Miller | MK000000 | Owner Manual | Miller SEAM TRACKING SYSTEM User manual

Miller SEAM TRACKING SYSTEM User manual
OM-284265A
2019−04
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
(Gas-and Self-Shielding)
Submerged Arc (SAW) Welding
Description
Automation Seam Tracker
Seam Tracking
System
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: Automation Accessories
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 help you figure out what the
problem is, and our extensive service
network is there to help fix the problem.
Warranty and maintenance information for
your particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
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 specification 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.
Mil_Thank1 2019−01
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
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. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Serial Number And Stock Number Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Slide Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Motorized Slide Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Seam Tracker Control Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Pendant Control Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Load Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − DESCRIPTION OF EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Guide Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Pendant Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Seam Tracker Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Fillets and V-Groove Tip Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Tube Mills Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Interconnection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Mounting The Cross-Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Mounting The Guide Sensor And Installing Sensor Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Installing The Control Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Installing The Seam Tracker Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Mounting The Payload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Drive Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Special Cable Length Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. System Interconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Seam Tracker Input/Output Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. Seam Tracker Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Seam Tracker Initial Configuration And Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13. Initial Setup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14. Seam Tracker Calibration Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15. Configuration Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Operation Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Program Menu Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Service Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Weld Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Error/E Stop Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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45
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49
49
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2018−01
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! 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
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 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
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 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 weld output in damp, wet, or confined spaces, 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 Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
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, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
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 Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
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. Disconnect cable for process not in
use.
D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn off unit, disconnect input power, and discharge input capacitors according to instructions in Manual before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-284265 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D Ventilate the work area and/or use local forced ventilation at the arc
to remove welding fumes and gases. The recommended way to
determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
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 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 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 while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
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 an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks 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,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
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 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 Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
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.
OM-284265 Page 2
D Do not cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
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, sparks, 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 body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing 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.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT 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.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
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.
Compressed 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, physical damage, 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 compressed 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. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the proper equipment, correct procedures, and sufficient
number of persons to lift, move, and transport cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use correct procedures and 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 Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
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.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
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.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
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.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
OM-284265 Page 3
H.F. RADIATION can cause interference.
ARC WELDING can cause interference.
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.
D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D 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.
D
D
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
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. California Proposition 65 Warnings
WARNING: This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65Warnings.ca.gov.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-284265 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
som_2018−01_fre
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une
personne qualifiée est définie comme celle qui, par la
possession d’un diplôme reconnu, d’un certificat ou d’un
statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec
succès sa capacité à résoudre les problèmes liés à la tâche,
le travail ou le projet et a reçu une formation en sécurité afin
de reconnaître et d’éviter les risques inhérents.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas utiliser de sortie de soudage CA dans des zones humides
ou confinées ou s’il y a un risque de chute.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
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).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
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.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Éteignez l’unité, débranchez le courant électrique, et déchargez
les condensateurs d’alimentation selon les instructions indiquées
dans le manuel avant de toucher les pièces.
OM-284265 Page 5
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant
de travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
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 Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquelles est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
D 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.
D 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.
D 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 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.
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 e
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 approuvé muni de verres filtrants
approprié pour protéger visage et yeux 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 lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
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.
OM-284265 Page 6
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 Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
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 couper ou souder des jantes ou des roues. Les pneus
peuvent exploser s’ils sont chauffés. Les jantes et les roues réparées peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans
les normes de sécurité.
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 et AWS A6.0
(voir les Normes de Sécurité).
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse 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, d’étincelles 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 un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans 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.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé 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, des dommages physiques, 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 comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter les
bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
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 dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter 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.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
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.
Les PIÈCES MOBILES peuvent
causer 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 gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
OM-284265 Page 7
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D 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 un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
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.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
D 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).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D 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.
2-4. Proposition californienne 65 Avertissements
AVERTISSEMENT : ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2,
from Canadian Standards Association, Standards Sales, 5060 Spec-
trum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N,
Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government
Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA
Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd,
Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
OM-284265 Page 8
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
médecin approuve, il est recommandé de suivre les procédures précédentes.
SECTION 3 − SPECIFICATIONS
3-1. Serial Number And Stock Number Label Location
The serial number and rating information for this product is located on the rear panel. For future reference, write serial number in space provided on
back cover of this manual.
3-2. Slide Specifications
Stock No.
