Manuals / Miller Electric / Power Tools / Welding System

Miller Electric Welder operating instructions Directives, Standards

Models: Welder

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Declaration of Conformity For

European Community (CE) Products

Manufacturer’s Name:

Manufacturer’s Address:

Declares that the product:

Miller Electric Mfg. Co.

1635 W. Spencer Street Appleton, WI 54914 USA

Auto Invision II

conforms to the following Directives and Standards:

Directives

Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC

Low Voltage Directive: 73/23/EEC

Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC

Standards

Electromagnetic compatibility (EMC) Product standard for arc welding equipment:

EN50199: December 1995

Arc Welding Equipment part 1: CEI IEC 60974

Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989

Draft IEC 60974-5 Arc Welding Equipment part 5: wire feeders JWG1 (Sec) 158 July 2000

Insulation coordination for equipment within low-voltage systems:

Part 1: Principles, requirements and tests: IEC 664-1: 1992

European Contact: Mr. Danilo Fedolfi, Managing Director ITW WELDING PRODUCTS ITALY S.r.l. Via Privata Iseo 6/E

20098 San Giuliano Milanese, Italy

Telephone: 39(02)982901

Fax: 39(02)98290–203

dec_con1_11/02

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Miller Electric Welder operating instructions Directives, Standards

Contents

OM-196 188K ProcessesDescription From Miller to You Table of Contents Introduction to Programming 100101 Setup Control MenuDirectives StandardsArc Welding Hazards Symbol UsageMarks a special safety message Electric Shock can killFlying Metal can injure eyes ARC Rays can burn eyes and skinWelding can cause fire or explo- sion Buildup of GAS can injure or killPrincipal Safety Standards EMF Information About PacemakersUN Choc Électrique peut tuer Signification des symbolesConsignes DE Securite Lire Avant Utilisation LES Fumées ET LES GAZ peuvent être dangereuxDES 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 blessuresPrincipales normes de sécurité Information sur les champs électromagnétiquesConsignes relatives aux stimulateurs cardiaques Definitions Manufacturer’s Warning Label Definitions∠ = 60 sHarmonic Data Symbols And DefinitionsManufacturer’s Rating Label Harmonic Data per IEC 61000-3-12, draftInstallation SpecificationsDimensions And Weight Movement Location Connection DiagramSelecting a Location Tipping10 100% Duty Cycle Weld Output Terminals And Selecting Cable SizesVolts AC Duplex Receptacle And Circuit Breakers Duty CycleThree-Phase Electrical Service GuideConnecting Input Power Always connect grounding conductor firstRear Panel Connections Example ReceptaclePeripheral Receptacle Functions Socket InformationTop View Touch Sensor Board PC18 Switch S1 SettingsTouch Sensor Operation FrontConnecting Setup Pendant To Welding Power Source Turn Off welding power source and weld controlOperation Operational TermsLower Front Panel Controls Meter FunctionsUpper Front Panel Controls Duty Cycle And Overheating Volt-Ampere CurvesOverheating Setup Pendant Controls Increase ButtonBlowing Out Inside Of Unit Maintenance & TroubleshootingRoutine Maintenance MonthsRemoving Case and Measuring Input Capacitor Voltage Voltmeter/Ammeter Help Displays Help 1 DisplayFront Panel Error Displays Weld Interface Board PC12 Diagnostic LED’s LED2 LED4 LED8 LED10 LED11 LED6 LED3 LED5 LED7 LED9 LED12Diagnostic LED’s On Weld Interface Board PC12 Status DiagnosisCustomer 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 Source203 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 AssemblyPLG21 RC10 194 Setup Pendant OptionalOM-196 188 Programming Instructions for Pulse MIG Programs Program Hardwire Selected Softwire SelectedIntroduction to Programming Standard Pulse Welding ProgramsProgram 1 1.2 mm Steel .045, 98-2 Argon-Oxy Program 2 1.0 mm Steel .040, 80-20 Argon-CO2Program 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-CO2Program 7 1.0 mm 308L .040, 98-2 Argon-CO2 Program 8 1.2 mm 308L .045, 98-2 Argon-CO2Program 1 1.2 mm Metal Core .045, 95-5 Argon-CO2 Program 2 1.4 mm Metal Core .052, 95-5 Argon-CO2Program 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, ArgonProgram 5 1.0 mm 5356 .040, Argon Program 6 1.2 mm ER 5356 .045, ArgonProgram 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 DisplaySetting Postflow Sequence Display Teaching a Pulse Welding ProgramPulse 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 TrimTeaching 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 DisplaySetting SharpArcE Control Selecting And Adjusting SharpArcE ControlUsing the Optional Data Card Installing Data CardUsing The Data Card Naming Programs And Writing To Card YesReading From Card Reading Or Deleting From An Empty Card Deleting Programs From CardSecurity lock works only when a data card is inserted Selecting Security LockFeatures Settings Default Section SetupSetup Flow Chart Display Features Settings DefaultUsing Setup Displays T u pSelecting Or Changing Access Code ZWXSelecting Voltage Correction Selecting Auxiliary OutputSelecting Voltage Sensing Method Resetting Arc Time Selecting Arc Start MethodSelecting Units For Wire Feed Speed And Motor Type Selecting Wire Type Defining Display ValueResetting Memory Selecting Arc Start/Volt Sense Error ShutdownRemote Program Select Selecting Program Name FeatureRemote Program Setting Program No Output a Output B Output CJog Wire Feed Speed Selection Flow SelectionArc Voltage Error Selection Stick Check SelectionSetting Ramps Function Exiting The Setup MenuSoftware Version Number Using Menu Display Control MenuSetting Rise Time Parameter Setting Adaptive ParametersSetting Auto Configure Parameter Setting Retract On/Off Setting Sharp Start On/OffExiting The Control Menu Page Service SupportOwner’s Record Miller Electric Mfg. Co