OM-172 324D September1998 Processes MIG (GMAW) Welding Pulsed MIG (GMAW-P) Automatic Welding Description Automatic Welding Interface Robotic Interface II Visit our website at www.MillerWelds.
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
TABLE OF CONTENTS OM-172 324D SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . .
TABLE OF CONTENTS SECTION 8 – TEACHING A MIG WELDING PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Weld Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Changing To MIG In The Process Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Setting Sequence MIG Welding Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROBOTIC INTERFACE II SET-UP INFORMATION Please fill out the following information when setting up your equipment. It can be used for your records and also be valuable if you ever need to call for service.
Declaration of Incorporation for European Community (CE) Products Miller Electric Mfg. Co. Manufacturer’s Name: 1635 W.
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2.
ARC RAYS can burn eyes and skin. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). Wear approved safety glasses with side shields under your helmet.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near combustible surfaces. Do not install unit near flammables. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in place.
1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields.
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Identifie un message de sécurité particulier. Signifie NOTA ; n’est pas relatif à la sécurité.
LES RAYONS DE L’ARC peuvent provoquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Porter un casque de soudage muni d’un écran de filtre approprié pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. DES ORGANES MOBILES peuvent provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables. Rester à l’écart des organes mobiles comme le ventilateur. Maintenir fermés et fixement en place les portes, panneaux, recouvrements et dispositifs de protection.
1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, de l’American Welding Society, 550 N.W.
SECTION 2 – INSTALLATION 2-1. Specifications Specification Description Type Of Input Power From Welding Power Source Single-Phase 115 Volts AC, 5 Amperes, 50/60 Hertz Welding Power Source Type Constant Voltage (CV) DC, With Contactor And 14-Pin Remote Control For GMAW Welding Constant Voltage (CV)/Constant Current (CC) DC Inverter, With Contactor And 14-Pin Remote Control For GMAW-P Welding Wire Feed Speed Range* Standard: 50 To 780 ipm (1.3 To 19.8 mpm) Wire Diameter Range .030 To .062 in (0.
2-3.
2-4. Connecting Optional Emergency Stop Push Button Terminal strip 2T provides connection points for an optional normally closed Emergency Stop (E-stop) push button. To make connections, proceed as follows. Remove top cover. 2 1 Terminal Strip 2T 2 Strain Relief Loosen strain relief and insert leads from normally closed E-stop push button. Route leads to 2T. 1 Remove jumper link across terminals A and B on 2T. Keep for future use.
Setup Screen Terms: Access Code NOTE: The optional Data Card is required to activate this feature. With code off, access to the setup displays is not restricted. With code on, the operator must know and enter the access code to access or change any of the setup displays. To use code, press Parameter Select button to enter access code. When the correct letter is entered, the indicator automatically moves to the next character.
SECTION 4 – OPERATION 4-1. Safety Equipment 1 2 3 Wear the following while welding: 1 Dry, Insulating Gloves 2 Safety Glasses With Side Shields 3 Welding Helmet With Correct Shade Of Filter (See ANSI Z49.1) sb3.1 1/94 4-2. Work Clamp 1 1 Tools Needed: Work Clamp Connect work clamp to a clean, paint-free location on workpiece, as close to weld area as possible. Use wire brush or sandpaper to clean metal at weld joint area. Use chipping hammer to remove slag after welding. sb4.
4-3. Controls Front Panel 3 2 1 1 Display 2 Reset Button After clearing an error, press this button to reset the display. 3 Purge Button Push to energize gas valve. If a purge time value is programmed, the gas will flow for the programmed length of time. If a value is not programmed, the gas flows until the Purge button is released. 8 7 This button allows purging of air from gun shielding gas line, and adjusting shielding gas regulator without energizing the welding circuit.
4-4. Shielding Gas 1 Shielding Gas Cylinder 2 2 Valve 1 Open valve on cylinder just before welding. Close valve on cylinder when finished welding. sb5.1* 6/92 – S-0621-C 4-5.
4-7. Control Settings On Dimension 452 Or 652 Ampere Model Welding Power Source 1 Dimension 452 Model Hot Start Switch 3 Amperage/Voltage Adjustment Control Setting at controls and switch position does not matter when Process Selector switch is in GMAW position and remote Amperage/Voltage Control switch is in REMOTE position. Set controls as shown for all welding processes when using this interface unit.