Input Power
JMS150
24 VDC, 8 A Per Axis
(Supplied From
Seam Tracker Control
Module)
JMS250
Length
Width
Depth
Net Weight
21.95 in.
(557.5 mm)
16 in.
(406.5 mm)
4.25 in.
(108 mm)
35 lb
(15.9 kg)
26.47 in.
(672.3 mm)
16.14 in.
(410 mm)
4.25 in.
(108 mm)
37 lb
(16.9 kg)
Face Mounting
Pattern
5.9 x 5.9 in.
(150 x 150 mm)
M8 Mounting
Holes
3-3. Motorized Slide Dimensions
JMS150
JMS250
L
21.95 in.
(557.5mm)
26.47 in.
(672.3 mm)
L2
17.13 in.
(435 mm)
21.72 in.
(551.6 mm)
L3
7.09 in.
(180 mm)
7.09 in.
(180 mm)
W
16 in.
(406.5 mm)
16.14 in.
(409.9 mm)
W2
7.09 in.
(180 mm)
7.09 in.
(180 mm)
D
4.25 in.
(108 mm)
4.25 in.
(108 mm)
D2
2.36 in.
(60 mm)
2.36 in.
(60 mm)
MH1
5.9 in.
(150 mm)
5.9 in.
(150 mm)
MH2
5.9 in.
(150 mm)
5.9 in.
(150 mm)
Hole
Pattern
M8 Mounting
Holes
M8 Mounting
Holes
L2
L3
W
W2
MH2
MH1
L
D2
D
3-4. Seam Tracker Control Module Specifications
Stock No.
Power Cable
Input Power
Length
Width
Depth
Net
Weight
JTST9700
115 V
6 ft (1.8 m)
(Factory-Supplied )
115/220 VAC,
10A
1-Phase,
50/60 Hz
12.25 in.
(311.2 mm)
15.5 in.
(393.7 mm)
8.2 in.
(208.3 mm)
29 lb
(13.2 kg)
Mounting Holes
5.9 x 5.9 in.
(150 x 150 mm)
0.315 (8mm)
Diameter Thru-Holes
3-5. Pendant Control Specifications
Stock No.
Input Power
Length
Width
Depth
Net Weight
Mounting Hole
9780STP
12 VDC, 2.5 A
(Supplied From Seam
Tracker Control Module)
12.95 in.
(329 mm)
5 in.
(127 mm)
2.56 in.
(65.1 mm)
4 lb
(1.8 kg)
0.0315 in (8mm)
Diameter
Thru-Hole
OM-284265 Page 9
3-6. Load Specifications
3-7. Environmental Specifications
A. IP Rating
IP Rating
IP2X
This equipment is designed for indoor use and is not intended to be used or stored outside.
IP2X 2014−06
B. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
ce-emc 3 2014-07
C. Temperature Specifications
Operating Temperature Range
Storage/Transportation Temperature Range
14 to 104F (−10 to 40C)
−4 to 131F (−20 to 55C)
OM-284265 Page 10
Temp1_016- 08
SECTION 4 − DESCRIPTION OF EQUIPMENT
4-1. General Description
Seam tracker systems are used in automated welding processes to ensure the welding torch is always in the correct position with respect to the joint
being welded. The operator can configure the system to provide many combinations of manual and automatic positioning maneuvers. A typical seam
tracker system consists of a seam tracker control module, cross slide, guide sensor (with ball tip and micro slide adjustment assembly), guide sensor
cable, and control pendent and cable. The welding torch or weld head is typically mounted off the faceplate of the cross slide but the most beneficial
and effective location of the torch/weld head is dependent on application. The seam tracker cross-slide assemblies are lightweight compact designs
consisting of two motorized linear slides mounted at right angles to provide X-Y axis positioning.
4-2. Guide Sensor
The guide sensor is typically mounted
on the welding torch by using the included micro slide unit. The sensor tip
on the guide sensor contacts the weld
joint and senses any horizontal or vertical movement of the weld joint with
respect to the welding torch. In response to movement of the weld joint,
the sensor generates an electrical signal proportional to the amount of deflection.
6 mm
probe tip
shown
1.18 in.
(30 mm)
2.82 in.
(71.62 mm)
8.16 in.
