Miller AUTO INVISION User manual

Miller AUTO INVISION User manual
OM-186 359J
June 2001
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Automatic Welding
Description
Automatic Welding Interface And
Arc Welding Power Source
Auto Invision
Visit our website at
www.MillerWelds.com
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.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
Miller is the first welding help you figure out what the problem is. The
equipment manufacturer in parts list will then help you to decide which
the U.S.A. to be registered to
the ISO 9001 Quality System exact part you may need to fix the problem.
Standard.
Warranty and service information for your
particular model are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
TABLE OF CONTENTS
WARNING
This product, when used
for welding or cutting,
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.)
OM-186 359
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 . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. 115 Volts AC Duplex Receptacle And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Selecting Input Voltage For 230/460 Volt Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-10. Rear Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-11. Peripheral Receptacle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-12. Touch Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-13. Connecting Setup Pendant To Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Lower Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Meter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Upper Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Setup Pendant Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – INTRODUCTION TO PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Pulse MIG Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Standard Pulse Welding Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Program 1 – .035 Steel, Argon-Oxy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Program 2 – .045” Steel, Argon-Oxy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Program 3 – .035 Steel, Argon-CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Program 4 – .045” Steel, Argon - CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Program 5 – .035” ER 309, Argon - CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Program 6 – .045” ER 309, Argon - CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Program 7 – 3/64” ER 5356, Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Program 8 – .035” SIB, Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Program 1 – .035” ER 4043, Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Program 2 – 3/64” ER 4043, Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Program 3 – 1/16” ER 4043, Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Program 4 – .035” ER 5356, Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Program 5 – 3/64” ER 5356, Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. Program 6 – 1/16” ER 5356, Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Program 7 – 3/64” ER 5356, Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-18. Program 8 – .035” ER 5356, Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-19. Setup Pendant Mode Select Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20. Setup Pendant Parameter Select Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-21. Setup Pendant Parameter Increase And Decrease Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – GETTING STARTED FOR PULSE WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Weld Cycle For Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Setting Preflow Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Setting Weld Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Setting Crater Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Setting Postflow Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – TEACHING A PULSE WELDING PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Pulse Waveform Explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Teach Points Explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Selecting Teach Point Wire Feed Speed For Pulse Welding Program . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
5
5
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11
12
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14
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15
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TABLE OF CONTENTS
6-4. Setting Teach Point Parameters For Pulse Welding Program . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6-5. Changing To Adaptive Pulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
SECTION 7 – TEACHING A MIG WELDING PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7-1. Weld Cycle For Mig Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7-2. Changing To Mig Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7-3. Setting Preflow Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7-4. Setting Start Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7-5. Setting Weld Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7-6. Setting Crater Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7-7. Setting Retract Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7-8. Setting Postflow Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
SECTION 8 – USING THE OPTIONAL DATA CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8-1. Installing Data Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8-2. Using The Data Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8-3. Naming Programs And Writing To Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8-4. Reading From Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8-5. Reading (Or Deleting) From An Empty Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8-6. Deleting Programs From Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
SECTION 9 – SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9-1. Setup Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9-2. Using Setup Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
9-3. Selecting Security Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
9-4. Selecting Or Changing Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9-5. Selecting Voltage Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9-6. Selecting Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9-7. Selecting Auxiliary Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9-8. Selecting Voltage Sensing Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9-9. Selecting Arc Start Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9-10. Resetting Arc Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9-11. Selecting Units For Wire Feed Speed And Motor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9-12. Selecting Wire Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9-13. Selecting Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9-14. Resetting Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9-15. Selecting Arc Start/Volt Sense Error Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9-16. Selecting Program Name Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9-17. Remote Program Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9-18. Remote Program Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9-19. Stick Check Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9-20. Jog Wire Feed Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9-21. Robot Control Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9-22. Flow Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9-23. Arc Voltage Error Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9-24. Software Version Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
SECTION 10 – CONTROL MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10-1. Using Menu Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10-2. Setting Rise Time Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10-3. Setting Auto Configure Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10-4. Setting Runin Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10-5. Setting Burnback Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SECTION 11 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11-3. Removing Case And Measuring Input Capacitor Voltage For 230/460 Volt Model . . . . . . . . . 68
11-4. Removing Case and Measuring Input Capacitor Voltage For 575 Volt Model . . . . . . . . . . . . . 69
11-5. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
11-6. Front Panel Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
11-7. Weld Interface Board PC12 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
11-8. Diagnostic LED’s On Weld Interface Board PC12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
11-9. Customer Interface Board PC14 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
11-10. Diagnostic LED’s On Customer Interface Board PC14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
11-11. Motor Board PC13 Diagnostic LED’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
11-12. Diagnostic LED’s On Motor Board PC13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
11-13. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
SECTION 12 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
SECTION 13 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
OPTIONS AND ACCESSORIES
WARRANTY
SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
som _nd_4/98
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 Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-4. Read and follow all
Safety Standards.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
D Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first – double-check connections.
D Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-186 359 Page 1
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.
D 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).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
OM-186 359 Page 2
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder – explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
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.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
D
OVERUSE can cause OVERHEATING
D
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
D
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. Principal Safety Standards
Safety in Welding and Cutting, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American
Welding Society Standard AWS F4.1, from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face
Protection, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-186 359 Page 3
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. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-186 359 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT
UTILISATION
som _nd_fre 4/98
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.
Y Identifie un message de sécurité particulier.
. Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des
risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN
MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles
et aux directives ci-dessous afin de connaître les mesures à prendre pour
éviter tout danger.
1-2. Dangers relatifs au soudage à l’arc
Y Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques
de danger. Lorsque vous voyez un symbole, soyez vigilant et
suivez les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité présentées ci-après ne font que résumer
l’information contenue dans les normes de sécurité énumérées
à la section 1-4. Veuillez lire et respecter toutes ces normes de
sécurité.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Y Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément
à ce manuel.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le câble de retour de façon à obtenir un bon contact métal-métal
avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.
D
Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec tout objet métallique.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est sur ON. Le circuit d’entrée et les
circuits internes de l’appareil sont également sous
tension à ce moment-là. En soudage semi-automatique ou automatique,
le fil, le dévidoir, le logement des galets d’entraînement et les pièces
métalliques en contact avec le fil de soudage sont sous tension. Des
matériels mal installés ou mal mis à la terre présentent un danger.
Il y a DU COURANT CONTINU IMPORTANT dans les
convertisseurs après la suppression de l’alimentation électrique.
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.
D Ne jamais toucher les pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs ne comportant
pas de trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.
D
D
D
Ne pas se servir de source électrique àcourant électrique dans les zones
humides, dans les endroits confinés ou là où on risque de tomber.
Se servir d’une source électrique àcourant électrique UNIQUEMENT si le
procédé de soudage le demande.
Si l’utilisation d’une source électrique àcourant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de
sécurité).
D Installer et mettre à la terre correctement cet appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la
borne de terre du sectionneur ou que la fiche du cordon est raccordée
à une prise correctement mise à la terre.
D En effectuant les raccordements d’entrée fixer d’abord le conducteur
de mise à la terre approprié et contre-vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas
endommagé ou dénudé – remplacer le cordon immédiatement s’il est
endommagé – un câble dénudé peut provoquer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode provenant d’une autre machine.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D
D
D
D
D
D
D Eloigner votre tête des fumées. Ne pas respirer
les fumées.
A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau
de l’arc pour l’évacuation des fumées et des gaz de soudage.
Si la ventilation est insuffisante, utiliser un respirateur à alimentation d’air homologué.
Lire les spécifications de sécurité des matériaux (MSDSs) et les
instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.
Travailler dans un espace fermé seulement s’il est bien ventilé ou en
portant un respirateur à alimentation d’air. Demander toujours à un
surveillant dûment formé de se tenir à proximité. Des fumées et des
gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations de
dégraissage, de nettoyage ou de pulvérisation. La chaleur et les
rayons de l’arc peuvent réagir en présence de vapeurs et former des
gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien
ventilé, et si nécessaire, en portant un respirateur à alimentation
d’air. Les revêtements et tous les métaux renfermant ces éléments
peuvent dégager des fumées toxiques en cas de soudage.
OM-186 359 Page 5
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.
D 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 énuméré dans les normes de sécurité).
D Porter des protections approuvés pour les oreilles si le niveau sondre est
trop élevé.
D Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair
et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.
D Porter des vêtements de protection constitué dans une matière durable, résistant au feu (cuir ou laine) et une protection des pieds.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent être
projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un
surchauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
D Se protéger et d’autres personnes de la projection d’étincelles et de
métal chaud.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber sur
des substances inflammables.
D Déplacer toutes les substances inflammables à une distance de 10,7
m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.
D Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et
des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que des
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 (voir les normes de
sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par
des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches
telles qu’un allumeur au butane ou des allumettes.
DES PARTICULES VOLANTES
peuvent blesser les yeux.
D Le soudage, l’écaillement, le passage de la pièce
à la brosse en fil de fer, et le meulage génèrent
des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D
Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.
OM-186 359 Page 6
LES ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou
même la mort.
D
D
Fermer l’alimentation du gaz protecteur en cas de
non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.
DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.
D Ne pas toucher des parties chaudes à mains nues
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D
D
Porteurs de stimulateur cardiaque, restez à distance.
Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher
des opérations de soudage à l’arc, de gougeage ou
de soudage par points.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut affecter
l’ouïe.
D
Porter des protections approuvés pour les oreilles si
le niveau sondre est trop élevé.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz
font normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de
se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec une
bouteille.
D Ne jamais souder une bouteille pressurisée – risque d’explosion.
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
D Maintenir le chapeau de protection sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille.
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P-1 CGA énumérées dans les normes de sécurité.
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.
D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables.
D Rester à l’écart des organes mobiles comme le
ventilateur.
D Maintenir fermés et fixement en place les portes,
panneaux, recouvrements et dispositifs de
protection.
D Ne pas installer l’appareil à proximité de produits inflammables
D Ne pas surcharger l’installation électrique – s”assurer que l’alimentation est correctement dimensionné et protégé avant de mettre
l’appareil en service.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
LA CHUTE DE L’APPAREIL peut
blesser.
D Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.
D Utiliser un engin d’une capacité appropriée pour
soulever l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du côté
opposé de l’appareil.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D
D
D
D
D
D Prévoir une période de refroidissement, respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
recommancer le soudage.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimes.
DES ORGANES MOBILES peuvent
provoquer des blessures.
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 gachette 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.
D Le rayonnement haute frequence peut provoquer
des interférences avec les équipements de radio–navigation et de communication, les services
de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance
correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.
D
D
D
D
D
D L’énergie électromagnétique risque de provoquer
des interférences pour l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.
OM-186 359 Page 7
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. Lejeune Rd, Miami FL
33126
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de la Compressed Gas Association, 1235 Jefferson Davis Highway,
Suite 501, Arlington, VA 22202.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
Afin de réduire les champs électromagnétiques dans l’environnement
de travail, respecter les consignes suivantes :
1
Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore
un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de
recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le
jugement du comité, n’a pas démontré que l’exposition aux champs
magnétiques et champs électriques à haute fréquence représente un
risque à la santé humaine”. Toutefois, des études sont toujours en cours
et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait
souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.
OM-186 359 Page 8
2
3
4
5
Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
Mettre tous les câbles du côté opposé de l’opérateur.
Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
Garder le poste de soudage et les câbles le plus loin possible de
vous.
Relier la pince de masse le plus près possible de la zone de
soudure.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est
alors recommandé de respecter les consignes ci–dessus.
SECTION 2 – INSTALLATION
2-1. Specifications
Input
Power
Three
Phase
Rated Welding
Output
450 A @ 38 Volts DC,
100% Duty Cycle;
565 A @ 43 Volts DC,
60% Duty Cycle
Voltage
Range
Wire
Diameter
Range
Wire Feed Speed
Range*
Standard:
50 To 780 ipm
(1.3 To 19.8 mpm)
10 – 38
.030 To .062 in
(0.8 To 1.6 mm)
Maximum
OpenCircuit
Voltage DC
95
Amperes Input
At Rated Load
Output 60 Hz,
Three-Phase
230/460 Volt Model
230 V
460 V
KVA
KW
50.8
(0.14**)
27.8
(0.09**)
21.2
(0.06**)
19.2
(0.04**)
575 Volt Model
575 V
KVA
KW
24.4
(0.12**)
24.3
(0.12**)
19.0
(0.07**)
*Wire feed speed ranges are for GMAW welding. While pulse welding, wire feed speed ranges may be more limited (see Section 5)
**While idling
2-2. Dimensions And Weight
Hole Layout Dimensions
F
A
A
14-21/64 in (363.9 mm)
B
20-3/4 in (527.1 mm)
C
23-27/64 in (594.9 mm)
D
24-31/32 in (634.2 mm)
26 in
(660 mm)
23-3/4 in
(603 mm)
D
C
B
E
12-3/8 in (314.3 mm)
F
9/32 in (7.1 mm) Dia.
14-1/2 in
(368 mm)
Weight
130 lb (59 kg)
E
801 914
OM-186 359 Page 9
2-3. Selecting A Location
2
Movement
Tipping
Y Do not move or operate
unit where it could tip.
3
OR
1
Location
1
Y Special installation may be required where gasoline or volatile
liquids are present – see NEC Article 511 or CEC Section 20.
5
Lifting Forks
Use lifting forks to move unit.
Extend forks beyond opposite side
of unit.
2
Lifting Handles
Use handles to lift unit.
3
4
18 in
(460 mm)
Hand Cart
Use cart or similar device to move
unit.
4
Rating Label
Use rating label to determine input
power needs.
5
Line Disconnect Device
Locate unit near correct input
power supply.
18 in
(460 mm)
loc_2 3/96 - 801 958 / 801 914
2-4. Connection Diagram
. The proper interface kit must
5
2
be installed in the interface unit
to allow it to be connected to the
robot.
3
1
4
1
6
7
8
13
11
12
Robot (Will Vary According To
Application)
2 Motor/Drive Assembly
3 Gas Cylinder
4 Gas Hose
5 Robot Control
6 Robot Input/Output Cable
7 Remote Program Select
Cable (Optional)
8 Gas And Motor Control Cable
9 Welding Power
Source/Interface Unit
10 Negative (–) Weld Cable
11 Workpiece
12 Voltage Sensing Lead
. Positive
9
(+) voltage sensing
lead is contained in the motor
cable.
13 Positive (+) Weld Cable
10
801 915-A
OM-186 359 Page 10
2-5. Weld Output Terminals And Selecting Cable Sizes
Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
Positive
(+)
Negative
(–)
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Welding
Amperes
10 – 60%
Duty Cycle
60 – 100%
Duty Cycle
100
4
4
4
3
2
1
1/0
1/0
150
3
3
2
1
1/0
2/0
3/0
3/0
200
3
2
1
1/0
2/0
3/0
4/0
4/0
250
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
300
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
350
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
400
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
500
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
600
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
10 – 100% Duty Cycle
Ref. 801 914
*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. Contact your
distributor for the mm2 equivalent weld cable sizes.
S-0007E
2-6. 115 Volts AC Duplex Receptacle And Circuit Breakers
1
115 V 10 A AC Receptacle
Power is shared between duplex
receptacle and internal 14 socket
receptacle.
2
3
1
4
2
3
Circuit Breaker CB1
Circuit Breaker CB2
CB1 protects duplex receptacle
and 115 volts ac portion of internal
14 socket receptacle from
overload.
Press button to reset breaker.