4-8. Control Settings On XMT 304 Inverter Model Welding Power Source Set controls as shown for all welding processes when using this interface unit. 1 4 2 3 ST-801 192 / Ref. ST-175 086 1 2 Voltage/Amperage Adjustment Control Mode Switch The Mode switch setting determines both the process and output On/Off control. Source of control (panel or remote) for the amount of output is selected on the V/A Control switch.
4-9. Control Settings On Invision 456P Inverter Model Welding Power Source Set controls as shown for all welding processes when using this interface unit. 1 2 3 ST-801 718 / ST-180 311-B 1 Voltage Adjustment Control 2 Inductance Control Inductance determines the “wetness” of the weld puddle. When set higher, “wetness” (puddle fluidity) increases. OM-172 324 Page 18 3 Remote On/Off Receptacle (Optional) Sockets 1 and 2 are connected in parallel with the Power On/Off switch.
4-10. Setting Switches On Maxtron 450 Ampere Inverter Model Welding Power Source Set switches as shown for all welding processes when using this interface unit. Ref. ST-150 171-C / Ref. SC-154 197 SECTION 5 – INTRODUCTION TO PROGRAMMING 5-1. Interface Unit 1 1 Interface Unit The interface unit is designed for use in pulse MIG welding (adaptive or standard), or MIG welding. The unit is factory-equipped with eight programs for pulse MIG welding (see Section 5-2).
5-2. Pulse MIG Programs Program Hardwire Selected* Softwire Selected* 1 .035” Steel, Argon – Oxy .045” 4043, Argon 2 .045” Steel, Argon – Oxy .045” 5356, Argon 3 .035” Steel, Argon – CO2 .035” 4043, Argon 4 .045” Steel, Argon – CO2 .035” 5356, Argon 5 .035” 309, Argon – CO2 1/16” 4043, Argon 6 .045” Steel, 309, Argon – CO2 1/16” 5356, Argon 7 3/64” 5356, Argon .045” Steel, Argon – CO2 8 .035” SIB, Argon .045” Steel, Argon – Oxy The eight pulse programs are shown in the table.
Program 1 – .035 Steel, Argon-Oxy Wire Size/Type: .035” Steel Gas: Ar - Oxy / 40 CFH IPM / MPM Apk Abk PPS PWms 750 / 19.1 460 90 210 2.4 700 / 17.8 450 90 200 2.4 650 / 16.5 440 85 190 2.3 600 / 15.2 430 85 180 2.3 550 / 14.0 420 80 170 2.3 500 / 12.7 410 80 160 2.2 450 / 11.4 400 75 150 2.2 400 / 10.2 380 70 140 2.2 350 / 8.9 360 65 130 2.1 300 / 7.6 340 60 120 2.1 250 / 6.4 320 55 110 2.0 200 / 5.1 300 50 100 2.0 150 / 3.
Program 3 – .035 Steel, Argon-CO2 Wire Size/Type: .035” Steel Gas: Ar - CO2 / 40 CFH IPM / MPM Apk Abk PPS PWms 750 / 19.1 470 90 210 2.3 700 / 17.8 470 90 210 2.3 650 / 16.5 460 85 200 2.3 600 / 15.2 450 85 190 2.2 550 / 14.0 440 80 180 2.2 500 / 12.7 430 80 170 2.2 450 / 11.4 410 80 160 2.2 400 / 10.2 390 75 150 2.1 350 / 8.9 370 70 140 2.0 300 / 7.6 350 70 120 2.0 250 / 6.4 330 65 100 2.0 200 / 5.1 310 55 80 2.0 150 / 3.8 290 50 65 1.
Program 5 – .035” ER 309, Argon - CO2 Wire Size/Type: .035” ER 309 Gas: Ar - CO2 / 40 CFH IPM / MPM Apk Abk PPS PWms 750 / 19.1 390 95 210 2.2 700 / 17.8 380 95 200 2.1 650 / 16.5 370 90 190 2.0 600 / 15.2 360 85 180 1.9 550 / 14.0 350 80 170 1.9 500 / 12.7 340 75 160 1.9 450 / 11.4 330 70 150 1.8 400 / 10.2 320 65 140 1.8 350 / 8.9 310 60 130 1.7 300 / 7.6 300 55 120 1.7 250 / 6.4 290 50 100 1.6 200 / 5.1 280 45 80 1.6 150 / 3.