(207.38 mm)
By locating the end of the probe in a
groove or along the edge of a work
piece, the position of the material to be
welded is indicated. Signals from the
guide sensor are translated by the
seam tracker control module, which
then provides drive signals to the motors on the slides to keep the weld
head positioned properly relative to
the seam. A standard 1/4 in. (6mm) diameter round tip and tip extension are
provided with each unit. Other tips are
available for most weld joints and applications.
Notes
OM-284265 Page 11
4-3. Pendant Control
The control pendent is connected to the seam tracker control module with the supplied cable assembly and provides 4-line display so that an operator
can set up, manually jog, and operate the seam tracker.
1
2
AUTO/MAN
6
3
JOG/NAV
ADJUST
4
7
8
5
START
STOP
TACK
9
E−STOP
1
Four-Line Display Screen
Display screen shows the current state of
the seam tracker.
2
Mode Control Button (Auto/Manual)
Press button to switch between automatic
and manual modes. When there is no weld
activity, the top line of the display indicates
if the seam tracker is in Auto or Manual
mode.
3
Jog/Nav Button
Press button (as an alternative to the joystick) to navigate through the menus and
move the seam tracker. When there is no
weld activity, the top line of the display indicates if the seam tracker is in Nav or Jog
mode.
4
Navigation/Jog Joystick
Use joystick to navigate through the menus
and move the seam tracker. When the joy-
stick is being used to move the seam tracker, a single press of the joystick will move
the seam tracker in that direction at the jog
speed. If the operator presses the joystick
quickly, releases, and presses it again,
about one second later the axis will move
at a rapid speed.
5
Start Button
Press button to start the system for a weld
cycle or, after the unit has been turned on,
to find its limit switches and determine the
home locations.
6
Navigation Adjustment Control
Rotate control to change the display currently highlighted. The operator is unable to
make a change to a mode if the Enter field
is enclosed in a box. A boxed field indicates
either the value cannot be changed or the
pendant control is in Jog mode.
. When
using the Adjustment dial to
change a numeric value, pushing the
joystick up will increase the value and
pushing the joystick down will decrease the value.
7
Stop Button
Press button to stop the current weld cycle,
stop a return to a home position, or clear error messages displayed on the screen.
8
Tack Button (Manual Mode)
Press button to lock out the auto tracking
feature and prevent the torch from moving
when a tack weld is encountered. Also,
when doing a manual jog, pressing the
Tach button will allow manual jog to override if the probe contacts the part or another
object.
9
E-Stop (Emergency Stop) Button
Press E-Stop button to disconnect input
power to the motor.
4-4. Seam Tracker Control Module
The seam tracker control module
contains the necessary controls to
drive the cross slides and interpret
feedback from the guide sensor and
motor encoders to position the slides
and track the weld joint.
OM-284265 Page 12
4-5. Fillets and V-Groove Tip Selection
1
1
Probe Tips
S JTSTPT3
3 mm probe ball
S JTSTPT6
6 mm probe ball
S JTSTPT10
10 mm probe ball
S JTSTPT15
15 mm probe ball
S JTSTPT20
20 mm probe ball
S JTSTPT30
30 mm probe ball
Jetline Probes Display
4-6. Tube Mills Tip
1
Copper Wheel Probe - JTSTPTWH
1
OM-284265 Page 13
SECTION 5 − INSTALLATION
5-1. Interconnection Diagram
2
5
3
6
7
4
8
16
9
10
1
11
15
12
14
!
Turn off, and disconnect input
power.
1
Auto-Continuum Welding Power
Source *
2
Wire Spool *
3
Wire Feeder *
4
Cross Slide Assembly
5
Welding Torch *
6
Auto-Continuum Interface - 72 Pin *
7
Seam Tracker Control Module
JTST9700
OM-284265 Page 14
13
8
9
10
11
12
13
14
15
16
*
AC Power Cord
5-Axis Mounting Bracket
Travel Control Module 9700T *
Pendant Assembly
Sensor-Probe Assembly
Workpiece *
Pendant Holder
Weld Power Cable *
Weld Work Cable *
Customer supplied -Not included
w/seam tracker
The major components provided in seam
tracker packages are listed below.
