OM-223 528L 2010−07 Processes MIG (GMAW) Welding Description Wire Feeder AROI (Automatic Remote Operator Interface) Visit our website at www.MillerWelds.
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TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3.
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2010−03 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
FUMES AND GASES can be hazardous. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor, wear an approved air-supplied respirator.
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can injure. D Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte. Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves.
Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES PIÈCES CHAUDES peuvent provoquer des brûlures. D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant de travailler à l’équipement.
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz protecteur en cas de non-utilisation. D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux. D Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.
Les PIÈCES MOBILES peuvent causer des blessures. LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site internet : www.global.ihs.com).
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SECTION 3 − INTRODUCTION 3-1. Specifications Type of Input Power Welding Power Source Type 40 Volts DC 10 Amperes Axcess Series Wire Feed Speed Range Wire Diameter Range Welding Circuit Rating Overall Dimensions Weight Standard: 40 To 1400 ipm (1.0 To 35.6 mpm) .030 To 1/8 in. (0.8 To 3.2 mm) 100 Volts, 750 Amperes, 100% Duty Cycle Length: 7-1/2 in. (191 mm) 10 lb (4.5 kg) Max Spool Weight: 60 lb (27 kg) Width: 7 in. (178 mm) Height: 12-1/2 in. (318 mm) SECTION 4 − INSTALLATION 4-1.
4-2. Installing Insulator Kit 1 ! Turn Off and disconnect input power. 1 2 3 4 5 6 ROI Control Insulator Plate Mounting Plate 1/4-20x3/4 in. Screw (4) Nylon Shoulder Washer (4) 3/8 in. Flat Washer (4) Place insulator plate between ROI base and metal mounting surface. Place nylon shoulder washer over screw. Place flat washer over shoulder washer. 2 Insert hardware assembly through hole in metal mounting base, insulator, and into ROI base (4 locations). Tighten hardware to secure control.
4-3. Rear Panel Connections 1 2 3 4 Input/Output Receptacle RC100 Motor Control/Shielding Gas Valve Receptacle RC8 9-Pin Network Receptacle RC1 Rating Label Location 1 2 4 3 804 091-A 4-4. 9-Pin Network Receptacle RC1 Information 9 F G E H I D A C 4-5.
4-6. Gun Recommendation Table Process Gun GMAW − Hard or Cored Wires 400, 500, And 600 Amp Air-Cooled Guns GMAW − Pulse Water-Cooled Guns 4-7. AROI Display At Power Up 1 2 Upper Display Lower Display 1 Program Volts Time WFS Amps Arc Adjust Arc Ctl Process Sequence Wire Type Gas Type Output B Output A Process Set Up Power Source 2 Adjust Upper Display Axcess Feeder Set Up Voltage Range Lower Display Net Wait DTEC OFF AROI 300/450/675 10 44 4-8.
4-9.
4-10.
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SECTION 5 − OPERATION 5-1. Operational Terms The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder: General Terms: Adaptive Pulse Welding When the “adaptive pulse” welding process is selected, the unit will attempt to automatically regulate weld output in order to maintain a constant arc length, regardless of change in welding wire stickout. Abk (Background Amperage) Abk is the low weld current.
General Terms: Arc Control Pressing this button will allow setting of inductance in MIG mode and arc control in pulse, Accu-pulse, and RMD (optional). In pulse and Accu-pulse mode this adjustment changes the arc cone by adjusting the preprogrammed factory pulse data. In RMD (optional) this control will affect the arc in much the same way as inductance.
5-2. Power Switch 1 Power Switch 1 803 694-A 5-3.
5-4. Program Push Button 1 Program Display The number of the active program is displayed. 2 3 Program Push Button Program Push Button LED The LED lights to indicate that programs can be changed using the Adjust knob. Momentarily press button to illuminate LED. To change the program number, rotate Adjust knob to select one of eight programs. 1 Program Pressing and holding the push button will display program wire size, wire type and process. 3 . Reset will not activate if Locks 2 are enabled.
5-6. Lower Display 5 7 Time 1 6 2 WFS Amps Arc Ctl 3 1 Lower Display The lower display shows WFS (wire feed speed), AMPS (amperage), ARC CTL (arc control), or Time. The feeder displays only preset wire speed at idle (not welding). While welding, the average amperage is displayed. The lower display shows welding sequence time when the Time LED is illuminated.