Program 7 – 3/64” ER 5356, Argon Wire Size/Type: 3/64” ER 5356 Gas: Argon / 40 CFH IPM / MPM Apk Abk PPS PWms 750 / 19.1 540 130 190 2.9 700 / 17.8 520 125 190 2.8 650 / 16.5 500 120 180 2.8 600 / 15.2 480 115 170 2.8 550 / 14.0 460 110 160 2.7 500 / 12.7 440 100 150 2.7 450 / 11.4 420 90 140 2.7 400 / 10.2 390 85 130 2.6 350 / 8.9 370 70 120 2.4 300 / 7.6 355 55 110 2.3 250 / 6.4 335 45 100 2.2 200 / 5.1 310 35 90 2.2 150 / 3.
NOTE The next 8 programs are available after changing software wiretype (see Section 10-13). Program 1 – .035” ER 4043, Argon Wire Size/Type: .035” ER 4043 Gas: Argon / 40 CFH IPM / MPM Apk Abk PPS PWms 750 / 19.1 450 140 155 2.0 730 / 18.5 445 135 150 1.9 720 / 18.3 440 130 145 1.9 710 / 18.0 430 130 140 1.8 655 / 16.6 415 120 135 1.7 600 / 15.2 400 118 125 1.7 545 / 13.8 395 115 115 1.6 490 / 12.4 370 100 105 1.5 435 / 11.0 350 90 100 1.4 380 / 9.
160 / 4.1 212 55 125 1.9 105 / 2.7 210 41 55 1.9 Program 3 – 1/16” ER 4043, Argon Wire Size/Type: 1/16” ER 4043 Gas: Argon / 40 CFH IPM / MPM Apk Abk PPS PWms 770 / 19.6 560 251 294 2.7 730 / 18.5 560 251 294 2.7 710 / 18.0 560 251 294 2.7 655 / 16.6 560 251 294 2.7 600 / 15.2 558 251 290 2.7 545 / 13.8 540 251 275 2.6 490 / 12.4 520 251 250 2.5 435 / 11.0 495 251 225 2.4 380 / 9.7 470 251 190 2.2 325 / 8.3 455 240 150 2.0 270 / 6.
160 / 4.1 175 33 45 2.3 105 / 2.7 175 25 29 2.2 Program 5 – 3/64” ER 5356, Argon Wire Size/Type: 3/64” ER 5356 Gas: Argon / 40 CFH IPM / MPM Apk Abk PPS PWms 755 / 19.2 465 138 270 3.0 730 / 18.5 445 130 265 2.9 700 / 17.8 425 128 255 2.8 680 / 17.3 405 120 245 2.7 655 / 16.6 385 110 235 2.6 600 / 15.2 365 100 228 2.5 545 / 13.8 345 92 215 2.5 490 / 12.4 330 85 200 2.4 435 / 11.0 320 80 193 2.3 380 / 9.7 310 78 186 2.2 325 / 8.
105 / 2.7 315 51 58 1.6 75 / 1.9 311 35 58 1.5 Program 7 – 3/64” ER 5356, Argon Wire Size/Type: 3/64” ER 5356 Gas: Argon / 40 CFH IPM / MPM Apk Abk PPS PWms 750 / 19.1 465 138 270 3.0 720 / 18.3 445 130 265 2.9 700 / 17.8 425 125 255 2.8 680 / 17.3 402 120 244 2.7 655 / 16.6 382 110 235 2.6 600 / 15.2 360 99 225 2.5 545 / 13.8 340 92 215 2.5 490 / 12.4 325 85 200 2.4 435 / 11.0 315 80 177 2.3 380 / 9.7 305 76 168 2.2 325 / 8.
160 / 4.1 180 30 43 2.1 105 / 2.7 180 23 30 2.0 5-4. Pulse Panel Mode Select Button Control circuit and interface operational power are On when using or changing the microprocessor settings. 1 Mode Display 2 Mode Select Button Press Mode Select button to move indicator in left window display. Go to Section 5-5. Pulse Panel 1 >P r o c e s s Ca r d Sequence P r oces s >C a r d Sequence > Pr g 1 Pu l s e 03 5 ” S t e e l Ar g o n–Ox y 2 Ref.