S Two motorized slides
S Seam tracking control module
S Seam tracker pendant
S Complete probe assembly
S Two 15 ft motor cables
S 15 ft pendant cable
S 15 ft probe cable
S 6 mm probe tip
5-2. Mounting The Cross-Slide
*MOUNTING PLATE IS SHOWN FOR ILLUSTRATION PURPOSES ONLY.
THESE SLIDES EASILY AND QUICKLY INSTALL WITHOUT EXPENSIVE
BRACKETS OR INTERFACING ON MANIPULATORS, SIDE BEAMS, AND
WELDING LATHES, AS WELL AS MOST CUSTOM WELDING FIXTURES.
!
Turn off, and disconnect input
power.
The cross-slide dimension drawings show
the size and locations of the holes for
mounting the unit in any position. To prevent binding, the mounting surface must
be nearly flat to ensure that no twist is applied to the base of the slide assembly
when it is secured. Also ensure the mounting surface is rigid to prevent movement or
vibration of the unit during operation.
For proper operation, the slide assembly
must be oriented correctly with respect to
the weld. Mount the lower (horizontal) axis
parallel to the plane of the weld, and the
upper (vertical) axis perpendicular to the
plane of the weld.
After the cross-slide assembly is mounted, verify that adequate clearance exists
between the moving slides and any objects that could resist the full travel of the
slides or interfere with the electrical
cables.
OM-284265 Page 15
5-3. Mounting The Guide Sensor And Installing Sensor Tips
!
Turn off, and disconnect input
power.
. For the system to operate properly, the
vertical axis of the sensor must be in
line with the vertical axis of the welding
torch and cross-slide assembly.
To make left or right angular adjustments of
the guide sensor relative to the work,
loosen the stud nuts on the arm assembly
base, rotate the base to the desired angle,
and retighten the stud nuts.
. Some
installations may require extreme left or right angular adjustments.
These situations may require additional compensation to keep the guide sensor axis properly oriented. Two addi-
OM-284265 Page 16
tional keyways in the casing are provided for this purpose; two small
screws are present to prevent unintentional use. Remove the screws first if it
is necessary to utilize one of these keyways.
To perform vertical angular positioning,
loosen the cap screw on the arm assembly
and rotate one side of the serrated arm until
the guide sensor is properly positioned to
provide vertical sensing in close proximity
to the welding torch. In combination with the
angular positioning, it may also be necessary to loosen the cap screw on the insulated arm assembly mounting clamp to obtain
the optimum position and orientation for
vertical sensing relative to the weld joint
and torch.
For best results, maintain an angle of less
than 45 degrees between the guide sensor
and the workpiece. Steeper angles may be
used, but performance is degraded as the
angle is increased. Verify proper operation
in each application. Locate the guide sensor tip as close as possible to the welding
torch. (A distance of 0.5 to 1 in. (13 to 25
mm) between tip and torch is acceptable for
most applications.)
Sensor Tips
The sensor tips are secured by set screws.
Tighten setscrews after installing tip. For
proper operation, be sure the sensor rod or
extension rod is fully inserted into the tip.
5-4. Installing The Control Pendant
!
Turn off, and disconnect input
power.
The seam tracker control pendant is
constructed from a rugged steel
housing with mounting brackets and
includes a standard 15 ft (4.6 m) cable. (Special cable lengths are available upon request.)
Notes
OM-284265 Page 17
5-5. Installing The Seam Tracker Control Module
!
Turn off, and disconnect input
power.
The seam tracker control module dimensional drawing shows the size
and location of holes for mounting the
control module in the proper position.
Mount the control module in a location where the power switch is readily
accessible and the hinged door can
be fully opened for inspection or parts
replacement.
In a high noise environment, connect
the chassis ground lug (located near
the power cord/RFI filter connection)
to a solid earth ground (Protective
Earth or PE). All system components
except the guide sensor and control
pendant are connected to chassis
ground through cable shields.
OM-284265 Page 18
5-6. Mounting The Payload
!
Turn off, and disconnect input
power.
*MOUNTING PLATE IS SHOWN FOR ILLUSTRATION PURPOSES ONLY. THESE SLIDES EASILY AND QUICKLY INSTALL WITHOUT EXPENSIVE BRACKETS OR INTERFACING
ON MANIPULATORS, SIDE BEAMS, AND WELDING LATHES,
AS WELL AS MOST CUSTOM WELDING FIXTURES.