CB2 protects 24 volts ac portion of
internal 14 socket receptacle from
overload.
Press button to reset breaker.
4
Circuit Breaker CB1
CB1 protects the motor control
circuitry from overload. If CB1 trips,
the wire drive motor is inoperative.
Press button to reset breaker.
801 916
OM-186 359 Page 11
2-7. Electrical Service Guide
Three-Phase
Input Voltage
230
460
575
Input Amperes At Rated Output
50.8
27.8
24.4
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
80
40
35
Min Input Conductor Size In AWG/Kcmil
6
10
10
138 (42)
233 (71)
371 (113)
8
10
10
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil
Reference: 1993 National Electrical Code (NEC).
S-0092J
2-8. Selecting Input Voltage For 230/460 Volt Model
. Be sure to reinstall all four screws
Y Turn Off welding power
source, disconnect input
power, and check voltage on
input capacitors according
to Section 11-3 before
proceeding.
securing relinking board in place.
Tools Needed:
5/16 in
Check input voltage available at
site.
1
1
Voltage Selection View
Window
Check voltage selected in unit.
Changing selection is only
necessary if selected value does
not match available input voltage.
2
3
4
5
Relinking Board PC6
Mounting Screws
Receptacle RC8 (Connection
For 230 VAC Input Power)
Receptacle RC7 (Connection
For 460 VAC Input Power)
Move relinking board as needed
and connect plug PLG4 (in unit) to
RC8 or RC7 according to input
power voltage.
2
3
4
5
3
801 914 / Ref. 801 917
OM-186 359 Page 12
2-9. Connecting Input Power
Y Turn Off welding power
source, and check voltage on
input capacitors according
to Section 11-3 before
proceeding.
1
Input And Grounding
Conductors
Select size and length using
Section 2-7. Connect as shown in illustration.
Contactor W1
For models with optional ground
current sensor, route grounding
conductor through reed relay from
right side, underneath, and through
reed relay again (two turns total) before connecting to ground terminal.
L1 L2 L3
2
Line Disconnect Device
See Section 2-7.
Reinstall right side panel.
1
2
Connections For
Standard Model
L1
L2
L3
Reed
Relay
Or
= GND/PE
Y Always connect grounding
conductor first.
1
Tools Needed:
L1
L2
L3
Connections For
Models With Optional
Ground Current Sensor
5/16 in
801 535-B / 801 822
OM-186 359 Page 13
2-10. Rear Panel Connections
1
1
2
3
2
B
C
D
E
To connect interconnecting cord to
receptacle, align keyway, insert
plug, and tighten threaded collar.
A
M
L
K
J
P NT
R S
FG
Secure ring terminal on remaining
end of cord to work.
H
4
Peripheral Receptacle
Receptacle provides connection to
touch sensor, water flow switch, jog
+/–, and n/o relay contacts circuitry.
Example Receptacle
5
3
7
10-Socket Receptacle
(Optional Remote Program
Select Connection To Robot
Control)
To connect matching interconnecting cord to one of the above
receptacles, align keyway, insert
plug, and tighten threaded collar.
Connect remaining end of cord to
matching receptacle on applicable
equipment (see Section 2-4).
6
Robot Control Receptacle
Receptacle will vary according to
the robot control being used with
the system.
6
4
5
Receptacle
Keyway
4-Pin Receptacle (Optional
External Voltage Sensing
Connection)
7
19-Socket Receptacle (Wire
Feed/Shielding Gas Control
Connection To Motor Drive
Assembly)
Ref. S-0003-A / 801 916
OM-186 359 Page 14
2-11. Peripheral Receptacle Functions
Function
A
Contact closure to B dependent upon state of
programmed output (see Section 9-7).
B
Contact closure to A dependent upon state of
programmed output (see Section 9-7).
C*
Circuit common.
D
Contact closure to C completes 24 volts dc
solenoid circuit to purge shielding gas line.
E
Contact closure to F indicates coolant flow switch is
closed and recirculating coolant system is
operational.
F*
Circuit common.
Jog +
H**
Contact closure to circuit common advances
welding wire at wire drive assembly.
Jog –
J**
Contact closure to circuit common retracts welding
wire at wire drive assembly.
K
Contact closure to L energizes Touch Sensor
circuitry.
L*
Circuit common.
M
Part touched +24 volts dc output signal referenced
to circuit common.
Purge
K
J
M
C
L
D
H
E F
801 916
Socket Information
A
Programmable
Output Relay Contacts
B
Socket
Coolant Flow
Switch Input
Signal
Touch Sensor ON
And Output Signal
*Circuit common is same electrical reference point.
**Speed of Jog + and Jog – is at setup value for Jog IPM parameter.
Note: A customer supplied matching amphenol plug (Part No. MS3106A20-33P and strain relief clamp AN3057-12) is required to use peripheral
receptacle.
2-12. Touch Sensor Operation
The touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source.
Voltage sense leads provide a path for touch sensor voltage when this feature is turned on at the peripheral receptacle.
Turning on touch sensor causes a dc voltage to be present on the welding wire. When welding wire touches the
weldment, the voltage sensing circuit closes, and a +24 volts dc output signal is sent to the robot control indicating
weldment detection. Touch sensor dc voltage on the welding wire will vary from 60 to 150 volts dc depending on the
welding power source. As soon as touch sensor turns on, DANGER SENSOR ON appears on the front panel display.
OM-186 359 Page 15
2-13. Connecting Setup Pendant To Welding Power Source
Y Turn Off welding power
source and weld control.
1
2
3
1
Welding Power Source
Interconnecting Cord
Setup Pendant
To make connections, align plug
with receptacle, insert plug, and
use bail locks on receptacle to
secure plug.
3
2
801 960
OM-186 359 Page 16
SECTION 3 – OPERATION
3-1. Operational Terms
The following is a list of terms and their definitions as they apply to this interface unit:
General Terms:
Adaptive Pulse Welding
When the “adaptive pulse” welding process is selected, the unit will attempt to automatically regulate
pulse frequency in order to maintain a constant arc length, regardless of change in welding wire stickout.
Abk (Background Amperage)
Abk is the low weld current. Background current preheats welding wire and maintains the arc. When
background current is too low, the arc is unstable and hard to maintain.
Apk (Peak Amperage)
Apk is the high pulse of welding current. Peak current melts the welding wire and forms a droplet. The
droplet is forced into the weld puddle.
Vpk (Peak Voltage)
Arc voltage during peak current phase of the pulse waveform. This determines arc length during
adaptive pulse welding.
Inductance
In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit
metal transfers per second (provided no other changes are made) and increase the arc-on time. The
increased arc-on time makes the pool more fluid.
PPS (Pulses Per Second)
PPS, pulse rate, and frequency (Hz) are used interchangeably. A PPS or pulse rate of 60 Hz means
60 pulses of current are produced each second.
PWms (Pulse Width in Milliseconds)
PWms is the time spent at peak current (1.2 ms is .0012 seconds). This time must be long enough to
form a droplet of welding wire. The stiffness or fluidity of the molten weld puddle is controlled by
PWms.
Synergic
Synergic refers to the unit’s ability to use preprogrammed pulse parameters to determine the actual
pulse settings of Peak Amperage, Background Amperage, Pulse Frequency and Pulse Width at any
specific wire feed speed setting.
Trim
Term used to represent arc length adjustments in pulse programs. Increasing trim increases the actual arc length. Likewise, decreasing trim shortens arc length. Trim is replaced by volts in MIG programs.
Setup Pendant Terms:
Card Mode
Is used to select use of the optional data card storage and retrieval capabilities.
Process Mode
Is used to select the type of process to be used, including Pulse, Adaptive Pulse, or Mig.
Sequence Mode
Is used to select and program the weld sequences which include preflow, run-in, weld, crater,
burnback, and postflow.
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. When the final access code letter is entered,
the display automatically changes to the initial setup display.
Arc Start
NOTE: Do not use the Hot Start setting for .035 in (9 mm) or smaller wire. Use the Hot Start mode for
pulse welding with 450 Ampere Inverter Model when high initial weld current is necessary to start
large diameter welding wires. When in Hot Start, the 450 Ampere Inverter Model starts the arc in the
CV mode and switches to CC once the arc is started. Do not use Hot Start unless using 450 Ampere
Inverter Model.
Arc Time
Allows actual arc time up to 9,999.99 hours and weld cycles up to 999,999 to be accumulated and
displayed on the digital display, and can be reset to zero as required.
Mig Type (Voltage
Correction)
With DVC Voltage Correction On, the unit uses closed-loop control based on voltage feedback 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.
Name Feature
When using the optional Data Card and turning the name feature on, programs written to the card can
be identified by name, number, job number, etc.
Program Reset
By selecting program reset in the memory reset mode, the unit defaults to original factory program
settings for the program last active. All other program and setup information remains the same.
Range
The interface requires that the voltage and amperage range of the welding power source be entered.
Obtain this information from the welding power source Owner’s Manual.
Security
NOTE: The optional Data Card is required to activate this feature. Is used to limit what the operator
can control. This includes accessing the number of the program, 1 through 8, and the range of welding parameters within the program.
Software Screen
Selection of this function will display the software version of the unit. When talking with factory service
personnel, this number may be required.
OM-186 359 Page 17
System Reset
By selecting system reset in the memory reset mode, the unit defaults to original factory settings for
all programs and all set up excluding System, Arc Time, and Model Type.
Voltage (Control Feedback)
Allows voltage to be monitored at the output terminals by two methods. This can be selected through
the internal connections of the unit, or through the unit’s external voltage sense lead.
When using the V. Sense setting, arc voltage feedback is through the voltage sense leads connected
to the feeder. Use this setting when there is more than 50 ft (15 m) of weld cable used.
Arc Start/Volt Sense Shutdown
When this feature is on, the system immediately shuts down if no arc voltage is sensed. An error
message is displayed. When this feature is off, wire feeds even when there is no arc voltage sensed.
Wire Feed Mode
Allows the selection of inches per minute or meters per minute for wire feed speed. This mode is also
used to select motor type; standard speed, low speed, or high speed.
3-2. Lower Front Panel Controls
1
1
2
Power Switch
2
Voltmeter (see Section 3-3)
3
3
Ammeter (see Section 3-3)
. The
fan motor is thermostatically
controlled and only runs when cooling is
needed.
186 067
3-3. Meter Functions
Note
The meters display the actual weld output values for approximately three seconds after the arc
is broken.
Mode
Meter Reading At Idle
V
MIG
Pulsed
MIG
OM-186 359 Page 18
A
24.5
Meter Reading While Welding
V
A
24.5
250
Preset Volts
Blank
Actual Volts
Actual Amps
V
A
V
A
PPP
PPP
24.5
250
Pulse Display
Pulse Display
Actual Volts
Actual Amps
3-4. Upper Front Panel Controls
8
1
1
Setup Pendant Receptacle
Receptacle for connecting
interconnecting cord.
2
2
3
4
pendant
Jog Forward Push Button
4
5
6
Jog Reverse Push Button
Retracts wire up into the gun.
5
Gas Indicator LED
LED lights when gas solenoid is energized.
Advances wire out of the gun.
6
3
Momentarily energizes gas solenoid to
purge air from gun shielding gas line, or to
adjust shielding gas regulator.
Wirefeed Indicator LED
LED lights when wire feed motor is
energized.
Purge Push Button
7
7
Contactor Indicator LED
LED lights when welding power source
contactor is energized.
8
Main Display
Shows system state, active program, error
messages, weld parameters at idle and
during welding.
184 197
OM-186 359 Page 19
3-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void warranty.
100% Duty Cycle At 450 Amperes
60% Duty Cycle At 565 Amperes
6 Minutes Welding
Continuous Welding
4 Minutes Resting
Overheating
A/V
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 – 181 560
3-6. Volt-Ampere Curves
Volt-ampere curves show minimum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall between curves shown.
va_curve1 4/95 – 181 562
OM-186 359 Page 20
3-7. Setup Pendant Controls
1
2
8
4
3
5
7
6
801 959
1 Increase Button
Works with security feature on welding
power source to allow increasing weld
parameter values within the allowable range.
2 Decrease Button
Works with security feature on welding
power source to allow decreasing weld
parameter values within the allowable range.
3
Parameter Select Button
Press button to move indicator in right
window display, and to make selections in
setup screens.
4
Mode Select Button
Press button to move indicator in left window
display.
5 Interconnecting Cable Receptacle
6 Parameter Display
7 Mode Display
8 Card Slot
OM-186 359 Page 21
SECTION 4 – INTRODUCTION TO PROGRAMMING
4-1. Pulse MIG Programs
The interface unit is designed for
use in pulse MIG welding (adaptive
or standard), or MIG welding.
. Selecting hardwire
or softwire is
done during setup (see Section 9)
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 unit is factory-equipped with
eight programs for pulse MIG
welding.
The unit also provides memory for
the creation of up to eight MIG
programs (see Section 7).
The weld programs require the user
to enter information specific to the
welding
application.
This
information is entered as a part of
program development (see Section
5 for pulsed MIG information), and
during setup (see Section 9).
The eight pulse programs are
shown in the table. Each program
can be used in standard pulse MIG
or adaptive pulse MIG.
In an adaptive pulse MIG program,
the unit manipulates certain weld
variables to hold arc voltage
constant. This feature is described
in Section 6-5.
The factory-set parameters for
each program can be changed to
customize them for an application
(see Section 6).
4-2. Standard Pulse Welding Programs
The following sixteen (16) pulse welding programs are in the control memory. Use this information if it is necessary to
change a standard program, or as a basis to build your own custom program. If at any time while changing a standard
program, or while building your own custom program, you want to go back to the standard program in the control
memory, see Section 9-14 for System memory Reset instructions. See Section 6 for explanation of Pulse welding
settings.