5-5. Pulse Panel Parameter Select Button Control circuit and interface operational power are On when using or changing the microprocessor settings. 1 Parameter Display 2 Moving Line Moving line is under value that can be changed. 3 Pulse Panel Parameter Select Button Press pulse panel parameter select button to move indicator in right window display.
5-6. Pulse Panel Parameter Increase And Decrease Buttons Control circuit and interface operational power are On when using or changing the microprocessor settings. Use mode select button to select mode to be changed (see Section 5-4). Use pulse panel parameter select button to select parameter to be changed (see Section 5-5). 1 Increase Button Press button to increase value that is underlined by the moving line. 2 Decrease Button Press button to decrease value that is underlined by the moving line.
SECTION 6 – GETTING STARTED FOR PULSE WELDING 6-1. Weld Cycle Weld Time Start Time Weld Speed Preflow Time Weld Start Arc Start Burnback Time Crater Speed Wire Speed Crater Time Start Speed Weld Stop Postflow Time Arc Out Time Ref. S-0271 NOTE The type of robot being used is defined during the setup process (see Section 10). The Robot type indicates which parts of the weld cycle the robot controls.
6-2. Setting Preflow Sequence Display 1 P r oces s Ca r d >S e q u e n c e Mode Select Button When unit is turned On, Process is the default mode, at other times, use mode select button to select Sequence. >P r e f l o w 0 . 0 Sec 2 Parameter Select Button Use parameter select button to select parameters. 3 2 1 Preflow Parameters Display Preflow can be adjusted from 0-9.9 seconds. If value set is zero (0), there is no Preflow sequence. Go to Section 6-3.
6-4. Setting Crater Sequence Display 1 1 Crater Parameters Display Parameter ranges are as follows: >C r a t e r 0 . 00 Sec 50 T r im 200 I PM Set Desired Time Parameter Select Seconds, 0-2.50 Sec. If value set is zero (0), there is no Crater sequence. Cr a t e r 0 . 20 Sec T r im >5 0 200 I PM Cr a t e r >0 .
SECTION 7 – TEACHING A PULSE WELDING PROGRAM Control circuit and interface operational power are On when using or changing the microprocessor settings. NOTE See GMAW-P (Pulsed MIG) Process Guide supplied with unit for more information. 7-1. Pulse Waveforms And Explanation Of Terms The interface, not the welding power source, controls weld output for pulsed welds. 1 ApK – Peak Current Of 100-565 Amperes ApK is the high pulse of welding current. Peak current melts the welding wire and forms a droplet.
7-2. Typical Teach Point Settings And Resulting Synergic Setting IPM 780 750 700 650 600 550 Example Of A Synergic Setting For 425 IPM With All Teach Points Set At 50 IPM Increments 500 450 400 350 300 250 200 ApK AbK 150 PPS 100 PWms 50 150 10 30 1 180 20 55 210 30 80 240 40 105 270 50 130 2 The teach mode allows the user to create custom pulse MIG welding programs. The teach mode has 15 teach points.
7-3. Selecting Teach Point Wire Feed Speed 1 1 2 2 >P r o c e s s Ca r d Sequence >P r Pu 03 A r Pu l se 035 ”S t ee l g 1 l se 5 ”S t ee l gon -Ox y Mode Select >T e a c h Of f Parameter Select Increase/ Decrease 3 Process Display When unit is first turned On, Process is the default screen, at other times use mode select button to select Process. Teach Display Use parameter select button to select Teach. Use increase/decrease buttons to select On.
7-4. Setting Teach Point Parameters On The Pulse Panel Increase/ Decrease >P r o c e s s Ca r d Sequence T e a c h On >4 5 0 I PM 340 Apk 70 Abk T e a c h On 450 I PM Apk >3 4 0 70 Abk Parameter Select Or T e a c h On 450 I PM >3 4 3 Apk 70 Abk 1 Parameter Select Increase/ Decrease Increase/ Decrease 34 9 >2 8 1 . 3 2 0 9 Apk Abk PPS P Wm s 34 9 >1 6 1 .
NOTE Make copies of this chart for future use. Program # Wire Size/Type Gas Program Name Card # Gun Model Flowrate IPM ApK AbK PPS PWms CFH COMMENTS Preflow: Sec. Run-In Trim: IPM: Sec.: Crater Trim: IPM: Sec.: Postflow: Sec.
7-5. Changing To Adaptive Pulse Welding Welding parameters are the same for both a Pulse and an Adaptive Pulse welding program. While welding adaptively, the unit uses feedback to attempt to maintain a constant arc length.