OM-284265 Page 19
5-7. Drive Cable
The drive cable connects each cross-slide assembly to the seam tracker control module. It transmits signals and power between the units. The standard drive cable length is 15 ft (4.6 m). Contact Miller to obtain longer drive cables.
5-8. Special Cable Length Assemblies
Special cables can be purchased for connecting the control pendant to the seam tracker control module in lengths up to 60 ft (18 m). Cables for connecting the cross-slide to the control module are available.
. Long, non-standard cables normally use larger gauge, heavier conductors to reduce voltage drop. Use only genuine Miller connection cables
supplied with the system. Use of non-Miller cables voids warranty and may affect system performance.
5-9. System Interconnection
1
2
!
Turn off, and disconnect input
power.
1
2
Seam Tracker Control Module
Pendant Assembly
After the cross−slide assembly and seam
tracker control module are properly mounted, the next step is to connect the cables.
OM-284265 Page 20
The illustration above shows connector arrangement on the seam tracker control
module. Connect the control pendant cable
to receptacle 11 on the seam tracker control
module, and the drive cable to receptacle
J2.
Additional connectors may be used in conjunction with various options to provide re-
lay switching for remote initiation of welding
power, carriage, travel, etc.
With the power off, check the following connections on the seam tracker system:
S Seam tracker control module to cross−
slides
S Control pendant
5-10. Seam Tracker Input/Output Information
Inputs
. Inputs may be a dry relay contact or an open collector signal. Components must be rated to handle 24 VDC at 20 mA.
Function/Pins
Description
Remote Start - J11 (pins 11 and 12)
A momentary short between these pins will cause the system to start a welding sequence.
Remote Stop – J12 (pins 1 & 2)
A momentary short between these pins will cause the system to stop when in a welding
sequence.
Reserved – J12 (pins 3 and 4)
--
Cut Off – J12 (pins 5 and 6)
A momentary short between these pins alerts the system that it has reached the end of a welding sequence.
Arc On – J12 (pins 7 and 8)
A short between these pins indicates that an arc has been established.
Reserved – J16 (pins 7 and 8)
--
Reserved – J16 (pins 9 and 10)
--
Outputs
. Output contacts are subject to these limitations: Max Voltage - 60 volts; Max Current - 100 mA; Resistance On - 16 ohms max.
If these output contact specifications are insufficient, a relay may be installed on the inside of the seam tracker to meet the requirements of the
equipment being interfaced.
Function/Pins
Description
In Cycle - J12 (pins 9 and 10)
Pins are shorted together when the system is in a welding cycle.
Home - J12 (pins 11 and 12)
Pins are shorted together when the system has completed a Return to Home action and no
other movement has taken place.
Start Out - J13 (pins 1 and 2)
Pins are momentarily shorted together when the system starts a welding cycle.
Stop Out - J13 (pins 3 and 4)
Pins are momentarily shorted together when the Stop button is pressed.
Current Detect Out - J13 (pins 5 and 6)
Pins are shorted together when the seam tracker has a valid arc input.
Error Out - J13 (pins 7 and 8)
Pins are shorted together when the seam tracker detects an error.
Cut Off Out - J13 (pins 9 and 10)
Pins are momentarily shorted together when the seam tracker receives a cut off input.
Power Supply Enable - J13 (pins 11 and 12)
Pins are shorted together when the seam tracker wants to operate the welding equipment.
Travel Enable - J14 (pins 1 and 2)
Pins are shorted together when the seam tracker wants the travel module to move during a
normal run.
Gas Out - J14 (pins 3 and 4)
Pins are shorted together when the seam tracker wants to purge gas on the welding power
source.
Program Select 0 - J14 (pins 5 and 6)
--
Program Select 1 - J14 (pins 7 and 8)
--
Program Select 2 - J14 (pins 9 and 10)
--
OM-284265 Page 21
5-10. Seam Tracker Input/Output Information (Continued)
Use the program select pins to set the program to be run from the welding power source.
Program
Program Select 0
Program Select 1
Program Select 2
1
Open
Open
Open
2
Closed
Open
Open
3
Open
Closed
Open
4
Closed
Closed
Open
5
Open
Open
Closed
6
Closed
Open
Closed
7
Open
Closed
Closed
8
Closed
Closed
Closed
Function/Pins
Description
Final Time - J15 (pins 1 and 2)
Pins are shorted together when the weld program is in the final time of the weld sequence.