Apk = Peak Amperage, Abk = Background Amperage, PPS = Pulses Per Second, PWms = Pulse Width (milliseconds), Vpk = Peak Voltage
OM-186 359 Page 22
4-3. Program 1 – .035 Steel, Argon-Oxy
Wire Size/Type: .035” Steel Gas: Ar - Oxy / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
750 / 19.1
460
90
210
2.4
32.0
700 / 17.8
450
90
200
2.4
31.9
650 / 16.5
440
85
190
2.3
31.8
600 / 15.2
430
85
180
2.3
31.3
550 / 14.0
420
80
170
2.3
30.2
500 / 12.7
410
80
160
2.2
29.5
450 / 11.4
400
75
150
2.2
28.9
400 / 10.2
380
70
140
2.2
28.3
350 / 8.9
360
65
130
2.1
27.4
300 / 7.6
340
60
120
2.1
26.9
250 / 6.4
320
55
110
2.0
26.4
200 / 5.1
300
50
100
2.0
25.5
150 / 3.8
280
45
80
1.9
24.0
100 / 2.5
260
40
60
1.6
23.2
50 / 1.3
230
35
40
1.5
22.0
COMMENTS
4-4. Program 2 – .045” Steel, Argon-Oxy
Wire Size/Type: .045” Steel
Gas: Ar - Oxy / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
750 / 19.1
540
150
250
3.0
33.5
700 / 17.8
530
150
240
3.0
33.0
650 / 16.5
520
145
230
2.9
32.6
600 / 15.2
510
135
220
2.9
32.4
550 / 14.0
500
125
210
2.8
32.0
500 / 12.7
490
115
200
2.8
31.5
450 / 11.4
480
110
190
2.7
31.0
400 / 10.2
470
105
175
2.7
30.0
350 / 8.9
460
98
165
2.6
28.5
300 / 7.6
450
95
150
2.6
28.4
250 / 6.4
430
85
130
2.6
27.0
200 / 5.1
410
75
110
2.5
27.2
150 / 3.8
370
55
90
2.5
25.8
100 / 2.5
330
40
70
2.4
25.2
50 / 1.3
300
30
55
2.3
24.6
COMMENTS
OM-186 359 Page 23
4-5. Program 3 – .035 Steel, Argon-CO2
Wire Size/Type: .035” Steel
Gas: Ar - CO2 / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
750 / 19.1
470
90
210
2.3
36.5
700 / 17.8
470
90
210
2.3
36.4
650 / 16.5
460
85
200
2.3
35.8
600 / 15.2
450
85
190
2.2
35.4
550 / 14.0
440
80
180
2.2
34.7
500 / 12.7
430
80
170
2.2
33.4
450 / 11.4
410
80
160
2.2
32.6
400 / 10.2
390
75
150
2.1
31.8
350 / 8.9
370
70
140
2.0
30.7
300 / 7.6
350
70
120
2.0
30.2
250 / 6.4
330
65
100
2.0
29.4
200 / 5.1
310
55
80
2.0
28.8
150 / 3.8
290
50
65
1.9
26.3
100 / 2.5
270
40
50
1.7
25.0
50 / 1.3
250
30
40
1.6
24.0
COMMENTS
4-6. Program 4 – .045” Steel, Argon - CO2
Wire Size/Type: .045” Steel
Gas: Ar - CO2 / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
750 / 19.1
560
135
240
3.0
35.5
700 / 17.8
560
130
235
3.0
35.2
650 / 16.5
550
130
230
2.9
34.9
600 / 15.2
540
125
225
2.9
34.7
550 / 14.0
530
120
220
2.8
34.3
500 / 12.7
520
115
210
2.8
33.8
450 / 11.4
495
110
195
2.8
32.8
400 / 10.2
480
100
180
2.8
31.5
350 / 8.9
465
90
165
2.7
30.7
300 / 7.6
450
85
150
2.6
29.8
250 / 6.4
430
80
130
2.6
28.5
200 / 5.1
410
70
110
2.5
27.9
150 / 3.8
38270
55
90
2.5
27.2
100 / 2.5
360
48
70
2.4
26.0
50 / 1.3
360
48
70
2.4
26.0
OM-186 359 Page 24
COMMENTS
4-7. Program 5 – .035” ER 309, Argon - CO2
Wire Size/Type: .035” ER 309
Gas: Ar - CO2 / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
750 / 19.1
390
95
210
2.2
38.0
700 / 17.8
380
95
200
2.1
38.0
650 / 16.5
370
90
190
2.0
37.6
600 / 15.2
360
85
180
1.9
36.2
550 / 14.0
350
80
170
1.9
35.3
500 / 12.7
340
75
160
1.9
35.2
450 / 11.4
330
70
150
1.8
35.0
400 / 10.2
320
65
140
1.8
34.8
350 / 8.9
310
60
130
1.7
34.8
300 / 7.6
300
55
120
1.7
34.1
250 / 6.4
290
50
100
1.6
32.5
200 / 5.1
280
45
80
1.6
30.7
150 / 3.8
270
40
60
1.6
28.0
100 / 2.5
270
36
40
1.5
27.5
50 / 1.3
260
30
30
1.5
26.0
COMMENTS
4-8. Program 6 – .045” ER 309, Argon - CO2
Wire Size/Type: .045” ER 309Gas: Ar - CO2 / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
750 / 19.1
490
110
260
2.3
38.5
700 / 17.8
480
110
260
2.3
38.0
650 / 16.5
470
105
260
2.2
38.0
600 / 15.2
460
100
240
2.1
38.0
550 / 14.0
450
100
240
2.0
37.5
500 / 12.7
440
95
220
1.9
37.0
450 / 11.4
430
95
200
1.9
37.0
400 / 10.2
420
95
180
1.9
36.5
350 / 8.9
410
95
160
1.8
35.9
300 / 7.6
400
90
140
1.8
34.8
250 / 6.4
380
85
120
1.8
34.6
200 / 5.1
360
80
100
1.7
33.6
150 / 3.8
340
70
80
1.6
31.9
100 / 2.5
320
50
60
1.6
31.5
50 / 1.3
320
45
45
1.6
30.1
COMMENTS
OM-186 359 Page 25
4-9. Program 7 – 3/64” ER 5356, Argon
Wire Size/Type: 3/64” ER 5356
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
750 / 19.1
470
95
210
2.6
37.0
700 / 17.8
465
92
205
2.6
36.9
650 / 16.5
455
87
190
2.5
36.3
600 / 15.2
450
85
175
2.5
35.9
550 / 14.0
435
80
170
2.4
35.2
500 / 12.7
428
78
160
2.4
33.9
450 / 11.4
408
78
155
2.3
33.1
400 / 10.2
389
75
146
2.2
32.3
350 / 8.9
370
75
140
2.1
31.3
300 / 7.6
350
72
133
2.1
30.7
250 / 6.4
330
65
110
2.0
29.9
200 / 5.1
310
63
83
1.9
29.3
150 / 3.8
290
50
65
1.9
26.8
100 / 2.5
270
40
50
1.7
25.5
50 / 1.3
250
30
40
1.6
24.5
COMMENTS
4-10. Program 8 – .035” SIB, Argon
Wire Size/Type: .035” SIB
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
750 / 19.1
480
100
260
2.6
37.0
700 / 17.8
470
98
240
2.5
36.9
650 / 16.5
460
95
230
2.5
36.3
600 / 15.2
450
93
220
2.4
35.9
550 / 14.0
440
90
215
2.4
35.2
500 / 12.7
430
85
205
2.3
33.9
450 / 11.4
410
80
205
2.3
33.1
400 / 10.2
390
78
190
2.3
32.3
350 / 8.9
370
75
180
2.2
31.3
300 / 7.6
350
70
160
2.2
30.7
250 / 6.4
330
65
140
2.2
29.9
200 / 5.1
310
55
120
2.0
29.3
150 / 3.8
290
50
100
1.9
26.8
100 / 2.5
270
40
80
1.7
25.5
50 / 1.3
250
30
70
1.6
24.5
OM-186 359 Page 26
COMMENTS
4-11. Program 1 – .035” ER 4043, Argon
Note
The next 8 programs are available after changing software wiretype (see Section 9-12).
Wire Size/Type: .035” ER 4043
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
750 / 19.1
450
140
155
2.0
32.1
730 / 18.5
445
135
150
1.9
31.5
720 / 18.3
440
130
145
1.9
32.7
710 / 18.0
430
130
140
1.8
31.6
655 / 16.6
415
120
135
1.7
33.9
600 / 15.2
400
118
125
1.7
31.4
545 / 13.8
395
115
115
1.6
30.9
490 / 12.4
370
100
105
1.5
32.1
435 / 11.0
350
90
100
1.4
27.8
380 / 9.7
320
78
95
1.3
30.8
325 / 8.3
285
72
80
1.2
31.9
270 / 6.9
265
60
75
1.1
18.6
215 / 5.5
245
48
70
1.1
16.1
160 / 4.1
205
41
49
1.0
12.8
140 / 3.6
200
38
46
1.0
11.4
COMMENTS
4-12. Program 2 – 3/64” ER 4043, Argon
Wire Size/Type: 3/64” ER 4043
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
750 / 19.1
530
170
270
3.0
37.0
740 / 18.8
515
168
265
3.0
36.0
720 /18.3
500
160
260
2.9
35.0
710 / 18.0
480
155
252
2.8
33.6
655 / 16.6
450
150
245
2.7
31.6
600 / 15.2
420
143
240
2.6
31.5
545 / 13.8
396
135
235
2.5
29.7
490 / 12.4
372
128
230
2.4
28.9
435 / 11.0
350
120
225
2.3
27.4
380 / 9.7
325
114
205
2.2
26.2
325 / 8.3
295
105
187
2.1
27.7
270 / 6.9
275
87
160
2.0
25.2
215 / 5.5
243
71
152
1.9
27.5
160 / 4.1
212
55
125
1.9
25.8
105 / 2.7
210
41
55
1.9
18.1
COMMENTS
OM-186 359 Page 27
4-13. Program 3 – 1/16” ER 4043, Argon
Wire Size/Type: 1/16” ER 4043
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
770 / 19.6
560
251
294
2.7
37.7
730 / 18.5
560
251
294
2.7
37.2
710 / 18.0
560
251
294
2.7
37.0
655 / 16.6
560
251
294
2.7
33.0
600 / 15.2
558
251
290
2.7
31.9
545 / 13.8
540
251
275
2.6
31.4
490 / 12.4
520
251
250
2.5
31.0
435 / 11.0
495
251
225
2.4
30.4
380 / 9.7
470
251
190
2.2
29.0
325 / 8.3
455
240
150
2.0
26.8
270 / 6.9
420
218
112
1.8
25.6
215 / 5.5
380
168
90
1.7
24.8
160 / 4.1
340
115
80
1.6
22.0
105 / 2.7
295
73
55
1.5
20.8
70 / 1.8
290
45
50
1.5
20.0
COMMENTS
4-14. Program 4 – .035” ER 5356, Argon
Wire Size/Type: .035” ER 5356
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
760 / 19.1
300
118
140
3.6
24.7
740 / 18.8
295
114
145
3.5
24.6
720 / 18.3
290
110
140
3.4
23.1
710 / 18.0
286
103
128
3.3
22.7
655 / 16.6
276
95
124
3.2
22.6
600 / 15.2
268
86
115
3.2
22.2
545 / 13.8
250
80
107
3.1
21.9
490 / 12.4
238
78
105
3.0
21.5
435 / 11.0
230
73
100
2.9
21.3
380 / 9.7
215
65
90
2.8
21.1
325 / 8.3
195
63
80
2.7
21.0
270 / 6.9
180
58
70
2.5
17.8
215 / 5.5
178
45
56
2.4
17.6
160 / 4.1
175
33
45
2.3
17.5
105 / 2.7
175
25
29
2.2
10.5
OM-186 359 Page 28
COMMENTS
4-15. Program 5 – 3/64” ER 5356, Argon
Wire Size/Type: 3/64” ER 5356
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
755 / 19.2
465
138
270
3.0
30.7
730 / 18.5
445
130
265
2.9
28.7
700 / 17.8
425
128
255
2.8
28.1
680 / 17.3
405
120
245
2.7
27.7
655 / 16.6
385
110
235
2.6
27.3
600 / 15.2
365
100
228
2.5
26.3
545 / 13.8
345
92
215
2.5
25.9
490 / 12.4
330
85
200
2.4
25.1
435 / 11.0
320
80
193
2.3
24.4
380 / 9.7
310
78
186
2.2
23.7
325 / 8.3
300
75
158
2.1
22.0
270 / 6.9
272
65
130
2.0
21.5
215 / 5.5
245
53
110
1.9
19.5
160 / 4.1
236
47
67
1.8
19.2
105 / 2.7
231
22
62
1.8
18.0
COMMENTS
4-16. Program 6 – 1/16” ER 5356, Argon
Wire Size/Type: 1/16” ER 5356
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
770 / 19.6
560
251
294
2.7
38.0
735 / 18.7
560
251
294
2.7
37.0
710 / 18.0
560
251
294
2.7
32.5
655 / 16.6
545
251
294
2.7
31.7
600 / 15.2
515
251
270
2.6
31.0
545 / 13.8
480
251
224
2.5
29.1
490 / 12.4
447
251
175
2.3
28.6
435 / 11.0
427
240
155
2.1
25.1
380 / 9.7
407
220
140
2.0
24.8
325 / 8.3
387
190
126
1.9
24.0
270 / 6.9
367
160
112
1.8
23.4
215 / 5.5
354
124
92
1.7
22.4
160 / 4.1
328
95
68
1.6
22.2
105 / 2.7
315
51
58
1.6
19.7
75 / 1.9
311
35
58
1.5
18.0
COMMENTS
OM-186 359 Page 29
4-17. Program 7 – 3/64” ER 5356, Argon
Wire Size/Type: 3/64” ER 5356
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
750 / 19.1
465
138
270
3.0
30.0
720 / 18.3
445
130
265
2.9
29.0
700 / 17.8
425
125
255
2.8
27.9
680 / 17.3
402
120
244
2.7
27.7
655 / 16.6
382
110
235
2.6
27.2
600 / 15.2
360
99
225
2.5
26.0
545 / 13.8
340
92
215
2.5
25.8
490 / 12.4
325
85
200
2.4
24.7
435 / 11.0
315
80
177
2.3
23.5
380 / 9.7
305
76
168
2.2
23.0
325 / 8.3
290
60
145
2.1
21.3
270 / 6.9
270
55
125
2.0
20.6
215 / 5.5
247
50
100
1.9
20.0
160 / 4.1
225
41
68
1.8
19.7
105 / 2.7
225
19
58
1.8
18.8
COMMENTS
4-18. Program 8 – .035” ER 5356, Argon
Wire Size/Type: .035” ER 5356
Gas: Argon / 40 CFH
IPM / MPM
Apk
Abk
PPS
PWms
Vpk
770 / 19.6
300
120
150
3.6
24.7
740 / 18.8
295
114
145
3.5
24.6
720 / 18.3
290
110
140
3.4
24.1
710 / 18.0
286
103
133
3.3
24.0
655 / 16.6
275
93
124
3.2
23.8
600 / 15.2
267
85
117
3.2
23.6
545 / 13.8
250
80
107
3.1
22.1
490 / 12.4
235
78
100
3.0
21.8
435 / 11.0
222
71
90
2.9
21.5
380 / 9.7
207
65
83
2.8
21.2
325 / 8.3
190
64
72
2.6
20.9
270 / 6.9
185
52
65
2.4
18.5
215 / 5.5
182
40
58
2.2
18.3
160 / 4.1
180
30
43
2.1
18.0
105 / 2.7
180
23
30
2.0
17.8
OM-186 359 Page 30
COMMENTS
4-19. Setup Pendant Mode Select Button
1
2
Mode Display
Mode Select Button
Press Mode Select button to move
indicator in left window display.
Go to Section 4-20.
1
>P r o c e s s
Ca r d
Sequence
P r ocess
>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. 154 109
OM-186 359 Page 31
4-20. Setup Pendant Parameter Select Button
1
2
Parameter Display
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.
2
1
>P r o c e s s
Ca r d
Sequence
> Pr
Pu
03
Ar
g 1
l se
5 ”S t ee l
g on – Ox y
P r
>P u
03
A r
g 1
l se
5 ”S t ee l
g on – Ox y
Pu
03
A r
>T e
l
5
g
a
se
”S t ee l
on – Ox y
c h Off
3
Ref. 154 109
OM-186 359 Page 32
4-21. Setup Pendant Parameter Increase And Decrease Buttons
Use mode select button to select
mode to be changed (see 4-19).
Use pulse panel parameter select
button to select parameter to be
changed (see 4-20).
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.