SECTION 8 – TEACHING A MIG WELDING PROGRAM Control circuit and interface operational power are On when using or changing the microprocessor settings. 8-1. Weld Cycle Weld Time Crater Time Start Speed Weld Speed Preflow Time Weld Start Arc Start Burnback Time Crater Speed Wire Speed Start Time Weld Stop Postflow Time Arc Out Time Ref. S-0271 NOTE The type of robot being used is defined during the setup process (see Section 10).
8-2. Changing To MIG In The Process Mode 1 Pulse Panel Display Default display when unit is first turned On, at other times use mode select button to select Process. Go to Section 8-3A.
8-3. Setting Sequence MIG Welding Parameters Control circuit and interface operational power are On when using or changing the microprocessor settings. A. Setting Preflow Sequence Display 1 1 >P r o c e s s Ca r d Sequence >P r g MIG 1 2 Parameter Select Button Use parameter select button to select parameters. 3 Preflow Parameters Display Preflow can be adjusted from 0-9.9 seconds. If value set is zero (0), there is no Preflow sequence.
B. Setting Start Sequence Display 1 1 >S t 0 . 24 9 Start Parameters Display Parameter ranges are as follows: a r t 2 Sec . 0Vo l t 0 I PM S t >0 . 24 9 Parameter Select a r t 5 Sec . 0Vo l t 0 I PM S t 0 . >1 8 9 Set Desired Time Parameter Select Set Desired Voltage Seconds, 0-2.5 Sec. If value set is zero (0), there is no Run-In sequence. Volts, 10.0-38.0 Volts Wire Feed Speed, 50-780 inches per minute, IPM Go on to Section 8-3C. Increase/ Decrease >S t 0 . 18 20 a r t 5 Sec .
D. Setting Crater Sequence Display 1 Crater Parameters Display Parameter ranges are as follows: 1 Seconds, 0-2.50 Sec. If value set is zero (0), there is no Crater sequence. >C r a t e r 0 . 02Se c 24 . 0Vo l t 9 0 I PM Volts, 10.0-38.0 Volts. Wire Feed Speed, 50 to 780 inches per minute, IPM. Go to Section 8-3E. Parameter Select Cr a t e r >0 . 1 2 S e c 24 . 0Vo l t 90 I PM Set Desired Time Cr 0 . >1 8 9 a t e r 12Se c .
F. Setting Postflow Sequence Display 1 1 >P o s t f l o w 0 . 0 Sec Po s t f l ow >0 . 0 Sec Parameter Select Set Desired Time Increase/ Decrease OM-172 324 Page 46 >P o s t f l o w 1 . 2 Sec Parameter Select Postflow Parameters Display Postflow can be adjusted from 0-9.9 seconds. If value set is zero (0), there is no Postflow sequence.
SECTION 9 – USING THE OPTIONAL DATA CARD 9-1. Installing Data Card Label 1 2 3 4 5 7 6 8 9 11 10 12 13 14 1 Peel backing from label and apply to data card with THIS SIDE UP by metal pins. THIS SIDE UP Write the names of the programs stored on the card on the label. Write the name of the piece of equipment the card is used with on the label. 2 Data Card 3 Card Slot Insert card into slot. To format card, turn On power to the unit. Select Card from menu.
9-3. Naming Programs And Writing To Card NOTE All program types (Pulse, Adaptive Pulse, and MIG) can be stored on a data card and retrieved. 1 1 P r oces s >C a r d Sequence 2 P r es s Be l ow Parameter Select 2 i a l n t e d e t e e Moving Line Moving line is under value that can be changed. Use increase or decrease button to change value. 3 >W r Re De Do Card Display Use Mode Select button to select Card.
9-4. Reading From Card 1 P r ocess >C a r d Sequence Use Mode Select button to select Card. P r es s Be l ow t e d e t e e Parameter Select Once # 1 Pu l se 035 ”S t ee l A r g o n –Ox y P r ess P r g1 Wi l l Be Los t Lose? Yes P r ess Read Display Use increase or decrease button to select feeder program number where the card program goes. 3 Read Ca r d t o Feede r P r g 1 P r ess Parameter Select WA R N I N G : Moving Line Moving line is under value that can be changed.