Return to Home – J15 (pins 3 and 4)
Pins are shorted together when the torch is in the return to home action of the weld sequence.
Wire Forward – J15 (pins 5 and 6)
Pins are shorted together when the operator wants to move the wire in the forward direction.
Wire Reverse – J15 (pins 7 and 8)
Pins are shorted together when the operator wants to move the wire in the reverse direction.
Travel Jog1 – J16 (pins 3 and 4)
Pins are shorted together when the seam tracker wants to jog the travel in one direction.
Travel Jog2 – J16 (pins 5 and 6)
Pins are shorted together when the seam tracker wants to jog the travel in the other direction.
Analog Outputs
Analog Travel Speed – J14 (pins 11 and 12)
+/− 10 VDC that is used to control the speed of the travel device.
5-11. Seam Tracker Initial Setup
Tracking Diagrams
Edge-L
!
!
!
!
Be sure that all components are
properly installed prior to applying
power to the seam tracker control
module.
Keep away from moving parts
(cross-slides) during operation.
Be sure the AC power is disconnected from the seam tracker control
module when making mechanical
adjustments.
Do not disconnect cables/connectors or remove circuit boards when
the power is connected to the seam
tracker control module.
OM-284265 Page 22
Edge-R
NOTICE − Be sure all cables are of adequate length and clear of moving parts to
prevent them from being damaged during
operation.
To take full advantage of seam tracker
stroke capability, position the cross−slide
assembly at the center of both horizontal
and vertical strokes.
Mount the welding torch so that it is approximately in its nominal welding position relative to the weld joint. This position allows for
error compensation in all directions during
welding. However, there are exceptions to
this recommendation.
For example, the operator may want the
majority of the vertical stroke to be available
for manually driving the slides upward and
clear of the part after welding for inspection,
part removal, and insertion of a new part.
When mounting the guide sensor and its
brackets , adjust the brackets and mounting
hardware to position the guide sensor in the
proper relationship to the torch. Keep the
manual sensor cross−slides at approximately their center position to permit fine
adjustment later.
5-12. Seam Tracker Initial Configuration And Calibration
Configuration Screens
Search Start Point
When Search Start PT in the Program screen
is set to Yes, the operator can establish the location of the start point.
Move the torch to the desired position (where
the torch should begin its search for the joint)
and move the joystick to the right. The seam
tracker will remember this position.
Weld Start Point
The Weld Start PT is the position the probe
tries to maintain in the weld joint. The probe
guides the seam tracker as it tracks a joint during the welding operation.
To set Weld Start PT, place the probe in the
joint and the torch in the desired position during
the weld. For both V and edge joints, be sure
there is enough downward force on the probe.
For edge joints, be sure there is also some lateral force on the probe.
Set Home Point
If RTH DLY (Return to Home Delay) is set in
the Program menu screens, the torch returns
to the home location established in the Set
Home PT screen. To set, move the torch to the
desired home position. In the menu screen,
move the joystick to the right. The seam tracker will remember this position.
Limit Side
The encoders on the seam tracker motors are
relative encoders, not absolute encoders. This
means that when the system is first turned on
the motors do not know their location in relation
to the limit switches. After the seam tracker is
turned on, it relies on the limit switches to guide
it to the defined positions. The Up/Down command will also move the upper limit switch, but
the operator can define which limit switch is affected. The default setting is the left side.
. If
the limit switch default setting is
changed, the Home and Search Start PT
settings will have to be reset.
Tool Offset Type
When tracking the joint, the movement of the
torch is delayed so the operator can follow the
position of the torch and not the position of the
probe. The delay can be done in two ways:
S If the seam tracker is not controlling the
speed of the weld, the approximate time
from when the part moves from under the
probe to when it moves under the torch
must be determined. Set the Tool Offset
Type to Time and then in the Program
screen enter the time value.
S If the seam tracker is controlling the
speed, set the Tool Offset Type to Dist. In
the Program screen enter the linear distance between the probe and torch. The
seam tracker will automatically adjust the
time delay based on the speed of the part.
Joint Type
Set Joint Type specifies the type of joint the
seam tracker should look for. There are three
options: Edge-L (left), Edge-R (right) or V (depending on the shape of the workpiece to be
welded).