1
>P r
Pu
03
A r
g 1
l se
5 ”S t ee l
g o n –Ox y
>P r
Pu
04
A r
g 2
l se
5 ”S t ee l
g on – Ox y
Increase
Increase
2
>P r
Pu
05
A r
g 3
l se
2 ”S t ee l
g on – Ox y
Decrease
>P r
Pu
04
A r
g 2
l se
5 ”S t ee l
g on – Ox y
Ref. 154 109
OM-186 359 Page 33
SECTION 5 – GETTING STARTED FOR PULSE WELDING
5-1. Weld Cycle For Pulse Welding
. The type of robot kit installation will determine
what combination of parameters are available.
Start
Power
Wire
Speed
Robot
Motion
Weld Time
Crater Time
Start
Speed
Burnback Time
Weld
Speed
Crater
Speed
Preflow
Time
Weld
Start
Run-In
Setting
Arc
Strike
Weld
Stop
Postflow
Time
Arc
Out
Time
Ref. S-0271
5-2. 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
1
2
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 5-3.
Mode Select
Parameter
Select
3
>P r e f l o w
0 . 0
Sec
Parameter
Select
Set Desired Time
Increase/
Decrease
OM-186 359 Page 34
>P r e f l o w
1 . 2
Sec
P r e f l ow
>0 . 0
Sec
Parameter
Select
Increase
Proceed to next Section.
5-3. Setting Weld Sequence Display
Set Desired Weld
Sequence Trim
>5 0
200
1
1
We l d
Weld Parameters Display
Parameter ranges are as follows:
Trim (Arc Length), 0-99
T r im
I PM
Wire Feed Speed, 50-780 Inches
Per Minute, IPM
Increase/
Decrease
Go to Section 5-4.
Parameter
Select
Set Desired Weld Sequence
Wire Feed Speed
We l d
60
>2 0 0
T r im
I PM
Increase/
Decrease
Parameter
Select
>We l d
60
300
T r im
I PM
Increase
Proceed to next Section.
5-4. Setting Crater Sequence Display
1
1
>C r a t e r
0 . 00 Sec
50
T r im
200
I PM
Parameter
Select
Set Desired
Time
Crater Parameters Display
Parameter ranges are as follows:
Cr a t e r
>0 . 0 0 S e c
50
T r im
200
I PM
Seconds, 0-2.50 Sec. If value set is
zero (0), there is no Crater
sequence.
Trim (Arc Length), 0-99
Parameter
Select
Wire Feed Speed, 50-780 Inches
Per Minute, IPM
Go to Section 5-5.
Increase/
Decrease
Cr a t e r
0 . 20 Sec
60
T r im
>1 5 0
I PM
>C r a t e r
0 . 20 Sec
60
T r im
150
I PM
Parameter
Select
Increase
Proceed to next Section.
Set Desired Wire
Feed Speed
Increase/
Decrease
Cr a t e r
0 . 20 Sec
>5 0
T r im
200
I PM
Parameter
Select
Set Desired
Trim
Increase/
Decrease
OM-186 359 Page 35
5-5. Setting Postflow Sequence Display
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
>P o s t f l o w
1 . 2
Sec
1
Postflow Parameters Display
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postflow sequence.
Parameter
Select
Increase
Proceed to next Section.
SECTION 6 – TEACHING A PULSE WELDING PROGRAM
Note
See GMAW-P (Pulsed MIG) Process Guide supplied with unit for more information.
6-1. Pulse Waveform Explained
This unit controls weld output for
pulsed welds.
1
Apk – Peak Current Of
100-600 Amperes
Apk is the high pulse of welding current. Peak current melts the welding wire and forms a droplet. The
droplet is forced into the weld
puddle.
2
3
Abk is the low weld current.
Background current preheats
welding wire and maintains the arc.
When background current is too
low, the arc is unstable and hard to
maintain.
Amps
(Current)
3
1
Abk – Background Current Of
10-255 Amperes
2
4
Time
PPS – Pulses Per Second Of
20-400
PPS, pulse rate, and frequency
(Hz) are used interchangeably. A
PPS or pulse rate of 60 Hz means
60 pulses of current are produced
each second.
4
PWms – Pulse Width Of
1.0-5.0 Milliseconds
PWms is the time spent at peak
current (1.2 ms is .0012 seconds).
This time must be long enough to
form a droplet of welding wire. The
stiffness or fluidity of the molten
weld puddle is controlled by PWms.
Vpk = Peak Voltage
Arc Voltage during peak current
phase of the pulse waveform. This
determines arc length during
adaptive pulse welding.
Ref. S-0259
OM-186 359 Page 36
6-2. Teach Points Explained
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
Apk
Abk
200
PPS
150
PWms
Vpk
100
50
150
10
30
1
2.5
180
20
55
210
30
80
240
40
105
5
7.5
10
270
50
130
300
60
160
330
70
185
12.5
15
17.5
2
The teach mode allows the user to create
custom pulse MIG welding programs. The
teach mode has 15 teach points. At each
teach point, the user can adjust five
parameters: peak amperage (Apk), background amperage (Abk), pulses per second
(PPS), pulse width in milliseconds (PWms),
and peak voltage (Vpk) to shape the pulse
waveform of the weld output.
Wire feed speed teach points can range from
the minimum to the maximum wire feed
speed of the feeder. When using a standard
speed motor, wire feed speed teach points
typically range from 50 to 750 ipm. The feeder uses pulse parameters at teach points to
establish the pulse parameters at any wire
feed speed setting.
Below the wire feed speed of the lowest
teach point, and above the wire feed speed
360
80
210
3
20
370
90
235
420
100
260
450
110
290
22.5
25
27.5
480
120
315
510
130
340
540
140
365
30
32.5
35
4
of the highest teach point, the unit may limit
wire feed speed settings in pulse MIG to
maintain all pulse parameters within the
capability of the unit.
Pulse MIG programs made by the
manufacturer have pulse waveform
information entered for all 15 teach points.
The operator can relocate and modify the
setting of one, or any number of the 15 teach
points if the factory set information is not
appropriate for a specific application.
After the parameters for each teach point are
established, an arc must be struck and maintained for at least 5 seconds in teach mode.
This allows the wire feeder to learn the arc
voltage length associated with the taught
pulse parameters. To ensure a proper arc
length reading, electrode stick-out must be
565
150
400
5
37.5
Apk
Abk
PPS
PWms
Vpk
carefully maintained. An alternate method is
to adjust the Vpk value, then turn off Teach
Mode and weld. If welding is performed with
Teach Mode on, Vpk will be updated for other
parameter settings.
The taught arc length represents a Trim (arc
length) setting of 50. Increasing the value of
Trim, increases the actual arc length. Likewise, decreasing the value of Trim will
decrease actual arc length.
In the Pulse mode, the unit does not maintain
a constant arc length with variations in electrode stick-out. In the Adaptive Pulse mode,
the unit adjusts pulse frequency to maintain
a constant arc length regardless of variations in electrode stick-out.
Proceed to next section to teach a pulse MIG
program.
OM-186 359 Page 37
6-3. Selecting Teach Point Wire Feed Speed For Pulse Welding Program
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
>T e a c h
Of f
Parameter
Select
3
Increase/
Decrease
Use increase/decrease buttons to
select On.
IPM (Teach Point)
The parameters associated with
this wire feed speed teach point can
be modified. The wire feed speed
value itself cannot be changed from
the set point.
To set or adjust teach point parameters, go to Section 6-4.
T e a c h On
>4 0 0
I PM
340
Apk
70
Abk
>T e a c h O n
400
I PM
340
Apk
70
Abk
Parameter
Select
OM-186 359 Page 38
Teach Display
Use parameter select button to
select Teach.
3
Mode
Select
Process Display
When unit is first turned On,
Process is the default screen, at
other times use mode select button
to select Process.
6-4. Setting Teach Point Parameters For Pulse Welding Program
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
>3 4 0
Apk
70
Abk
Parameter
Select
Or
1
Parameter
Select
Increase/
Decrease
Increase/
Decrease
34
9
>2 8
1 .
3
2
0
9
Apk
Abk
PPS
P Wm s
T e a c h On
450
I PM
>3 4 3
Apk
70
Abk
34
9
>1 6
1 .
3
2
0
9
Apk
Abk
PPS
P Wm s
I PM
Apk
Abk
PPS
450
343
> 70
160
3
2
0
9
Apk
Abk
PPS
P Wm s
2
Wait for 5
seconds
Increase/
Decrease
34
9
28
>1 .
I PM
Apk
Abk
PPS
Parameter
Select
3
Parameter
Select
450
343
> 92
160
34
9
28
>3 .
3
2
0
6
Apk
Abk
PPS
P Wm s
92
280
3 . 6
>2 8 . 9
92
280
3 . 6
>3 1 . 4
Abk
PPS
P Wm s
Vpk
Parameter
Select
Increase/
Decrease
4
Abk
PPS
P Wm s
Vpk
Parameter
Select
5
6
Increase/
Decrease
P r
Pu
03
A r
g
l
5
g
Pu
03
A r
>T e
1
C
se
”S t ee l
on -Ox y
l
5
g
a
se
”S t ee l
on -Ox y
ch Of f
>T e a c h O n
450
I PM
343
Apk
92
Abk
Parameter
Select
When the Process Teach mode is On, and
one of the following pulse parameters is selected: Apk, Abk, PPS, PWms, or Vpk, the
pulse panel displays the selected pulse parameter instead of Trim (arc length). When
the pulse parameter is selected, the value
can be changed with the pulse panel controls
as follows:
1
Apk Display
2 Abk Display
3 PPS Display
4 PWms Display
5 Vpk Display
When values have been set for a teach point,
strike and maintain an arc for five seconds.
Repeat procedure at each teach point until
custom program is complete (see Section
6-2).
Turn Teach mode Off.
6
Custom Pulse Screen
The letter C will appear in the upper right
corner of all customized programs.
Customized programs can be reverted back
to factory-set values through memory reset
(see Section 9-14).
OM-186 359 Page 39
Note
Make copies of this chart for future use.
Program #
Wire Size/Type
Gas
Program Name
Card #
Gun Model
Flowrate
IPM
Preflow:
Apk
Abk
PPS
PWms
Vpk
Sec.
Run-In Trim:
IPM:
Sec.:
Crater Trim:
IPM:
Sec.:
Postflow:
OM-186 359 Page 40
Sec.
CFH
COMMENTS
6-5. 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. To change to
Adaptive Pulse welding, proceed
as shown:
Mode
Select
1
1
>P r o c e s s
Ca r d
Sequence
Setup Pendant Display
Default display when unit is first
turned On, at other times use mode
select button to select Process.
>P r g 1
MIG
035 ”S t ee l
A r g o n –Ox y
Parameter
Select
>P r o c e s s
Ca r d
Sequence
P r g 1
>M I G
035 ”S t ee l
A r g o n –Ox y
>P r o c e s s
Ca r d
Sequence
P r
>A d
03
A r
g 1
a p tP u l s e
5 ”S t ee l
g o n –Ox y
Increase/
Decrease
SECTION 7 – TEACHING A MIG WELDING PROGRAM
7-1. Weld Cycle For Mig Welding
. The type of robot kit installation will determine
what combination of parameters are available.
Start
Power
Wire
Speed
Robot
Motion
Weld Time
Crater Time
Start
Speed
Burnback Time
Weld
Speed
Crater
Speed
Preflow
Time
Weld
Start
Run-In
Setting
Arc
Strike
Weld
Stop
Postflow
Time
Arc
Out
Time
Ref. S-0271
OM-186 359 Page 41
7-2. Changing To Mig Welding
1
Mode
Select
Setup Pendant Display
Default display when unit is first
turned On, at other times use mode
select button to select Process.
1
Go to Section 7-3.
>P r o c e s s
Ca r d
Sequence
>P r
Ad
03
A r
g 1
a p tP u l s e
5 ”S t ee l
g o n –Ox y
Parameter
Select
>P r o c e s s
Ca r d
Sequence
P r
>A d
03
A r
g 1
a p tP u l s e
5 ”S t ee l
g o n –Ox y
P r g
>M I G
>P r o c e s s
Ca r d
Sequence
1
Increase/
Decrease
7-3. Setting Preflow Sequence Display
1
Setup Pendant Display
When unit is turned On, Process is
the default mode. Use mode select
button to select Sequence.
1
>P r o c e s s
Ca r d
Sequence
>P r g
MIG
2
1
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.
Mode
Select
P r ocess
Ca r d
>S e q u e n c e
Go to Section 7-4.
>P r e f l o w
0 . 0
Sec
3
2
P r e f l ow
>0 . 0
Sec
Parameter
Select
Set Desired Time
Increase/Decrease
OM-186 359 Page 42
>P r e f l o w
1 . 2
Sec
Parameter
Select
Increase
Proceed to next Section
7-4. Setting Start Sequence Display
1
1
Start Parameters Display
Parameter ranges are as follows:
>S t
0 .
24
9
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
Set Desired Time
S t
0 .
>1 8
9
Parameter
Select
a r t
5 Sec
. 0Vo l t
0 I PM
Set Desired Voltage
a r t
5 Sec
. 0Vo l t
0 I PM
Parameter
Select
Wire Feed Speed, 50-780 inches
per minute, IPM
Increase/
Decrease
S t
0 .
18
>2 0
Increase
Proceed to next Section.
Volts, 10.0-38.0 Volts
Go on to Section 7-5.
Increase/
Decrease
>S t
0 .
18
20
Seconds, 0-2.5 Sec. If value set is
zero (0), there is no Run-In
sequence.
a r t
5 Sec
. 0Vo l t
0 I PM
Set Desired Wire
Feed Speed
Parameter
Select
Increase/
Decrease
7-5. Setting Weld Sequence Display
1
1
>We
I n
18
20
l d
duc t 20
. 0Vo l t s
0 I PM
We
>I n
18
20
l d
duc t 20
. 0Vo l t
0 I PM
Parameter
Select
Set Desired
Inductance
Weld Parameters Display
Parameter ranges are as follows:
We
>I n
18
20
l d
duc t 30
. 0Vo l t
0 I PM
Inductance, 0-99
Volts, 10.0-38.0 Volts
Wire Feed Speed, 50-780 Inches
Per Minute, IPM
Go to Section 7-6.
Increase/
Decrease
Parameter
Select
We
I n
20
>2 0
l d
duc t 30
. 0Vo l t
0 I PM
We
I n
>2 0
20
l d
duc t 30
. 0Vo l t
0 I PM
Set Desired
Voltage
We
I n
>1 8
20
l d
duc t 30
. 0Vo l t
0 I PM
Increase/
Decrease
Parameter
Select
Set Desired Wire Feed Speed
Increase/
Decrease
We
I n
20
>4 2
l d
duc t 30
. 0Vo l t
0 I PM
Parameter
Select
>We
I n
20
42
l d
duc t 30
. 0Vo l t s
0 I PM
Increase
Proceed to next Section.
OM-186 359 Page 43
7-6. Setting Crater Sequence Display
1
>C r a t e r
0 . 02Se c
24 . 0Vo l t
9 0 I PM
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.
Volts, 10.0-38.0 Volts.
Parameter
Select
Wire Feed Speed, 50 to 780 inches
per minute, IPM.
Go to Section 7-7.
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
Parameter
Select
Increase/
Decrease
a t e r
12Se c
. 0Vo l t
0 I PM
Cr
0 .
18
>2 0
Set Desired
Voltage
Parameter
Select
a t e r
12Se c
. 0Vo l t
0 I PM
Set Desired Wire
Feed Speed
Increase/
Decrease
Increase/
Decrease
>C r
0 .
18
20
a t e r
12Se c
. 0Vo l t
0 I PM
Parameter
Select
Increase
Proceed to next Section.