9-6. Deleting Programs From Card Use Mode Select button to select Card. 1 P r ess Be l ow Mode Select Twice i a l n Card Display 2 Moving Line Moving line is under value that can be changed. P r oces s >C a r d Sequence Wr Re >D e Do 1 3 Delete Display Select program number to be deleted from card.
SECTION 10 – SETUP 10-1. Setup Flow Chart 1 Display Selections 2 Features 2 3 Settings 3 To set up features that customize operation, use the setup displays. Features that can be customized are as follows: 1 >R a Se Ac Mi nge cu r i t y ces s g Type Vo l t 10 . 0 Mi n Vo l t Example Of Pulse Panel Setup Display Display Selection >Range Features Settings Volt Min 0.0 - 25.0 V Volt Max 25.0 - 99.
10-2. Using Setup Displays 1 2 3 Mode Select Front Panel Setup Display Front panel display during setup. Parameter Select 2 Pulse Panel Mode And Parameter Select Buttons 3 Power Switch On Rear Panel Press and hold down both buttons while turning On unit. 4 Pulse Panel Setup Display Follow this procedure any time access is required. Once in the setup displays, use the Mode Select button to select a particular display.
10-3. Selecting Welding Power Source Range NOTE Welding power source minimum and maximum voltage values are always required. Amperage values are required for pulse welding. 1 >R a Se Ac Mi Access Setup Display nge cu r i t y cess g Type 1 >V o l t M i n 10 . 0Vo l t Range Display See welding power source Owner’s Manual for voltage and amperage ranges. Set values to match welding power source ranges. 2 Minimum Voltage Display Range is 0 to 25.0 volts.
10-4. Selecting Security Lock NOTE Security lock works only when a data card is inserted (see Section 9). 1 Security Display Use this display to lock a program’s weld parameters so that changes can not be made using pulse panel controls. Access Setup Display 1 2 2 Program Number Choose the program number (1 through 8) to be locked.
10-5. Selecting Or Changing Access Code NOTE Access code works only when a data card is inserted (see Section 9). 1 Access Setup Display Code Display With code off, access to the setup displays is not restricted. 1 With code on, the operator must know and enter the access code to access or change any of the setup displays.
10-6. Selecting Voltage Correction 1 Mig Type Display With DVC Voltage Correction On, the unit uses closed-loop feedback from the 17-pin cord or voltage sensing leads to maintain set voltage parameters. With DVC Voltage Correction Off, feedback from the arc is not used for closed-loop feedback to maintain voltage parameters. Feedback from the arc is still used for other functions.
10-9. Selecting Voltage Sensing Method 1 Voltage Feedback Display When using the 17 Pin setting, arc voltage feedback is through the welding power source and the feedback signal is sent through the 17-pin cord to the feeder. If the 17 Pin setting is used, it is recommended that the voltage sensing terminals on the welding power source be used to monitor arc voltage at the workpiece. When using the V. Sense setting, arc voltage feedback is through the voltage sense leads connected to the feeder.
10-11.Resetting Arc Time 1 Arc Time Display The unit accumulates arc hours up to 9999.99 hours or 999999 weld cycles before rolling over to zero (0). The arc timer can be reset using this display. 1 Press Mode Select Access Setup Display Vo A r >A r Wi l t age c S t a r t c T i me r e f eed 0 . 0 0H r s 0Cy c l >N o R e s e t 0 . 0 0H r s 0Cy c l >R e s e t P r ess Increase 10-12.
10-13.Selecting Wire Type NOTE If wire type is changed, perform a memory reset (see Section 10-15) immediately after selecting wire type to bring up the correct welding programs. 1 Wire Type Display Select soft wire when using aluminum wire in the wire feeder. Select hard wire when using any other kind of wire.
10-15.Resetting Memory 1 No Reset Memory cannot be reset. Press Mode Select Access Setup Display 1 Wi r e D i sp >M e m o Shu t t l r d ype ay y own >N o 2 Re s e t 3 Increase/ Decrease >P r o g r a m Re s e t 4 >P r Pu 03 A r g 1 l se 5 ”S t ee l gon Ox y System Reset Press Parameter Select button to reset programs and setup to original factory settings. System, Arc Time, and Model Type settings are not affected by the system reset.
