OM-196 188K | Miller Electric Welder instruction

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OM-196 188K

July 2003

Processes

MIG (GMAW) Welding

Pulsed MIG (GMAW-P)

Flux Cored (FCAW) Welding

Automatic Welding

Description

Automatic Welding Interface And

Arc Welding Power Source

Operating Instructions and Programming Instructions for

Auto Invision II

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Miller Electric Welder operating instructions OM-196 188K, Processes, Description

Contents

Processes OM-196 188KDescription From Miller to You Table of Contents 100 Introduction to Programming101 Control Menu Setup Standards Directives Marks a special safety message Symbol UsageArc Welding Hazards Electric Shock can kill Welding can cause fire or explo- sion ARC Rays can burn eyes and skinFlying Metal can injure eyes Buildup of GAS can injure or kill Principal Safety Standards About Pacemakers EMF Information Consignes DE Securite Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereux DES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un incendie ou une explosionDES Pièces Chaudes peuvent pro- voquer des brûlures graves LE Bruit peut affecter l’ouïe LA Chute DE L’APPAREIL peut blesser Risque D’INCENDIE OU’EMPLOI Excessif peut DES Organes Mobiles peuvent provoquer des blessures Information sur les champs électromagnétiques Principales normes de sécuritéConsignes relatives aux stimulateurs cardiaques Manufacturer’s Warning Label Definitions Definitions 60 s ∠ = Manufacturer’s Rating Label Symbols And DefinitionsHarmonic Data Harmonic Data per IEC 61000-3-12, draft Specifications InstallationDimensions And Weight Selecting a Location Connection DiagramMovement Location Tipping Volts AC Duplex Receptacle And Circuit Breakers Weld Output Terminals And Selecting Cable Sizes10 100% Duty Cycle Duty Cycle Connecting Input Power Electrical Service GuideThree-Phase Always connect grounding conductor first Example Receptacle Rear Panel Connections Socket Information Peripheral Receptacle Functions Touch Sensor Operation Touch Sensor Board PC18 Switch S1 SettingsTop View Front Turn Off welding power source and weld control Connecting Setup Pendant To Welding Power Source Operational Terms Operation Meter Functions Lower Front Panel Controls Upper Front Panel Controls Volt-Ampere Curves Duty Cycle And OverheatingOverheating Increase Button Setup Pendant Controls Routine Maintenance Maintenance & TroubleshootingBlowing Out Inside Of Unit Months Removing Case and Measuring Input Capacitor Voltage Help 1 Display Voltmeter/Ammeter Help Displays Front Panel Error Displays LED2 LED4 LED8 LED10 LED11 LED6 LED3 LED5 LED7 LED9 LED12 Weld Interface Board PC12 Diagnostic LED’s Status Diagnosis Diagnostic LED’s On Weld Interface Board PC12 Customer Interface Board PC14 Diagnostic LED’s Diagnostic LED’s On Customer Interface Board PC14 Motor Board PC13 Diagnostic LED’s Troubleshooting Diagnostic LED’s On Motor Board PC13Trouble Remedy OM-196 188 Circuit Diagram For Welding Power Source Electrical Diagrams 203 505-A Circuit Diagram For Control Board PC1 Part 1 203 311 1 Circuit Diagram For Control Board PC1 Part 2 203 311 2 Circuit Diagram For Control Board PC1 Part 3 203 311 3 Circuit Diagram For Function/Meter Board PC3 190 Circuit Diagram For Interconnect Board PC2 OM-196 188 Circuit Diagram For Interface Module 193 709-A Circuit Diagram For Microprocessor Board PC11 191 10. Circuit Diagram For Motor Board PC13 212 354-A 11. Circuit Diagram For Switch Board PC15 12. Circuit Diagram For Junction Board PC16 13. Circuit Diagram For Interface Board PC12 Part 1 191 843-A Part 1 