7-7. Setting Retract Sequence Display
1
1
Re t r a c t
>0 . 1 2 S e c
>R e t r a c t
0 . 00 Sec
Retract Parameter Display
Parameter range is as follows:
>R e t r a c t
0 . 12 Sec
Seconds, 0-0.25 seconds. If value
set is zero (0), there is no Burnback
sequence.
Go to Section 7-8.
Parameter
Select
Set Desired Time
Increase/
Decrease
OM-186 359 Page 44
Parameter
Select
Increase
Proceed to next Section.
7-8. Setting Postflow Sequence Display
1
1
>P o s t f l o w
0 . 0
Sec
>P o s t f l o w
1 . 2
Sec
Po s t f l ow
>0 . 0
Sec
Parameter
Select
Set Desired Time
Postflow Parameters Display
Postflow can be adjusted from
0-9.9 seconds. If value set is zero
(0), there is no Postflow sequence.
Parameter
Select
Increase/
Decrease
SECTION 8 – USING THE OPTIONAL DATA CARD
8-1. Installing Data Card
1
Label
1
2
3
4
5
6
7
8
9
11
10
12
13
THIS SIDE UP
60-M Data Card
14
Peel backing from label and apply
to data card with THIS SIDE UP by
metal pins.
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. Data card formats
when unit enters Card mode. Exit
Card mode and turn Off power.
3
2
1
Ref. 801 960 / Ref. 155 823
OM-186 359 Page 45
8-2. Using The Data Card
Use Mode Select button to select
Card.
1
P r oces s
>C a r d
Sequence
P r ess
Be l ow
1
Card Display
2
Write
Used to transfer program data from
unit to card. The program card can
hold up to 32 programs. When
writing to the card, the next
available program number is
automatically assigned.
3
Parameter
Select Once
Read
Used to transfer program data from
card to unit.
4
Delete
Used to delete program data from
card.
2
5
>W r
Re
De
Do
3
4
5
OM-186 359 Page 46
i
a
l
n
Done
Used to exit card display.
t e
d
e t e
e
# 1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
6
6
Moving Line
Moving line is under value that can
be changed.
8-3. 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
P r ocess
>C a r d
Sequence
P r ess
Be l ow
2
>W r
Re
De
Do
i
a
l
n
t e
d
e t e
e
Parameter
Select
#1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
Parameter
Select
Allowable characters include: 0 thru 9, :, ;, <, =,
>, ?, @, A thru Z, [, , ], ^, _,‘, a thru z , blank , !, ”,
#, $, %, &, ’, (, ), *, +, –, ., /,
3
Increase/
Decrease
N ame ? N o
035 ”S t ee l
A r g o n –Ox y
P r es s
N ame ? Y e s
035 ”S t ee l
A r g o n –Ox y
P r ess
Yes
No
Increase
N ame ? Y e s
035 ”S t ee l
A r g o n –Ox y
⇒P r e s s
N ame ? Y e s
5007992
F r ame
⇒P r e s s
Parameter
Select
Parameter
Select
Parameter
Select
Wr i t eDo n e
P r g 1 t o
Ca r dP r g 1
P r es s
Parameter
Select
#1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r es s
1 Card Display
Use Mode Select button to select Card.
2 Moving Line
Wr i t eDo n e
P r g1 t o
Ca r d P r g1
P r ess
N ame ?
No
5007992
F r ame
P r ess
Parameter
Select
N ame ? Y e s
5007992
F r ame
P r ess
Increase
Parameter
Select
#1 Pu l se
5007992
F r ame
P r ess
Moving line is under value that can be
changed. Use increase or decrease button
to change value.
3 Name Display
If no name is desired, press Parameter Select button to continue the write procedure.
OM-186 359 Page 47
8-4. Reading From Card
1
P r ocess
>C a r d
Sequence
P r ess
Be l ow
Mode
Select
Twice
Parameter
Select Once
2
3
Wr
>R e
De
Do
i
a
l
n
t e
d
e t e
e
# 1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
Read Ca r d
t o Feede r
P r g 1
P r ess
Parameter
Select
WA R N I N G :
P r g1 Wi l l
Be Los t
Lose? Yes
P r ess
P r g1 Wi l l
Be Los t
Lo s e? No
P r ess
No
Yes
Increase
Parameter
Select
# 1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
Parameter
Select
Parameter
Select
Read Done
Ca r d P r g1
t o P r g 1
P r ess
Use Mode Select button to select Card.
1 Card Display
2 Moving Line
Moving line is under value that can be
OM-186 359 Page 48
Parameter
Select
# 1 Pu l se
035 ”S t ee l
A r g o n –Ox y
P r ess
changed. Use increase or decrease button
to select program number to read from card
to feeder.
3
Read Display
Use increase or decrease button to select
feeder program number where the card program goes.
8-5. Reading (Or Deleting) From An Empty Card
1
1
Wr
>R e
De
Do
i
a
l
n
t e
d
e t e
e
Warning Display
If there are no programs on the
card, this series of displays appear.
WA R N I N G :
C a r d Emp t y
P r ess
Be l ow
Parameter
Select Once
Wr
Re
De
>D o
i
a
l
n
>P r o c e s s
Ca r d
Sequence
t e
d
e t e
e
>P r g
MIG
2
P r es s
Parameter
Select
8-6. Deleting Programs From Card
Use Mode Select button to select
Card.
1
P r oces s
>C a r d
Sequence
P r ess
Be l ow
1
Card Display
2
Moving Line
Moving line is under value that can
be changed.
3
Mode
Select
Twice
Wr
Re
>D e
Do
i
a
l
n
Parameter
Select Once
t e
d
e t e
e
#
2
Delete Display
Select program number to be
deleted from card.
MIG
WA R N I N G :
P r es s
Parameter
Select
2
3
De l e t e
Ca r d P r g2
Lo s e? No
P r ess
De l e t e
Ca r d P r g2
L o s e ? Y e s No
P r es s
Yes
Increase
#2
MIG
P r ess
Parameter
Select
Parameter
Select
Ca r d P r g2
De l e t ed
#3
P r es s
MIG
P r ess
Parameter
Select
OM-186 359 Page 49
SECTION 9 – SETUP
9-1. Setup Flow Chart
1
2
3
1
>S e
Ac
Mi
I n
cu r i t y
ces s
g Type
duc t .
>V o l t
10 . 0
Mi n
Vo l t
2
Display Selections
Features
Settings
To set up features that customize
operation, use the setup displays.
Features that can be customized
are as follows:
3
Example Of Setup Pendant Display
Display
Selection
>Security
Features
Settings
Program
Number
Lock
Off/On
Default
Section
9-3
Code
Off/On
Off
9-4
>Mig Type
Voltage
Correction
DVC On/Off
Adapt A or No
Adapt
Off
Adapt A
9-5
Output On
w/Feeder
w/Arc
w/Weld Cycle
Never
Never
9-7
Control
Feedback
Internal
Volt Sense
Internal
Arc Start
Type
Standard
Hot Start
Soft Start
Standard
>Arc Start
>Display
>Memory
>Access
>Voltage
Features
Off
Press Mode Select To
Go To Next Setup Display
>Aux Output Auxiliary
Output
Display
Selection
Run Hours
Default
Actual
Amps
Command
Command
9-13
No Reset
9-14
No Reset
Section
Program
Reset
System
Reset
>Shutdown
Arc Start/
Volt Sense
Off/On
On
9-15
>Name
Card
Programs
Off/On
On
9-16
>Program
Remote
Select
Off/On
Off
9-17
>Stick
Stick Check
Off/On
Off
9-19
>Jog IPM
Robot Jog
Remote/Local
Local
50 - 780
200
9-20
Auto Set
Auto Set
9-21
9-8
9-9
Local Jog
IPM
>Arc Time
Settings
0–9999.99
Hours
0–999,999
Cycles
9-10
>Robot
No Reset
>Flow
Detect Flow
Off/On
Off
9-22
>Monitor
Arc Volt Error Off/On
Off
9-23
Reset
>Wire Feed
Display
IPM/MPM
IPM
Motor Type
Standard
Low Speed
High Speed
Standard
9-11
>Software
>Wiretype
Wire Type
In Feeder
OM-186 359 Page 50
Hardwire/
Softwire
Hardwire
9-12
Range
0.1 - 9.9
Sec
0.1 - 25
Version
Number
9-24
9-2. Using Setup Displays
1
3
2
2
Mode Parameter
Select Select
Front Panel Setup Display
Front panel display during setup.
3
Pulse Panel Mode And
Parameter Select Buttons
Power Switch On Rear Panel
Press and hold down both buttons
while turning On unit.
4
Setup Pendant Display
Follow this procedure any time
access is required. Once in the setup displays, use the Mode Select
button to select a particular display.
To save any or all of the changes
made while in the setup displays,
and/or to exit the setup displays,
turn power to the unit Off and back
On.
1
S e t u p
Front Panel Display
4
>S e
Ac
Mi
I n
cu r i t y
cess
g
Type
duc t .
>V o l t
10 . 0
Mi n
Vo l t
Setup Pendant Display
OM-186 359 Page 51
9-3. Selecting Security Lock
Note
Security lock works only when a data card is inserted (see Section 8).
1
Access
Setup
Display
1
cu r i t y
ces s
g
Type
duc t .
>P r o g
Lock
Press Mode
Select
2
On
P r og
>L o c k
2
On
>P r o g
Loc k
Increase
3
Of f
Program Lock Display
When lock is off a program, the
operator can change all weld
parameters of that program without
restriction.
>P r o g
Lock
Parameter
Select
Parameter
Select
OM-186 359 Page 52
3
1
Of f
2
Of f
Program Number
Choose the program number (1
through 8) to be locked.
With lock on a program, the
operator
cannot
change
parameters of that program.
Increase
Increase
>P r o g
Lock
2
2
>S e
Ac
Mi
I n
P r og
>L o c k
Security Display
Use this display to lock a program’s
weld parameters so that changes
can not be made using pulse panel
controls.
2
Of f
3
9-4. Selecting Or Changing Access Code
Note
Access code works only when a data card is inserted (see Section 8).
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.
Se
>A c
Mi
I n
cu r i t y
ces s
g Type
duc t .
Co d e
>O f f
2
Access Display
With a code set, this display
appears when power is turned on
while holding the pulse panel Mode
and Parameter Select buttons.
Press Mode
Select
Increase
Code
>O n
AAA
Press Parameter Select button to
enter access code. When the
correct letter is entered, the
indicator automatically moves to
the next character. When the final
access code letter is entered, the
display automatically changes to
the initial setup display.
Parameter
Select
Co d e
On
>A A A
⇒P r e s s
Increase/Decrease
To Set Code
Parameter Select
To Move Indicator
Co d e
On
>Z WX
⇒P r e s s
Turn Power Off And Back On
And Access Security Display
2
En t e r
Ac ces s
Code
>C o d e
⇒P r
AAA
ess
OM-186 359 Page 53
9-5. Selecting Voltage Correction
1
Se
Ac
>M i
I n
Access
Setup
Display
cu r i t y
ces s
g Type
duc t .
MI G
>D V C O f f
Pu l se
Adap t A
1
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.
Press Mode
Select
Increase
MI G
DVC On
Pu l se
>N o A d a p t
MI G
DVC On
Pu l se
>A d a p t A
Mig Type Display
With DVC Voltage Correction On,
the unit uses closed-loop feedback
or voltage sensing leads to
maintain set voltage parameters.
Be sure voltage sensing leads are
connected or voltage feedback is
available through the 17-pin
receptacle via the welding power
source.
MI G
>D V C O n
Pu l se
Adap t A
Parameter
Select
Increase
9-6. Selecting Inductance
1
Access
Setup
Display
Inductance Display
The inductance level can be varied
between 0 (zero) and 99.
Press Mode
Select
1
Ac c
Mi
>I n
Au
es s
g Type
duc t .
x Ou t p u t
Increase
Le v e l
30
Le v e l
99
9-7. Selecting Auxiliary Output
1
1
Mi
I n
>A u
Vo l
Access
Setup
Display
g Type
duc t .
x Ou t p u t
t age
Aux
Ou t p u t O n
>w / F e e d e r
On whenever the wire feeder is operating
On during the welding arc until arc
goes out
Press Mode
Select
Increase
Aux
Ou t p u t
>N e v e r
Aux
Ou t p u t O n
>w / W e l d C y c
On
Increase
OM-186 359 Page 54
Aux
Ou t p u t
>w / A r c
Increase
Auxiliary Output
This output can be set to several
conditions:
On
On during the entire weld cycle
Off or never On.
9-8. Selecting Voltage Sensing Method
1
Access
Setup
Display
Press Mode
Select
When using the V. Sense setting,
arc voltage feedback is through the
voltage sense leads connected to
the feeder. Use this setting when
there is more than 50 ft (15 m) of
weld cable used or when using
Touch Sensor.
1
I n
Au
>V o
A r
duc t
x Ou
l t ag
cS t a
Voltage Feedback Display
If the Internal 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.
.
t pu t
e
r t
Co n t r o l
Fe e d b a c k
>In t e r n a l
Increase
Co n t r o l
Fe e d b a c k
>V . S e n s e
9-9. Selecting Arc Start Method
Note
Arc Start selection is not used when welding in non-pulsed MIG.
Do not use the Hot Start setting for .035 in (9 mm) or smaller wire.
1
Access
Setup
Display
2
x Ou t p u t
l t age
cS t a r t
c T i me
3
Pu l se
Ar c S t a r t
>S t a n d a r d
Ar c S t a r t
Ty p e
>H o t S t a r t
Increase
Soft Start
Use the Soft Start mode for .035 in
(9 mm) or smaller wire. Low wire
feed speeds may also require the
Soft Start mode. Arc start is at 75%
of maximum amperage for pulse
welding and once an arc is
established, welding is performed
at set parameter values.
1
2
Hot Start
Use the Hot Start mode for pulse
welding when high initial weld
current is necessary to start large
diameter welding wires. When in
Hot Start, welding power source
starts the arc in the CV mode and
switches to CC once the arc is
started.
Press Mode
Select
Au
Vo
>A r
A r
Standard Start
Welding operation is performed at
set values for welding parameters.
Ar c S t a r t
Ty p e
>S o f t S t a r t
3
OM-186 359 Page 55
9-10. Resetting Arc Time
1
Access
Setup
Display
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.
Press Mode
Select
1
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
Increase
0 . 0 0H r s
0Cy c l
>R e s e t
P r ess
9-11. Selecting Units For Wire Feed Speed And Motor Type
1
Wire Feed Display
The displayed unit of wire speed
(IPM or MPM) can be changed
along with the wire feed motor type
(Standard, Low Speed, or High
Speed).
Access
Setup
Display
Press Mode
Select
1
A r
A r
>W i
Wi
cS t a r t
c T i me
r e f eed
r e t ype
Di s p l a y
>I PM
Mo t o r T y p e
S t anda r d
Increase
Di s p l a y
I PM
Mo t o r T y p e
>L o w S p d
Di s p l a y
I PM
Mo t o r T y p e
>H i g h S p d
Increase
OM-186 359 Page 56
Di s p l a y
I PM
Mo t o r T y p e
>S t a n d a r d
Increase
Di s p l a y
>MP M
Mo t o r T y p e
S t anda r d
Parameter
Select
Decrease
9-12. Selecting Wire Type
Note
If wire type is changed, perform a system reset (see Section 9-14) immediately after selecting
wire type to bring up the correct welding programs.