10-17.Selecting Program Name Feature 1 1 Access Setup Display Press Mode Select Memo r y Sh u t d own >N a m e P r o g r am Name Display When a data card is used, the programs written from the unit to the card can be named. Ca r d Pr o g r a m s >O n Ca r d Pr o g r a m s >O f f Increase 10-18.Remote Program Select NOTE Remote Program Select is in binary code, with “A” the least significant bit, and “C” the most significant bit.
10-20.Jog Wire Feed Speed Selection 1 This feature is only used with arc-On style robots. Jog IPM Display Jog wire feed speed can be varied between 50 and 780 inches per minute, IPM. 1 Press Mode Select Access Setup Display P r S t >J o Ro o g r am i c k g I PM bo t I PM >5 0 I PM >7 8 0 Increase 10-21.
10-22.Arc Voltage Error Selection 1 When a system reset is done, Monitor is set to Off. Access Setup Display Press Mode Select When this feature is off, arc voltage or arc length variations will not cause an error or shut the unit down. 1 Ro A r >M o So bo t c Fa i l n i t o r f t wa r e Monitor Display Provides a means to enable/disable the arc voltage error feature and to set an acceptable range of deviation from set arc voltage or arc length (trim) before the error will actuate.
SECTION 11 – CONTROL MENU The control menu allows the user access to rise time setting that controls rise and fall time of the pulse square wave. Changing the rise time setting changes the square wave shape by rounding off the corners, and makes it possible to quiet the pulse arc by just changing the rise time. 11-1. Using Menu Display 1 2 Front Panel Control Display Front panel display during control setting.
11-2. Setting Rise Time NOTE Maximum Rise Time setting will make the welding power source go to its maximum output. 1 1 Access Control Display >R i s e T i me >1 2 5 0 A / ms Rise Time Display Setting is depend on desired arc characteristics. Make a sample weld after each setting until desired arc characteristics are obtained. Use Increase or decrease button to change setting. Range is 250 to 1250 A/ms. Press Reset button to save setting and exit Control menu.
SECTION 12 – MAINTENANCE & TROUBLESHOOTING 12-1. Routine Maintenance Turn Off all power before maintaining. 3 Months 3 Months 6 Months Tape Or Replace Cracked Weld Cable Replace Unreadable Labels Blow Out Or Vacuum Inside OR During Heavy Service, Clean Monthly Replace Cracked Parts 14-Pin Cord Gas Hose Gun Cable 12-2. Overload Protection 1 Turn Off robot, interface, and welding power source. 1 Circuit Breaker CB1 CB1 protects the interface from overload. If CB1 trips, the unit shuts down.
12-3. Front Panel Error Displays 1 Memory CRC Error Display Corrupted program data has been detected or loaded. The “X” value indicates the program number. 1 Memo r y P r g X CRC E r r o r 2 Memo r y P r g X R a n g e E r r o r 3 May be caused by incompatible information on the data card or bad memory. 2 May be caused by improper range settings or improper data loaded into the interface unit.
12-4. Error Displays (Continued) 1 1 S t o p We l d E r r o r C y c l e D e t e c t e d 2 2 Error Card Read Display The card reader is not working properly. May be caused by a bad data card, a bad data card reader, a faulty microprocessor circuit board, or a wiring problem. E r r o r C a r d R e a d 3 Robot E-Stop Display The robot E-Stop is active. The interface unit will remain in a locked stated until the E-Stop is released.
12-5. Interface Board PC5 Diagnostic LED’s 1 Diagnostic LED’s Cover Remove cover. 2 Interface Board PC5 Diagnostic LED’s are visible inside unit, located on edge of Interface Board PC5 facing front of unit. Refer to Section 12-6 for information on diagnostic LED’s. 1 Reinstall cover after checking diagnostic LED’s. LED5 LED4 LED3 LED6 LED7 LED8 LED9 LED2 LED1 2 ST-800 755-B / ST-801 094 12-6.
12-7. Customer Interface Board PC4 Diagnostic LED’s 1 Robotic Interface II 2 Customer Interface Board PC4 Diagnostic LED’s are visible inside unit, located on PC4 mounted to center panel facing front of unit. Refer to Section 12-8 for information on diagnostic LED’s. Reinstall top cover after checking diagnostic LED’s. LED12 LED23 LED25 LED26 LED22 LED24 LED8 LED9 LED7 LED4 LED3 LED10 LED5 LED1 LED11 LED2 LED6 LED13 LED14 LED15 LED19 LED16 LED17 LED18 2 LED21 LED20 1 Ref.