14. Circuit Diagram For Interface Board PC12 Part 2 191 843-A Part 2 15. Circuit Diagram For Customer Interface Board PC14 Part 1 Pensar 86147s03 Part 1 16. Circuit Diagram For Customer Interface Board PC14 Part 2 Pensar 86147s03 Part 2 17. Circuit Diagram For Customer Interface Board PC14 Part 3 Pensar 86147s03 Part 3 18. Circuit Diagram For Touch Sensor Board PC18 19. Circuit Diagram For Setup Pendant 200 21. Circuit Diagram For Power Distribution Board PC20 Complete Assembly Parts List PLG21 RC10 Optional 194 Setup Pendant OM-196 188 Programming Instructions for Introduction to Programming Program Hardwire Selected Softwire SelectedPulse MIG Programs Standard Pulse Welding Programs Program 2 1.0 mm Steel .040, 80-20 Argon-CO2 Program 1 1.2 mm Steel .045, 98-2 Argon-Oxy Program 4 .8 mm 316 .030, 98-2 Argon-CO2 Program 3 1.2 mm Steel .045, 80-20 Argon-CO2Gas Ar CO2 / 19 L/min 40 CFH Program 6 1.2 mm 316 .045, 98-2 Argon-CO2 Program 5 1.0 mm 316 .040, 98-2 Argon-CO2 Program 8 1.2 mm 308L .045, 98-2 Argon-CO2 Program 7 1.0 mm 308L .040, 98-2 Argon-CO2 Program 2 1.4 mm Metal Core .052, 95-5 Argon-CO2 Program 1 1.2 mm Metal Core .045, 95-5 Argon-CO2 Wire Size/Type 1.0 mm .040 ER Gas Ar / 19 L/min 40 CFH Wire Size/Type 1.2 mm .045 ER Gas Ar / 19 L/min 40 CFHProgram 3 1.2 mm ER 4043 .045, Argon Program 4 1.0 mm ER 4043 .040, Argon Program 6 1.2 mm ER 5356 .045, Argon Program 5 1.0 mm 5356 .040, Argon Program 8 1.0 mm Steel .040, 98-2 Argon-Oxy Program 7 .8 mm Steel .030, 98-2 Argon-OxyGas Ar Oxy/ 19 L/min 40 CFH Setup Pendant Mode Select Button Setup Pendant Parameter Select Button Setup Pendant Parameter Increase And Decrease Buttons Getting Started for Pulse Welding Setting Preflow Sequence DisplayWeld Cycle For Pulse Welding Setting Crater Sequence Display Setting Weld Sequence Display Teaching a Pulse Welding Program Setting Postflow Sequence DisplayPulse Waveform Explained IPM Teach Points ExplainedPage Setting Teach Point Parameters For Pulse Welding Program Card # Gun Model Flowrate Wire Size/Type GasPWms Vpk Sec Run-In Trim Changing To Adaptive Pulse Welding Teaching a MIG Welding ProgramWeld Cycle For Mig Welding Changing To Mig Welding Setting Start Sequence Display Setting Retract Sequence Display Poflw Sec Parameter Select Postflow Parameters Display Setting Run-in Sequence Display Selecting And Adjusting SharpArcE Control Setting SharpArcE Control Installing Data Card Using the Optional Data Card Using The Data Card Yes Naming Programs And Writing To Card Reading From Card Deleting Programs From Card Reading Or Deleting From An Empty Card Selecting Security Lock Security lock works only when a data card is inserted Setup Flow Chart SetupFeatures Settings Default Section Display Features Settings Default T u p Using Setup Displays ZWX Selecting Or Changing Access Code Selecting Auxiliary Output Selecting Voltage CorrectionSelecting Voltage Sensing Method Selecting Arc Start Method Resetting Arc Time Selecting Units For Wire Feed Speed And Motor Type Defining Display Value Selecting Wire Type Selecting Arc Start/Volt Sense Error Shutdown Resetting Memory Remote Program Setting Selecting Program Name FeatureRemote Program Select Program No Output a Output B Output C Flow Selection Jog Wire Feed Speed Selection Stick Check Selection Arc Voltage Error Selection Exiting The Setup Menu Setting Ramps FunctionSoftware Version Number Control Menu Using Menu Display Setting Adaptive Parameters Setting Rise Time Parameter Setting Auto Configure Parameter Setting Sharp Start On/Off Setting Retract On/Off Exiting The Control Menu Page Support Service Miller Electric Mfg. Co Owner’s Record