. After using system reset to store wire type selection into
memory, all other setup parameters return to factory default
settings. See Section 9-2 for procedure to return to setup
displays and reset parameters.
Access
Setup
Display
Press Mode
Select
A r
Wi
>W i
D i
c T i me
r e f eed
r e t ype
sp l ay
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.
1
Wi r e Type
I n Feede r
>H a r d w i r e
Wi r e Type
I n Feede r
>S o f t w i r e
Increase
9-13. Selecting Display
1
Access
Setup
Display
Press Mode
Select
Wi r e
Wi r e
>D i s p
Memo
f
t
l
r
Display Select Display
The display can show amps, actual
reading or print out command.
eed
ype
ay
y
1
>C o mm a n d
Increase
>A c t u a l
Increase
>A m p s
OM-186 359 Page 57
9-14. Resetting Memory
1
No Reset
Memory cannot be reset.
1
Press Mode
Select
Access
Setup
Display
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
System Reset
Press Parameter Select button to
reset programs and setup to
original factory settings. System,
Arc Time, and Robot Control
settings are not affected by the
system reset.
1
P r ess
>P r o c e s s
Sequence
Ca r d
Program Reset
Press Parameter Select button to
reset last active program to original
factory program settings. All other
program and setup information
remains the same.
4
Reset (Default) Displays
1
Voltage Shutdown Display
2
Parameter
Select
g 1
l se
5 ”S t ee l
gon Ox y
Increase/
Decrease
>S y s t e m
Re s e t
3
P r ess
Parameter
Select
9-15. Selecting Arc Start/Volt Sense Error Shutdown
Access
Setup
Display
With Arc Start/Volt Sense on, the
unit shuts down when no arc
voltage is sensed. If the unit shuts
down, an error message appears
(see Section 11-6).
Press Mode
Select
With Arc Start/Volt Sense off, the
unit continues to feed wire even
when there is no arc voltage
sensed.
1
D i sp l ay
Memo r y
>S h u t d o w n
N ame
OM-186 359 Page 58
Ar c S t a r t /
Vo l t S e n s e
>O n
Increase
Ar c S t a r t /
Vo l t S e n s e
>O f f
9-16. Selecting Program Name Feature
1
Access
Setup
Display
Name Display
When a data card is used, the programs written from the unit to the
card can be named.
Press Mode
Select
1
Memo r y
Sh u t d own
>N a m e
P r o g r am
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
9-17. Remote Program Select
1
Program Display
When Program is On, a remote
device may be used to select programs (see Section 9-18). When
Off, program selection must be
done from robot Teach Pendant or
interface pulse panel.
Access
Setup
Display
Press Mode
Select
Sh u t d own
N ame
>P r o g r a m
S t i c k
1
Re m o t e
Se l e c t
>O f f
Re m o t e
Se l e c t
>O n
Increase
9-18. Remote Program Setting
See the following table for the remote program select binary code.
Program No.
Output A
Output B
Output C
1
Off
Off
Off
2
On
Off
Off
3
Off
On
Off
4
On
On
Off
5
Off
Off
On
6
On
Off
On
7
Off
On
On
8
On
On
On
OM-186 359 Page 59
9-19. Stick Check Selection
1
Access
Setup
Display
Stick Check Display
When stick check is On, a stick
check routine is performed at the
end of each weld. When Off, no
stick check is done.
Press Mode
Select
1
N ame
P r o g r am
>S t i c k
J o g I PM
St i c k
Ch e c k
>O n
St i c k
Ch e c k
>O f f
Increase
9-20. Jog Wire Feed Speed Selection
1
Access
Setup
Display
When not welding, a Robot Jog
local setting will jog wire at the Local
Jog ipm setting, even if robot provides wire jog signal.
Press Mode
Select
P r
S t
>J o
Ro
o g r am
i c k
g I PM
bo t
1
Robo
>r e mo
Loca
200
A Robot Jog remote setting
requires that the robot provide a jog
command and jog speed signal.
t Jog
t e
l Jog
i pm
Ro
>l o
Lo
20
bo t Jog
ca l
ca l Jog
0 i pm
Increase
Parameter
Select
Parameter
Select
Ro
l o
Lo
>4 2
Ro
l o
Lo
>2 0
bo t Jog
ca l
ca l Jog
5 i pm
Increase/
Decrease
OM-186 359 Page 60
Jog IPM Display
Jog wire feed speed can be varied
between 50 and 780 inches per
minute, IPM.
bo t Jog
ca l
ca l Jog
0 i pm
Auxiliary jog connections at the
peripheral receptacle and front
panel jog push buttons will jog wire
at the Local Jog ipm setting even if
Robot Jog is set for remote.
9-21. Robot Control Selection
. AUTOSET parameter must be turned off before changes
Access
Setup
Display
can be made to Robot settings.
Press Mode
Select
S t
Jo
>R o
F l
i c k
g I PM
bo t
ow
1
Robot Control Display
This interface can be programmed
to work with three different types of
robot controllers.
The robot has control of arc on but
the interface has control of weld sequences. There are two analog
channel for the robot to use.
1
Co n t r o l o f
>A r c O n
NoAna l og
I npu t s
Co n t r o l o f
>A r c O n
&An a l o g
I npu t s
Increase
Increase
The robot has control of arc on but
the interface has control of weld sequences. There are no analog
channels for the robot to use.
The robot has control of arc on, the
welding power source contactor,
wire feed speed, gas valve and two
analog channels.
The setting of robot control
selection affects the programming
capabilities of the interface. See
Sections 4 and 6.
Co n t r o l o f
>P S, W i r e ,
Ga s &
Ana l og
9-22. Flow Selection
1
Access
Setup
Display
. When
a system reset is
done, Flow is set to Off.
When this feature is off,
no
monitoring is done for a flow switch
input signal.
Press Mode
Select
1
Jo
Ro
>F l
Mo
g I PM
bo t
ow
n i t o r
Flow Display
Provides
a
means
to
enable/disable the flow switch
input.
When this feature is on, the flow
detect input monitors flow switch
signal and will cause an error if flow
is not present.
De t e c t
Fl ow
>O f f
De t e c t
Fl ow
>O n
Increase
OM-186 359 Page 61
9-23. Arc Voltage Error Selection
1
Access
Setup
Display
. When
a system reset is
done, Monitor is set to Off.
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.
Ar c V o l t s
>O n
2 . 0 Vo l t s
1 . 0 Sec
A r c
>O f f
Vo l t s
Increase
When this feature is on and a range
of deviation is set (±0.1 – 9.9 volts
from desired weld voltage), arc voltage or arc length variations outside
of the range for a period of time
longer than that set by the Arc Error
timer, causes either the error relay
to energize or the unit to shut down
depending on the Arc Start/Volt
Sense shutdown error setting.
9-24. Software Version Number
1
Access
Setup
Display
Press Mode
Select
OM-186 359 Page 62
Ro
A r
Mo
>S o
bo t
c Fa i l
n i t o r
f t wa r e
Ve r s i o n
#1 2 3 4 5 6 Z
1
Example Version Number
Display
When talking
with
service
personnel, this number may be
required. (Check actual unit display
for number.) The factory keeps this
number on file with the serial number of the unit.
SECTION 10 – 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.
10-1. Using Menu Display
1
2
3
2
Increase
Button
Front Panel Control Display
Front panel display during control
setting.
3
Setup Pendant Increase And
Decrease Buttons
Power Switch On Front Panel
Press and hold down both buttons
while turning On unit. Release
buttons when Control appears on
the front panel display.
Decrease
Button
4
Setup Pendant Control
Display
Follow this procedure any time
access is required. To save any
changes made while in the control
display, and/or to exit the control
display, cycle power off and back
on at power switch.
1
C o n t r o l
Front Panel Display
4
>R i s e T i m e
Au t oCo n f i g
Run i n
B u rn b a c k
A r c
Ha r s hne s s
>8 0 0
Pulse Panel Display
OM-186 359 Page 63
10-2. Setting Rise Time Parameter
Note
Maximum Rise Time setting will make the welding power source go to its maximum output.
1
1
>R i s e T i m e
Au t oCo n f i g
Run i n
B u rn b a c k
Access
Control
Display
A r c
Ha r s hne s s
>8 0 0
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 200 to 2550.
Press Mode Select button to go to
next parameter or cycle power off
and back on at power switch to save setting and exit Control menu.
Increase/Decrease
>P r o c e s s
Sequence
Ca r d
>P r
Pu
03
A r
g 1
l se
5 ”S t ee l
gon Ox y
Power
Switch
A r c
Ha r s hne s s
>6 8 0
Mode
Select
Or
Go To
Section 10-3
10-3. Setting Auto Configure Parameter
1
1
R i s e T i me
>A u t o C o n f i g
Run i n
B u rn b a c k
Access
Control
Display
Au t o
Con f i gu r e
> Of f
Auto Configure Display
Setting allows user to do manual
configuration
or
automatic
configuration by welding power
source/interface.
Use Increase or Decrease button to
change setting.
Press Mode Select button to go to
next parameter or cycle power off
and back on at power switch to save setting and exit Control menu.
Increase/Decrease
>P r o c e s s
Sequence
Ca r d
>P r
Pu
03
A r
g 1
l se
5 ”S t ee l
gon Ox y
Power
Switch
Au t o
Con f i gu r e
> On
Or
Mode
Select
Go To
Section 10-4
OM-186 359 Page 64
10-4. Setting Runin Parameter
1
R i s e T i me
Au t oCo n f i g
>R u n i n
B u rn b a c k
Access
Control
Display
1
RUN I N
>2 8 . 0 V o l t s
50
T r im
1 0 0 I pm
Runin Parameter Display
Settings allow user to do a global runin parameter.
Use Increase or Decrease button to
change volts setting.
Range is 10.0 to 38.0 volts.
Press Parameter Select button to
go to Trim parameter or cycle power off and back on at power switch
to save setting and exit Control
menu.
Increase/
Decrease
Use Increase or Decrease button to
change trim setting.
>P r o c e s s
Sequence
Ca r d
>P r
Pu
03
A r
Power
Switch
g 1
l se
5 ”S t ee l
gon Ox y
RUN I N
>2 2 . 8 V o l t s
50
T r im
1 0 0 I pm
Range is 0 to 100 trim.
Press Parameter Select button to
go to Ipm parameter or cycle power
off and back on at power switch to
save setting and exit Control menu.
Range is 50 to 780 ipm.
Parameter
Select
Or
Press Mode Select button to go to
Burnback parameter or cycle power off and back on at power switch
to save setting and exit Control
menu.
RUN I N
22 . 8Vo l t s
>5 0
T r im
1 0 0 I pm
Increase/
Decrease
RUN I N
22 . 8Vo l t s
>6 5
T r im
1 0 0 I pm
Or
Parameter
Select
RUN I N
22 . 8Vo l t s
65
T r im
>1 0 0 I p m
Increase/
Decrease
Mode
Select
Go To
Section 10-5
Or
RUN I N
22 . 8Vo l t s
65
T r im
>3 4 2 I p m
OM-186 359 Page 65
10-5. Setting Burnback Parameter
. Retract
1
setting allows welding wire to be activated in place of a
conventional voltage burnback.
1
R i s e T i me
Au t oCo n f i g
Run i n
>B u rn b a c k
Access
Control
Display
Press Parameter Select button to
go to ipm parameter or cycle power
off and back on at power switch to
save setting and exit Control menu.
Re t r a c t
>O f f
Use Increase or Decrease button to
change ipm setting.
Range is 50 to 780 ipm.
Cycle power off and back on at
power switch save setting and exit
Control menu.
Increase/
Decrease
>P r o c e s s
Sequence
Ca r d
>P r
Pu
03
A r
g 1
l se
5 ”S t ee l
gon Ox y
Power
Switch
Re t r a c t
>O n
1 5 0 i pm
Parameter
Select
Or
Re t r a c t
On
>1 5 0 i p m
Increase/
Decrease
Re t r a c t
On
>3 2 0 i p m
OM-186 359 Page 66
Retract Setting Display
Use Increase or Decrease button to
change setting.
SECTION 11 – MAINTENANCE & TROUBLESHOOTING
11-1. Routine Maintenance
Y Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
3 Months
Replace
damaged or
unreadable
label.
Repair or
replace
cracked
cables.
Replace
cracked
torch body.
Repair or
replace cracked
cables and cords.
6 Months
Clean and
tighten weld
terminals.
Blow out
inside.
11-2. Blowing Out Inside Of Unit
Y Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
801 914
OM-186 359 Page 67
11-3. Removing Case And Measuring Input Capacitor Voltage For 230/460 Volt Model
Y Significant DC voltage can remain on capacitors after unit is Off. Always check the voltage as shown
to be sure the input capacitors have discharged before working on unit.
Tools Needed:
1
5/16 in
Turn Off welding power source, and
disconnect input power.
1
Outside Handle Screws
To loosen top, remove two outside
handle screws from both handles
and all side bolts.
2
Relinking Board PC6
3
Voltmeter
Measure the dc voltage across the
screw terminals on PC6 as shown
until voltage drops to near 0 (zero)
volts.
1
Proceed with job inside unit.
Reinstall cover when finished.
2
3
230 VAC input:
+ lead to lower terminal, –
lead to upper terminal
2
3
460 VAC input:
+ lead to lower right terminal,
– lead to upper left terminal
801 914 / 801 917
OM-186 359 Page 68
11-4. Removing Case and Measuring Input Capacitor Voltage For 575 Volt Model
Y Significant DC voltage can remain on capacitors after unit is Off. Always check the voltage as shown
to be sure the input capacitors have discharged before working on unit.
1
Tools Needed:
5/16 in
1
Turn Off welding power source, and
disconnect input power.
1
Outside Handle Screws
To loosen top, remove two outside
handle screws from both handles
and all side bolts.
2
Interconnect Board PC2
3
Voltmeter
Measure the dc voltage across the
screw terminals on PC2 as shown
until voltage drops to near 0 (zero)
volts.
Proceed with job inside unit. Reinstall cover when finished.
2
3
+ lead to lower right
terminal, – lead to
upper right terminal
Ref. 801 914 / Ref. 801 917
OM-186 359 Page 69
11-5. Voltmeter/Ammeter Help Displays
. All directions are in reference to
the front of the unit. All circuitry
referred to is located inside the
unit.
1
Help 1 Display
Indicates a malfunction in the
primary power circuit. If this display
is shown, contact a Factory
Authorized Service Agent.
2
Help 2 Display
Help 3 Display
Indicates the left side of the unit has
overheated. The unit has shut down
to allow the fan to cool it (see Section 3-5). Operation will continue
when the unit has cooled.
4
A
HE.L
P–2
V
A
HE.L
P–3
V
A
HE.L
P–4
V
A
HE.L
P–5
V
A
HE.L
P–6
V
A
HE.L
P–7
V
A
HE.L
P–8
5
6
Help 7 Display
Indicates that the input voltage is
too high and the unit has
automatically shut down. Operation
will continue when the voltage is
within ±15% of the operating range.
If this display is shown, have an
electrician check the input voltage.
8
V
4
Help 6 Display
Indicates that the input voltage is
too low and the unit has
automatically shut down. Operation
will continue when the voltage is
within ±15% of the operating range.
If this display is shown, have an
electrician check the input voltage.
