Miller Electric Welder manual

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Miller Electric Welder operating instructions

Contents

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