5-7. Feeder Set Up Push Button 3 4 Sequence 5 Output A Start Time Output B 1 2 Crater Time Preflow Time Postflow Time 6 Sequence Diagram Feeder Set Up 1 Feeder Set Up Push Button LED 2 Feeder Set Up Push Button • Press button to choose Sequence. Feeder Set Up push-button LED will illuminate. 3 Sequence LED • When the Feeder Set Up button is pressed once, the Sequence LED will illuminate and the upper display will show sequence options.
5-8. Setting Output Relay A And Outut Relay B Start Time Crater WFS Preflow Time Weld WFS Wire Speed Weld Time Crater Time Postflow Time Time Retract Preflow Arc Strike Weld Crater Postflow Sequence End Sequence Diagram • When the Feeder Set Up button is pressed once, the Sequence LED will illuminate and the upper display will show sequence options. See Section 5-7 for set up procedures.
5-9. Adjust Knob 1 Adjust Knob The Adjust knob is used to change functions and parameters. Refer to the front panel sections for information regarding use of this control. 1 Adjust 5-10. Process Set Up Push Button 1 2 3 3 Process Set Up Push Button Process Set Up LED Program Selection LEDs Process Wire Type Gas Type 2 1 Process Set Up . Holding the Process Set Up push button in during power up will display the software versions of each circuit board.
Table 5-1.
SECTION 6 − SETTING SEQUENCE PARAMETERS 6-1. Sequence Parameters In A Program . For more information on Sequence mode, see Feeder Set Up Push Button in Section 5-7. Sequence If time is set to zero in any timed sequence, the sequence is skipped. Parameters Volts/Arc Adjust IPM . Maximum IPM may actually be lower depending on the process and wire type selection. Seconds 1. Preflow —— —— Off-10.0 2. Postflow —— —— Off-10.0 3. Start 10.0-44.0/ 0-99 50-1400*/ 0-99 Off-5.0 4. Crater 10.0-44.
SECTION 7 − MAINTENANCE 7-1. Routine Maintenance ! n = Check Z = Change ~ = Clean * To be done by Factory Authorized Service Agent Every 3 Months Every 6 Months l Unreadable Labels OR ~ Inside Unit OM-223 528 Page 28 nl Cracked Parts Disconnect power before maintaining. l = Replace nl Cords . Maintain more often during severe conditions.
7-2. Diagnostics The following error messages are shown on the upper and lower displays to indicate specific errors. Explanations are in the text below: ERR ERR ERR ERR ERR ERR TACH MOTR WFS STRT STOP FLOW Indicates a tachometer error. Indicates a motor error. Indicates a wire feed speed error. Indicates an arc start error. Indicates an arc stop error. Indicates a gas flow error. ERR ERR ERR ERR ERR ERR COOL GND STUK TEMP LINE ARC Indicates a coolant flow error.
7-2. Diagnostics (Continued) WELD MOTR PLS LOW E OVER WAIT COM WAIT WFS STOP AVG Indicates a weld cycle wait error. Indicates a motor communication error. Indicates a low WFS Indicates a UIM communication error. command error. REL TRIG ERR OVER TRIG STUK UNKN CRNT Indicates a contactor on error. Indicates a trigger closed error. Indicates an unknown error. Indicates an over Indicates an emergency stop error. average current error. Indicates an overcurrent error.
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SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1.
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SECTION 9 − PARTS LIST . Hardware is common and not available unless listed. 18 5 4 1 3 2 4 8 7 17 20 6 11 12 13 14 19 10 15 9 16 804 092-E Figure 9-1. Remote Operator Interface Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-1. Remote Operator Interface . . . 1 . . . . . . . . . . . . . . +214 839 . . . 2 . . . . . . . . . . . . . . . 233584 . . . 3 . . . . . . . . . . . . . . . 212 808 . . . 4 . . . . . . . . . . . . . . . 097 132 . . . 5 . . . . PC6 . . . . . 221 280 .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 9-1. Remote Operator Interface (Continued) . . . 12 . . . . PC1 . . . . . . . . 13 . . . . RC4 . . . . . . . . 14 . . . . . . . . . . . . . . . . . . 15 . . . . . . . . . . . . . . . . . . 16 . . . . . S2 . . . . . . ..................... ..................... ..................... . . . 17 . . . . . . . . . . . . . . . . . . 18 . . . . . . . . . . . . . . . . . . 19 . . . . PC8 . . . . . . . . 20 . . . . . . . . . . . . . . . . . . . . . . . .
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