7
P–1
3
Help 5 Display
Indicates the right side of the unit
has overheated. The unit has shut
down to allow the fan to cool it (see
Section 3-5). Operation will
continue when the unit has cooled.
6
HE.L
Help 4 Display
Indicates a malfunction in the
thermal protection circuitry located
on the right side of the unit. If this
display is shown, contact a Factory
Authorized Service Agent.
5
A
2
Indicates a malfunction in the
thermal protection circuitry located
on the left side of the unit. If this
display is shown, contact a Factory
Authorized Service Agent.
3
V
1
7
Help 8 Display
Indicates a malfunction in the secondary power circuit of the unit. If
this display is shown, contact a
Factory Authorized Service Agent.
In addition, when the optional
ground current sensor is installed,
this display indicates weld current
in the ground conductor. When this
occurs, have an electrician check
the primary and secondary
connections.
OM-186 359 Page 70
8
11-6. Front Panel Error Displays
7
1
Mem
CRC
E r r o r
S t o p
2
Mem
R a n g e
E r r
E r r o r
V o l t
S e n s e d
E r r o r
N o
T a c h
S e n s e d
E r r o r
1
S t o p
E r r o r
S t a r t
C u r r e n t
W i r e
E r r o r
Memory CRC Error Display
Memory Range Error Display
Improper welding power source range is
selected. The “X” value indicates the program number.
May be caused by improper range settings
or improper data loaded into the interface
unit.
No Volt Sensed Error Display
The arc voltage sense circuit did not receive
feedback within the required time after an arc
was established.
May be caused by an inability to establish an
arc in the pulse schedule, or a lack of voltage
feedback.
4
D e t e c t e d
D e t e c t
S t i c k
E r r o r
12
May be caused by incompatible information
on the data card or bad memory.
3
R e a d
11
Corrupted program data has been detected
or loaded. The “X” value indicates the program number.
2
F l o w
G r d
6
A r c
C a r d
10
5
A r c
E r r
9
4
N o
C y c l e
8
3
N o
We l d
No Tach Sensed Error Display
A r c
F a i l
The motor tachometer feedback is not
reaching the control.
May be caused by obstructions in the wire
feed system or a faulty wire drive system.
5
Arc Stop Error Display
Trouble is occurring at arc end.
T i me O u t
E r r
May be caused by a bad data card, a bad
data card reader, a faulty microprocessor
circuit board, or a wiring problem.
9
No Flow Detected
No coolant is detected after preflow in the
weld cycle. Check coolant system and flow
switch for proper operation.
May be caused by obstructions in the wire
feed system or a faulty wire drive system or
torch is touching part at end of weld.
10 Ground Current Detect Error Display
6
May be caused by a conductor making
connection to the unit chassis.
Arc Start Error Display
Trouble is occurring at arc start.
May be caused by obstructions in the wire
feed system or a faulty wire drive system.
7
Stop Weld Cycle Error Display
Weld current has been detected in the earth
ground connection.
11 Wire Stick Error Display
The welding wire has stuck to the workpiece
at the end of the weld.
May be caused by poor weld conditions.
An error has been detected and the robot
hasn’t stopped the weld cycle, causing the
interface unit to stop the weld cycle and wait
for the robot to stop.
12 Arc Fail Time Out Error Display
8
May be caused by an inoperable wire drive,
absence of shield gas, or improperly operating welding power source.
Error Card Read Display
The card reader is not working properly.
An arc was not established within the allotted
time.
OM-186 359 Page 71
11-7. Weld Interface Board PC12 Diagnostic LED’s
1
Weld Interface Board PC12
Diagnostic LED’s are visible inside
unit, located on PC12 mounted to
inner side panel at left side of unit.
LED13 LED12 LED11 LED10 LED9 LED8
LED7 LED6 LED5 LED4 LED3 LED2
Refer to Section 11-8 for information
on diagnostic LED’s.
Reinstall cover and left side panel
after checking diagnostic LED’s.
1
LED1
Left Side View
184 803
OM-186 359 Page 72
11-8. Diagnostic LED’s On Weld Interface Board PC12
LED
Status
1
On
Indicates an Emergency Stop condition is not present.
Off
Indicates an Emergency Stop condition is present.
On
Indicates auxiliary output relay is not energized.
Off
Indicates auxiliary output relay is energized.
On
Indicates +15 volts dc is present on weld interface board PC12.
Off
Indicates +15 volts dc is not present on weld interface board PC12.
On
Indicates +5 volts dc is present on weld interface board PC12.
Off
Indicates +5 volts dc is not present on weld interface board PC12.
On
Indicates –15 volts dc is present on weld interface board PC12.
Off
Indicates –15 volts dc is not present on weld interface board PC12.
On
Input signal for no Jog advance.
Off
Input signal for Jog advance.
On
Input signal for no welding power source contactor.
Off
Input signal for welding power source contactor.
On
Indicates +24 volts dc is present for gas valve.
Off
Indicates +24 volts dc is not present for gas valve.
On
Indicates CV mode is selected.
Off
Indicates CC mode is selected.
10
On
Indicates gas valve is not energized.
Off
Indicates gas valve is energized.
11
On
Input signal for no Jog retract.
Off
Input signal for Jog retract.
On
Indicates +15 volts dc power source supply is present on weld interface board PC12.
Off
Indicates +15 volts dc power source supply is not present on weld interface board PC12.
On
Indicates –15 volts dc power source supply is present on weld interface board PC12.
Off
Indicates –15 volts dc power source supply is not present on weld interface board PC12.
2
3
4
5
6
7
8
9
12
13
Diagnosis
OM-186 359 Page 73
11-9. Customer Interface Board PC14 Diagnostic LED’s
1
Customer Interface Board PC14
Diagnostic LED’s are visible inside
unit, located on PC14 mounted to
interface module at upper portion of
unit.
Refer to Section 11-10 for information
on diagnostic LED’s.
Reinstall top cover after checking
diagnostic LED’s.
1
LED27 LED23 LED24
LED26
LED20 LED18 LED16 LED15 LED14 LED13
LED28
LED25
LED22
LED21
LED19
LED17
LED8
LED5
LED4 LED2
LED3
LED6
LED1 LED29 LED30 LED7
Top View
185 004
OM-186 359 Page 74
11-10. Diagnostic LED’s On Customer Interface Board PC14
LED
Status
Diagnosis
On
Indicates +24 volts dc RD supply is present on customer interface board PC14.
Off
Indicates +24 volts dc RD supply is not present on customer interface board PC14.
On
Input signal On from relay CR5 for arc detect.
Off
Input signal Off from relay CR5 for no arc detect.
On
Indicates +15 volts dc RA supply is present on customer interface board PC14.
Off
Indicates +15 volts dc RA supply is not present on customer interface board PC14.
On
Input signal On from relay CR6 for flow (shielding gas or coolant) present.
Off
Input signal Off from relay CR6 for flow (shielding gas or coolant) not present.
On
Input signal On from relay CR4 for wire stuck in weld joint.
Off
Input signal Off from relay CR4 for wire not stuck in weld joint.
On
Indicates –15 volts dc RA supply is present on customer interface board PC14.
Off
Indicates –15 volts dc RA supply is not present on customer interface board PC14.
On
Input signal On from peripheral for shielding gas purge.
Off
Input signal Off from peripheral for no shielding gas purge.
On
Input signal On from relay CR1 for welding power source ready and no detected errors present.
8
Off
Input signal Off from relay CR1 for welding power source not ready, detected errors are present, or unit
is in Setup or Control mode.
13
On
Input signal On from peripheral for jog retract.
Off
Input signal Off from peripheral for no jog retract.
On
Input signal On from peripheral for jog advance.
Off
Input signal Off from peripheral for no jog advance.
15
On
Input signal On from peripheral for flow switch.
Off
Input signal Off from peripheral for no flow switch.
16
On
Input signal On from peripheral for touch sensor.
Off
Input signal Off from peripheral for no touch sensor.
On
Input signal On from relay CR2.
Off
Input signal Off from relay CR2.
18
On
Input signal On from robot for shielding gas.
Off
Input signal Off from robot for no shielding gas.
19
On
Indicates remote program A selected.
Off
Indicates remote program A not selected.
On
Input signal On from robot to energize contactor.
Off
Input signal Off from robot to not energize contactor.
On
Input signal On from robot for jog retract.
Off
Input signal Off from robot for no jog retract.
On
Indicates automatic configuration Bit C is set.
Off
Indicates automatic configuration Bit C is not set.
On
Input signal On from robot for jog advance.
Off
Input signal Off from robot for no jog advance.
On
Indicates automatic configuration Bit A is set.
Off
Indicates automatic configuration Bit A is not set.
On
Indicates automatic configuration Bit D is set.
Off
Indicates automatic configuration Bit D is not set.
On
Input signal On for RPS-B.
Off
Input signal Off for RPS-B.
1
2
3
4
5
6
7
14
17
20
21
22
23
24
25
26
OM-186 359 Page 75
LED
27
28
29
30
Status
Diagnosis
On
Indicates automatic configuration Bit B is set.
Off
Indicates automatic configuration Bit B is not set.
On
Input signal On for RPS-C.
Off
Input signal Off for RPS-C.
On
Input signal On for touch sensor.
Off
Input signal Off for no touch sensor.
On
Input signal On from robot for no Emergency Stop.
Off
Input signal Off from robot for Emergency Stop.
11-11. Motor Board PC13 Diagnostic LED’s
1
Motor Board PC13
Diagnostic LED’s are visible inside
unit, located on PC13 mounted to interface module at upper portion of
unit.
Refer to Section 11-12 for information
on diagnostic LED’s.
Reinstall cover
diagnostic LED’s.
after
checking
Top View
LED2 LED1
1
LED4
LED3
LED6
LED7
LED8
LED5
177 288
OM-186 359 Page 76
11-12. Diagnostic LED’s On Motor Board PC13
LED
Status
1
On
Indicates motor reverse relay is energized.
Off
Indicates motor reverse relay is not energized.
On
Indicates bus voltage is present.
Off
Indicates bus voltage is not present.
On
Indicates microprocessor is operational.
Off
Indicates microprocessor is not operational.
On
Indicates tachometer feedback signal is present.
Off
Indicates tachometer feedback signal is not present.
On
Indicates +5 volts dc is present on motor board PC13.
Off
Indicates +5 volts dc is not present on motor board PC13.
On
Indicates +15 volts dc is present on motor board PC13.
Off
Indicates +15 volts dc is not present on motor board PC13.
On
Indicates auxiliary forward signal is present.
Off
Indicates auxiliary forward signal is not present.
On
Indicates auxiliary output signal is present.
Off
Indicates auxiliary output signal is not present.
2
3
4
5
6
7
8
Diagnosis
11-13. Troubleshooting
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position (see Section 2-9).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 2-9).
Check for proper input power connections (see Section 2-9).
No weld output; meter display On.
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 3-5).
Check voltmeter/ammeter Help displays.
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 2-5).
Clean and tighten all weld connections.
No 115 volts ac output at duplex
receptacle, Remote 14 receptacle.
Reset circuit breaker CB1 (see Section 2-6).
No 24 volts ac output at Remote 14 receptacle.
Reset circuit breaker CB2 (see Section 2-6).
OM-186 359 Page 77
SECTION 12 – ELECTRICAL DIAGRAMS
Figure 12-1. Circuit Diagram For 230/460 Volt Model Welding Power Source
OM-186 359 Page 78
Ref. 181 412-D
OM-186 359 Page 79
Figure 12-2. Circuit Diagram For 575 Volt Model Welding Power Source
OM-186 359 Page 80
186 987-A
OM-186 359 Page 81
Figure 12-3. Circuit Diagram For Control Board PC1 (Part 1 of 3)
OM-186 359 Page 82
186 648 (1 of 3)
OM-186 359 Page 83
Figure 12-4. Circuit Diagram For Control Board PC1 (Part 2 of 3)
OM-186 359 Page 84
186 648 (2 of 3)
OM-186 359 Page 85
Figure 12-5. Circuit Diagram For Control Board PC1 (Part 3 of 3)
OM-186 359 Page 86
186 648 (3 of 3)
OM-186 359 Page 87
Figure 12-6. Circuit Diagram For Function/Meter Board PC3
OM-186 359 Page 88
182 970-A
OM-186 359 Page 89
184 183
Figure 12-7. Circuit Diagram For Interconnect Board PC2
173 599
Figure 12-8. Circuit Diagram For Gate Boards PC4 And PC5
OM-186 359 Page 90
Notes
OM-186 359 Page 91
Figure 12-9. Circuit Diagram For Interface Module
OM-186 359 Page 92
192 200
OM-186 359 Page 93
Figure 12-10. Circuit Diagram For Microprocessor Board PC11
OM-186 359 Page 94
183 230-B
OM-186 359 Page 95
Figure 12-11. Circuit Diagram For Customer Interface Board PC14 (Part 1 of 3)
OM-186 359 Page 96
SD-185 005-A (Part 1 of 3)
OM-186 359 Page 97
Figure 12-12. Circuit Diagram For Customer Interface Board PC14 (Part 2 of 3)
OM-186 359 Page 98
185 005-A (Part 2 of 3)
OM-186 359 Page 99
Figure 12-13. Circuit Diagram For Customer Interface Board PC14 (Part 3 of 3)
OM-186 359 Page 100
185 005-A (Part 3 of 3)
OM-186 359 Page 101
Figure 12-14. Circuit Diagram For Motor Board PC13
OM-186 359 Page 102
177 289-A
OM-186 359 Page 103
182 996
Figure 12-15. Circuit Diagram For Switch Board PC15
OM-186 359 Page 104
183 002
Figure 12-16. Circuit Diagram For Junction Board PC16
OM-186 359 Page 105
Figure 12-17. Circuit Diagram For Interface Board PC12 (Part 1 of 2)
OM-186 359 Page 106
184 804 (Part 1 of 2)
OM-186 359 Page 107
Figure 12-18. Circuit Diagram For Interface Board PC12 (Part 2 of 2)
OM-186 359 Page 108
184 804 (Part 2 of 2)
OM-186 359 Page 109
174 578-A
Figure 12-19. Circuit Diagram For Touch Sensor Board PC18
OM-186 359 Page 110
186 305
Figure 12-20. Circuit Diagram For Setup Pendant
OM-186 359 Page 111
183 002
Figure 12-21. Circuit Diagram For Setup Pendant Centronix Junction Board PC3
OM-186 359 Page 112
Notes
OM-186 359 Page 113
Figure 12-22. Circuit Diagram For ABB Receptacle Kit
OM-186 359 Page 114
192 213
OM-186 359 Page 115
Figure 12-23. Circuit Diagram For Fanuc Receptacle Kit
OM-186 359 Page 116
192 214
OM-186 359 Page 117
Figure 12-24. Circuit Diagram For Daihen Receptacle Kit
OM-186 359 Page 118
192 215
OM-186 359 Page 119
Figure 12-25. Circuit Diagram For Motoman Receptacle Kit
OM-186 359 Page 120
192 216
OM-186 359 Page 121
Figure 12-26. Circuit Diagram For Nachi Receptacle Kit
OM-186 359 Page 122
191 405-A
OM-186 359 Page 123
Figure 12-27. Circuit Diagram For Kawasaki Receptacle Kit
OM-186 359 Page 124
To PC1
in
Invision
192 200
OM-186 359 Page 125
Figure 13-1. Complete Assembly
OM-186 359 Page 126
84
85
86
81
87
83
88
89
82
90
93
91
81
80
79
78
92
77
1
76
7
2
75
8
73
9
74
6
5
4
3
96
71
69
72
10
70
11
12
68
64
61
63
62
67
13
66
14
65
41
40
94
19
15
20
21
39
17
18
22
60
10
51
42
16
52
44
43
45
38
57
53
47
35
33
26
58
36
46
37
24
25
59
95
23
56
54
49
55
50
34
48
29
30
31
32
28
27
SECTION 13 – PARTS LIST
. Hardware is
common and
not available unless listed.