12-8. Diagnostic LED’s On Interface Board PC4 LED 1 2 3 4 5 6 7 8 9 10 11 12 to 21 22 23 24 25 26 Status Diagnosis On Input signal On for RPS8-A. Off Input signal Off for RPS8-A. On Input signal On from robot for shielding gas valve. Off Input signal Off from robot for shielding gas valve. On Input signal On for welding power source contactor. Off Input signal Off for welding power source contactor. On Input signal On for RPS8-C. Off Input signal Off for RPS8-C.
SECTION 13 – ELECTRICAL DIAGRAMS Figure 13-1.
SD-185 806 OM-172 324 Page 73
Figure 13-2.
SD-161 039-A OM-172 324 Page 75
Figure 13-3.
SD-083 388-B OM-172 324 Page 77
Figure 13-4.
SD-180 191 (Part 1 of 2) OM-172 324 Page 79
Figure 13-5.
SD-180 191 (Part 2 of 2) OM-172 324 Page 81
Figure 13-6.
SD-165 466 OM-172 324 Page 83
SB-179 739 Figure 13-7.
SC-165 462-A Figure 13-8.
SA-156 626-A Figure 13-9. Circuit Diagram For Data Card Board PC8 SA-158 163 Figure 13-10.
SC-176 534 Figure 13-11.
SECTION 14 – PARTS LIST Hardware is common and not available unless listed. 1 2 7 6 3 5 24 13 4 14 8 23 9 10 22 15 12 11 16 17 21 20 2 19 18 ST-801 142 Figure 14-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 14-1. Case Section w/Components . . . 1 . . . . PC3 . . . . . 071 642 . . CIRCUIT CARD ASSEMBLY, motor speed control . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . . . . . . . . . . . 098 691 . . STAND-OFF, No. 6-32 x .500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . 3 . . . . . C1 . . . . . . 031 692 . . CAPACITOR, elctlt 750uf 200VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 14-2. Panel, Front w/Components . . . 1 . . DSPL1 . . . 165 459 . . CIRCUIT CARD ASSEMBLY, display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . 166 355 . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 057 359 . . BLANK, snap-in nyl .375mtg hole . . . . . . . . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 14-3. Panel, Center w/Components . . . 1 . . . . . . . . . . . . . 099 037 . . . 2 . . . . . 2T . . . . 157 169 . . . 3 . . . . . . . . . . . . . 038 839 . . . . . . . . . . . . . . . . . . . 601 219 . . . 4 . . . . CR2 . . . 052 964 . . . 5 . . . . . . . . . . . . . 134 201 . . . 6 . . . . . . . . . . . . . 166 354 . . . 7 . . . . PC4 . . . 180 189 . . . . . . . . . . . . . . . . . . . 012 633 . . . . . . . . . . PLG3 . . . 158 768 . . . . . . .
Hardware is common and not available unless listed. 3 2 4 3 1 5 13 6 12 10 9 8 7 11 ST-801 145 Figure 14-4.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 14-4. Panel, Rear w/Components . . . 1 . . . . . . . . . . . . . 171 363 . . . 2 . . . . . S1 . . . . . 111 997 . . . 3 . . . . . . . . . . . . . 046 432 . . . 4 . . . . . F1 . . . . 012 655 . . . 5 . . . . . . . . . . . . . 139 042 . . . 6 . . . . . . . . . . . . . 171 367 . . . . . . . . . . PC2 . . . 134 560 . . . . . . . . . . . R4 . . . . . 074 110 . . . . . . . . . . RC21 . . . 076 624 . . . 7 . . . . RC9 . . . 152 492 . . . . . . . . . . .
Hardware is common and 31 36 37 38 39 40 41 35 34 2 3 4 5 6 7 8 33 9 32 1 14 16 15 10 11 12 Includes Items 13-16 34 33 17 13 32 14 18 19 20 21 22 24 25 30 26 23 27 28 29 29 not available unless listed. ST-801 153 Figure 14-5.
Item No. Part No. Description Quantity Figure 14-5. Motor & Drive Assembly . . . 1 . . . . . 046 779 . . DRIVE ASSEMBLY, wire (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 2 . . . . . 602 154 . . . . SCREW, cap stl hexhd .250-20 x .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 3 . . . . . 010 224 . . . . PIN, spring CS .187 x 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes OM-172 324 Page 96
Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
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.
