Owner’s Record, Miller Electric Mfg. Co | Miller Electric Welder

Owner’s Record

Please complete and retain with your personal records.

Model Name	Serial/Style Number
Purchase Date	(Date which equipment was delivered to original customer.)

Distributor

Address

City

State	Zip

For Service

Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:	Welding Supplies and Consumables
	Options and Accessories
	Personal Safety Equipment
	Service and Repair
	Replacement Parts
	Training (Schools, Videos, Books)
	Technical Manuals (Servicing Information
	and Parts)
	Circuit Diagrams
	Welding Process Handbooks

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.
PRINTED IN USA	 2003 Miller Electric Mfg. Co. 1/03

Miller Electric Mfg. Co.

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters–USA

USA Phone: 920-735-4505 Auto-Attended

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

European Headquarters –

United Kingdom

Phone: 44 (0) 1204-593493

FAX: 44 (0) 1204-598066

www.MillerWelds.com

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Miller Electric Welder operating instructions Owner’s Record, Miller Electric Mfg. Co

Contents

OM-196 188K ProcessesDescription From Miller to You Table of Contents Introduction to Programming 100101 Setup Control Menu Directives Standards Symbol Usage Marks a special safety messageArc Welding Hazards Electric Shock can kill ARC Rays can burn eyes and skin Welding can cause fire or explo- sionFlying Metal can injure eyes Buildup of GAS can injure or kill Principal Safety Standards EMF Information About Pacemakers Signification des symboles Consignes DE Securite Lire Avant UtilisationUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereux LE Soudage peut provoquer un incendie ou une explosion DES Particules Volantes peuvent blesser les yeuxDES Pièces Chaudes peuvent pro- voquer des brûlures graves LE Bruit peut affecter l’ouïe Risque D’INCENDIE OU LA Chute DE L’APPAREIL peut blesser’EMPLOI Excessif peut DES Organes Mobiles peuvent provoquer des blessures Principales normes de sécurité Information sur les champs électromagnétiquesConsignes relatives aux stimulateurs cardiaques Definitions Manufacturer’s Warning Label Definitions ∠ = 60 s Symbols And Definitions Manufacturer’s Rating LabelHarmonic Data Harmonic Data per IEC 61000-3-12, draft Installation SpecificationsDimensions And Weight Connection Diagram Selecting a LocationMovement Location Tipping Weld Output Terminals And Selecting Cable Sizes Volts AC Duplex Receptacle And Circuit Breakers10 100% Duty Cycle Duty Cycle Electrical Service Guide Connecting Input PowerThree-Phase Always connect grounding conductor first Rear Panel Connections Example Receptacle Peripheral Receptacle Functions Socket Information Touch Sensor Board PC18 Switch S1 Settings Touch Sensor OperationTop View 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 Duty Cycle And Overheating Volt-Ampere CurvesOverheating Setup Pendant Controls Increase Button Maintenance & Troubleshooting Routine MaintenanceBlowing Out Inside Of Unit 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 Diagnostic LED’s On Motor Board PC13 TroubleshootingTrouble 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 Program Hardwire Selected Softwire Selected Introduction to ProgrammingPulse MIG Programs 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 3 1.2 mm Steel .045, 80-20 Argon-CO2 Program 4 .8 mm 316 .030, 98-2 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 Wire Size/Type 1.2 mm .045 ER Gas Ar / 19 L/min 40 CFH Wire Size/Type 1.0 mm .040 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 5 1.0 mm 5356 .040, Argon Program 6 1.2 mm ER 5356 .045, Argon Program 7 .8 mm Steel .030, 98-2 Argon-Oxy Program 8 1.0 mm Steel .040, 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 Setting Preflow Sequence Display Getting Started for Pulse WeldingWeld Cycle For Pulse Welding Setting Weld Sequence Display Setting Crater Sequence Display Setting Postflow Sequence Display Teaching a Pulse Welding ProgramPulse Waveform Explained Teach Points Explained IPMPage Setting Teach Point Parameters For Pulse Welding Program Wire Size/Type Gas Card # Gun Model FlowratePWms Vpk Sec Run-In Trim Teaching a MIG Welding Program Changing To Adaptive Pulse WeldingWeld 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 Setup Setup Flow ChartFeatures Settings Default Section Display Features Settings Default Using Setup Displays T u p Selecting Or Changing Access Code ZWX Selecting Voltage Correction Selecting Auxiliary OutputSelecting 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 Selecting Program Name Feature Remote Program SettingRemote Program Select Program No Output a Output B Output C Jog Wire Feed Speed Selection Flow Selection Arc Voltage Error Selection Stick Check Selection Setting Ramps Function Exiting The Setup MenuSoftware 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