802 017-C
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Complete Assembly
. . . 1 . . . . . . . . . . . . . . . . 185 970 . . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . . 195 585 . . . HANDLE, carrying rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . Not used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . +185 967 . . . PANEL, side RH (230/460 volt model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 178 551 . . . INSULATOR, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . . 180 994 . . . LABEL, warning match input (230/460 volt model) . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . 134 327 . . . LABEL, warming general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . . . . . . . . . . . . . . . . 183 827 . . . BUS BAR, output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . HD1 . . . . . . 168 829 . . . TRANSDUCER, current 100A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG19 . . . . . 115 094 . . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . +179 902 . . . WINDTUNNEL, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . . . . . . . 185 835 . . . LABEL, warning electric shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 11 . . . . . T1 . . . . . . . 179 933 . . . TRANSFORMER, HF (230/460 volt model) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . T1 . . . . . . . 186 984 . . . TRANSFORMER, HF (575 volt model) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . FM2 . . . . . . 183 918 . . . MOTOR, fan 24VDC 3000RPM 43CFM w/10 ohm resistor . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . . 194 450 . . . BRACKET, mtg capacitor/PC board/fan . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . PC1 . . . . . . 201 451 . . . CIRCUIT CARD ASSEMBLY, control (230/460 volt model) . . . . . . . . . . 1
. . . 14 . . . . PC1 . . . . . . 201 457 . . . CIRCUIT CARD ASSEMBLY, control (575 volt model) . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG2 . . . . . . 115 092 . . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . . . 130 203 . . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG5 . . . . . . 113 752 . . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG7 . . . . . . 115 094 . . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG21 . . . . . 181 410 . . . PLUG, w/leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . C3-6 . . . . . . 192 935 . . . CAPACITOR, elctlt 2700uf 420 (230/460 volt model) . . . . . . . . . . . . . . . 4
. . . 15 . . . . C3-6 . . . . . . 193 738 . . . CAPACITOR, elctlt 1800uf 500 (575 volt model) . . . . . . . . . . . . . . . . . . . 4
. . . 16 . . . . RC1 . . . . . . 134 735 . . . CONNECTOR, circ ms/cpc 14 skt size 20 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . RC9 . . . . . . 134 734 . . . CONNECTOR, circ ms/cpc 14 pin size 20 . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 079 739 . . . CONNECTOR, clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . SR11 . . . . . . 035 704 . . . RECTIFIER, integ 40A 800V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . C11 . . . . . . 169 080 . . . CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . PC11 . . . . . . 187 248 . . . CIRCUIT CARD, process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . PC12 . . . . . . 184 806 . . . CIRCUIT CARD, weld in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 178 417 . . . CABLE, ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . PC14 . . . . . . 185 003 . . . CIRCUIT CARD, customer interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG15,16 . . . . 113 750 . . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . PC16 . . . . . . 183 000 . . . CIRCUIT CARD, connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . 185 960 . . . CABLE, ribbon 24 posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . . 097 132 . . . STAND-OFF, No. 6-32 x .375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
. . . 25 . . . . . R11 . . . . . . 188 676 . . . RESISTOR, w/terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . 1T . . . . . . . 038 782 . . . BLOCK, term 20A 10P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . PC13 . . . . . . 187 627 . . . CIRCUIT CARD, 115V motor board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . PC18 . . . . . . 174 573 . . . CIRCUIT CARD, touch sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . CR12 . . . . . . 187 252 . . . SWITCH, reed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . . . 185 969 . . . PANEL, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . 2T . . . . . . . 038 772 . . . BLOCK, term 20A 6P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . T12 . . . . . . 186 104 . . . TRANSFORMER, control 115/115-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . T11 . . . . . . 192 199 . . . TRANSFORMER, signal 115V 300VA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . ♦043 609 . . . ABB RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . ♦043 600 . . . BABCOCK & WILSON RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . ♦043 601 . . . BABCOCK & WILCOX RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . ♦043 608 . . . COMAU RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . ♦043 607 . . . FANCU RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . ♦043 606 . . . HITACHI RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . ♦043 605 . . . KAWASAKI RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . ♦043 603 . . . MOTOMAN RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . ♦043 604 . . . NACI RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . ♦043 602 . . . PANASONIC RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . ♦043 373 . . . DAIHEN RECEPTACLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . . 185 945 . . . NAMEPLATE, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-186 359 Page 127
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Complete Assembly (Continued)
. . . 36 . . . . . . . . . . . . . . . . 185 966
. . . 37 . . . . RC21 . . . . . . 076 624
. . . 38 . . . . RC25 . . . . . . 073 515
. . . 39 . . . . . L1 . . . . . . . 180 026
. . . 40 . . . . . Z1 . . . . . . . 180 029
. . . 41 . . . . . . . . . . . . . . . . 181 925
. . . 42 . . . . . T2 . . . . . . . 183 192
. . . 42 . . . . . T2 . . . . . . . 185 232
. . . . . . . . . . RC10 . . . . . . 166 679
. . . 43 . . . . RC2 . . . . . . 604 176
. . . . . . . . . . . . . . . . . . . . . . 175 282
. . . 44 . . . . CB1 . . . . . . 083 432
. . . 45 . . . . CB2 . . . . . . 093 995
. . . 46 . . . . CR11 . . . . . . 106 462
. . . 47 . . . . CB11 . . . . . . 011 991
. . . 48 . . . . RC8 . . . . . . 153 884
. . . 49 . . . . . . . . . . . . . . . . 179 847
. . . 50 . . . . . . . . . . . . . . . . 187 140
. . . 51 . . . . . . . . . . . . . . . . 180 105
. . . 52 . . . . . . . . . . . . . . +194 449
. . . 53 . . . . . . . . . . . . . . . . 025 248
. . . 54 . . . . . W1 . . . . . . . 180 270
. . . 55 . . . . C1,2 . . . . . . 186 015
. . . 55 . . . . C1,2 . . . . . . 195 939
. . . 56 . . . . . . . . . . . . . . . . 185 992
. . . 57 . . . . CT1 . . . . . . 181 271
. . . 58 . . . . . . . . . . . . . . . . 177 547
. . . 59 . . . . PC6 . . . . . . 180 131
. . . 60 . . . . PC2 . . . . . . 187 243
. . . 60 . . . . PC2 . . . . . . 187 244
. . . . . . . . . . PLG4 . . . . . . 131 056
. . . . . . . . . . PLG9 . . . . . . 115 091
. . . . . . . . . PLG12 . . . . . 115 093
. . . 61 . . . . . . . . . . . . . . . . 176 844
. . . 62 . . . . . . . . . . . . . . . . 180 103
. . . 63 . . . . . . . . . . . . . . . . 182 654
. . . 64 . . . . . . . . . . . . . . . . 180 271
. . . . . . . . . . . . . . . . . . . . . . 182 738
. . . 65 . . . . SR1 . . . . . . 184 260
. . . 66 . . . PM1,2 . . . . . 184 258
. . . 67 . . . . RT1,2 . . . . . 173 632
. . . 68 . . . . . . . . . . . . . . . . 179 930
. . . 69 . . . . . . . . . . . . . . . . 179 900
. . . 70 . . . . . . . . . . . . . . . . 204 165
. . . 71 . R1,2,C9-12 . . . 175 194
. . . 72 . . . . D1-4 . . . . . . 201 531
. . . 73 . . . . . . . . . . . . . . . . 179 826
. . . . . . . . . . . . . . . . . . . . . . 181 853
. . . 74 . . . . FM1 . . . . . . 175 084
. . . 75 . . . . . . . . . . . . . . . . 179 928
. . . 76 . . . . PC15 . . . . . . 182 998
. . . 77 . . . . . . . . . . . . . . . . 091 772
. . . 78 . . . . PC3 . . . . . . 190 694
. . . . . . . . . PLG11 . . . . . 115 091
. . . . . . . . . . . . . . . . . . . . . . 185 959
. . . 79 . . . . . . . . . . . . . . . . 184 197
. . . 80 . . . . . . . . . . . . . . . . 182 707
. . . 81 . . . . . . . . . . . . . . . . 186 543
. . . 82 . . . . . . . . . . . . . . . . 187 139
OM-186 359 Page 128
. . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CONNECTOR, circ ms/met 4 pin size 14s . . . . . . . . . . . . . . . . . . . . . . . .
. . . CONNECTOR, circ ms/met 11skt size 20 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . INDUCTOR, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . STABILIZER, output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . INSULATOR, stabilizer lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . TRANSFORMER, control 230/460 VAC . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . TRANSFORMER, control 460/575 VAC . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . HOUSING RECEPTACLE PINS & SOCKETS . . . . . . . . . . . . . . . . . . . . .
. . . RECEPTACLE, str dx grd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . .
. . . COVER, receptacle weatherproof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CIRCUIT BREAKER, man reset 1P 10A 250 VAC . . . . . . . . . . . . . . . . .
. . . CIRCUIT BREAKER, man reset 1P 15A 250 VAC . . . . . . . . . . . . . . . . .
. . . RELAY, encl 24VDC DPDT 20A/120VAC . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CIRCUIT BREAKER, man reset 1P 1.5A 250 VAC . . . . . . . . . . . . . . . . .
. . . CONNECTOR, circ ms/met 19skt size 22 . . . . . . . . . . . . . . . . . . . . . . . .
. . . PLATE, identification (order by model & serial number) . . . . . . . . . . . . .
. . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BRACKET, mtg transformer aux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . WINDTUNNEL, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . STAND-OFF, insul .250-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CONTACTOR, def prp 40A 3P 24VAC . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CAPACITOR, polyp .34uf 1000VAC (230/460 volt model) . . . . . . . . . . .
. . . CAPACITOR, polyp .22uf 1000VAC (575 volt model) . . . . . . . . . . . . . . .
. . . BUS BAR, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . TRANSFORMER, current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BUSHING, snap-in nyl ct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CIRCUIT CARD, relink (230/460 volt model) . . . . . . . . . . . . . . . . . . . . . .
. . . CIRCUIT CARD, interconnecting 230/460 volt model) . . . . . . . . . . . . . .
. . . CIRCUIT CARD, interconnecting (575 volt model) . . . . . . . . . . . . . . . . .
. . . HOUSING RECEPTACLE & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CORE, ferrite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . COIL, DI/DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . GASKET, DI/DT rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BRACKET, mtg choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . HOLDER, DI/DT coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . KIT, diode power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . KIT, transistor IGBT module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . THERMISTOR, NTC 30K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . HEAT SINK, power module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . HEAT SINK, rect dual diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . RESISTOR/CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . KIT, diode ultra-fast recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . INSULATOR, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . INSULATOR, screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . MOTOR, fan 24VDC 3000 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . SHROUD, fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CIRCUIT CARD, switch board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . STAND-OFF, No. 6-32 x .625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CIRCUIT CARD, front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . HOUSING PLUG & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CABLE, ribbon 34 posn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . NAMEPLATE, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . TERMINAL, pwr output black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CAPACITOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
2
2
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
2
1
1
1
2
4
1
4
1
1
1
4
1
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 13-1. Complete Assembly (Continued)
. . . 83 . . . . . . . . . . . . . . . . 180 732
. . . 84 . . . . . . . . . . . . . . . . 179 848
. . . . . . . . . . . . . . . . . . . . . . 181 169
. . . . . . . . . . . . . . . . . . . . . . 180 735
. . . 85 . . . . . . . . . . . . . . . . 181 245
. . . 86 . . . . . S1 . . . . . . . 128 756
. . . . . . . . . . . . . . . . . . . . . . 176 226
. . . 87 . . . . . . . . . . . . . . . . 144 842
. . . 88 . . . . . . . . . . . . . . . . 186 067
. . . 89 . . . . . . . . . . . . . . . . 185 965
. . . 90 . . . . . . . . . . . . . . . . 144 844
. . . 91 . . . . PC17 . . . . . . 177 290
. . . 92 . . . . . . . . . . . . . . . . 191 423
. . . 93 . . . . . . . . . . . . . . . . 185 968
. . . 93 . . . . . . . . . . . . . . . . 185 968
. . . 94 . . . . . . . . . . . . . . . . 194 371
. . . 95 . . . . . . . . . . . . . . . . 134 560
. . . 96 . . . . . . . . . . . . . . . . 199 840
. . . BOOT, negative output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BOOT, positive output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . SPACER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . WASHER, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . TERMINAL, pwr output red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . SWITCH, tgl 3PST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . INSULATOR, switch power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . ACTUATOR, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . NAMEPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . STAND-OFF, No. 6-32 x .875 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . DISPLAY, LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CABLE, interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . PANEL, side LH (230/460 volt model) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . PANEL, side (575 volt model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . SPACER, al 3.500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . CIRCUIT CARD ASSY, filter hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . BUS BAR, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
1
1
1
3
1
1
5
1
1
1
2
1
1
4
♦OPTIONAL
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Setup Pendant
. . . . . . . . . . . . . . . . . . . . . . 186 528 . . . CASE, front/bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 186 529 . . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 173 111 . . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE (order by model and serial number) . . . . . . . . . . . . . . . . .
. . . . . . . . . . PC1 . . . . . . 158 160 . . . CIRCUIT CARD ASSY, side display . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PC2 . . . . . . 156 623 . . . CIRCUIT CARD ASSY, data card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PC3 . . . . . . 183 000 . . . CIRCUIT CARD ASSY, connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 186 530 . . . CABLE, ribbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 149 818 . . . CABLE, interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . PB1-4 . . . . . 144 842 . . . ACTUATOR, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 150 961 . . . CABLE, centronics 6ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 604 804 . . . SCREW, 8-15 x .375 hexwhd-pln stl pld sht met . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 072 785 . . . SCREW, 6-32 x .375 hexwhd-slt stl pld slffmg . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 181 157 . . . STAND-OFF, No. 6-32 x .843 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 098 691 . . . STAND-OFF, No. 6-32 x .500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 133 528 . . . RIVET, al .125 dia x .188-.250 grip blk blind dome . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 602 062 . . . SCREW, 4-40 x .375 pa hd-phl stl pld cone . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 019 663 . . . MOUNT, NPRN 15/16OD x 3/8REC 3/16 x 3/8 . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 601 892 . . . RIVET, al .125 dia x .188-.250 grip blind domed hd . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 150 316 . . . CONNECTOR, rect univ 039 6p/s 3 row . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 155 024 . . . LENS, clear anti-glare .030 x 2.000 x 4.250 . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
4
1
9
12
4
2
11
2
4
4
2
1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-186 359 Page 129
Notes
OM-186 359 Page 130
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.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
International distributor.
1.
5 Years Parts – 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
Grids
Maxstar 140
Spot Welders
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate 185 & Spoolmate 250
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 7/00
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
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
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
 2000 Miller Electric Mfg. Co.
6/00
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