 11-6. Setting Crater Sequence Display 11-7. Setting Retract Sequence Display 11-8. Setting Postflow Sequence Display . 11-9. Setting Run-in Sequence Display SECTION 12 SETTING SharpArcE CONTROL 12-1. Selecting And Adjusting SharpArcE Control SECTION 13 USING THE OPTIONAL DATA CARD 13-1. Installing Data Card 13-2. Using The Data Card 13-3. Naming Programs And Writing To Card 13-4. Reading From Card Programs developed on the Auto Invision will not run the same on Auto Invision II. 13-5. Reading (Or Deleting) From An Empty Card 13-6. Deleting Programs From Card 13-7. Selecting Security Lock Security lock works only when a data card is inserted. SECTION 14 SETUP 14-1. Setup Flow Chart 14-2. Using Setup Displays Set up 14-3. Selecting Or Changing Access Code Access code works only when a data card is inserted (see Section 13). 14-4. Selecting Voltage Correction 14-5. Selecting Auxiliary Output 14-6. Selecting Voltage Sensing Method 14-7. Selecting Arc Start Method 14-8. Resetting Arc Time 14-9. Selecting Units For Wire Feed Speed And Motor Type 14-10. Selecting Wire Type . 14-11. Defining Display Value 14-12. Resetting Memory 14-13. Selecting Arc Start/Volt Sense Error Shutdown 14-14. Selecting Program Name Feature 14-15. Remote Program Select 14-16. Remote Program Setting See the following table for the remote program select binary code. 14-17. Jog Wire Feed Speed Selection . 14-18. Flow Selection . 14-19. Arc Voltage Error Selection 14-20. Stick Check Selection 14-21. Setting Ramps Function 14-22. Software Version Number 14-23. Exiting The Setup Menu SECTION 15 CONTROL MENU 15-1. Using Menu Display Con t r o l 15-2. Setting Rise Time Parameter 15-3. Setting Adaptive Parameters . 15-4. Setting Auto Configure Parameter 15-5. Setting Retract On/Off 15-6. Setting Sharp Start On/Off . 15-7. Exiting The Control Menu Page Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Effective January 1, 2002 (Equipment with a serial number preface of LC or newer) Please complete and retain with your personal records. For Service Always provide Model Name and Serial/Style Number. Owners Record