To Work/To Joint
To Work allows the operator to set the direction
the probe moves to find the workpiece, either
down, down left, down right, or none. The operator can also change the speed of the search by
using the Work Spd L/R and Work Spd U/D
screens. After the seam tracker locates the
workpiece, the operator can set the direction the
torch moves as it looks for the joint. Change the
speed of the search by changing Weld Spd L/R.
Reverse Left/Right
When set to Yes, Reverse Left/Right reverses
left and right for all options and controls. Including the joystick. Preferred setting depends
on where the operator stands in relation to the
seam tracker.
Probe Left/Right
When set to Rev (Reverse), Probe Left/Right
reverses left and right for controls. Preferred
setting depends on the side of the torch that
the probe is on. If the probe is on the other side
of the torch from the slide, select Rev (reverse). If the probe is on the same side of the
torch as the slide, select Norm (normal).
Check operation by setting Program screen to
Dry Run and verifying the torch is following the
joint.
Calibration Screens
Set Null
The null point is the location where there is no
deflection on the probe. The null point must be
set properly to prevent the operator from moving the job into another object when using the
joystick. If null is not set, the seam tracker can
inform the operator that the probe has contacted another object. If contact occurs, press the
Stop button on the pendant to clear the error
condition. To move the torch farther, press the
Tach button (which acts as an override feature) when moving the torch, or enter the Configuration menu and increase the Jog Flex
value.
Calculate Up/Down
Calculate Up/Down matches the value of torch
probe movement to the actual movement of
the motors. Running this function will change
the value of the menu Probe U/D. This function
will show the flex of the probe in the up/down
position in reference to the Null point. At this
point the probe is not touching anything so the
reading should be close to 0. Use the joystick
to drive the probe down so it barely touches the
work and the value on the screen changes.
Stop the movement of the torch and press the
Tack button. Use the joystick to drive down the
probe to obtain a deflection of 0.5 in. (13 mm)
on the probe. The value should change. Press
the Tack button again for the second position;
the Calibration screen should be displayed.
. The operator can exit this function and re-
turn to the Calibration screen at any time
by pressing the Stop button.
Calculate Left/Right
Calculate Left/Right matches the value of the
torch probe movement to the actual movement
of the motors. Running this function will
change the value of the menu Probe L/R. This
function will show the flex of the probe in the
left/right position in reference to the Null point.
At this point the probe is not touching anything
so the reading should be close to 0. Use the
joystick to drive the probe either left or right so
it barely touches a solid surface and the value
on the screen changes. Stop the movement of
the torch and press the Tack button. Use the
joystick to drive the probe either left or right to
obtain a deflection of 0.5 in. (13 mm) on the
probe. The value should change. Press the
Tack button again for the second position; the
Calibration screen should be displayed.
. The operator can exit this function and re-
turn to the Calibration screen at any time
by pressing the Stop button.
Tack Window And Tack Y
Tack Window and Tack values establish how
far the probe needs to move Y within the specified time (window) to be defined as the start of
a tack. Also use this menu to define the end of
a tack. To determine how much the probe
should move, go to the Probe Pos configuration screen and manually raise the torch to see
the change in value as the probe moves over
the tack.
. Y units are in thousandths of an inch.
End Window And End Y
End Window and End values establish how far
the probe needs to move Y within the specified time (window) to be defined as the end of
part for overlap or off part. To determine how
much the probe should move, go to the Probe
Pos Configuration screen and manually raise
the torch to see the change in value as the
probe moves over the tack.
Part Window And Y
Part Window and Part values establish how far
the probe needs to move Y within the specified time (window) to be defined as find Part or
Work. To determine how much the probe
should move, go to the Probe Pos Configuration screen and manually raise the torch to see
the change in value as the probe moves over
the tack.
Joint Window And Y
Joint Window and Joint values establish how
far the probe needs to move Y within the specified time (window) to be defined as finding the
joint. In finding the joint, the tracker is looking
for an edge that flex the probe in the left/right
direction. For a V-joint, the seam tracker is
looking for flex of th e probe in the down direction. To determine how much the probe should
move, go to the Probe Pos Configuration
screen and manually raise the torch to see the
change in value as the probe moves over the
tack.
Out Window And Y
Out Window and Out values establish how far
the motors for left/right need to move Y within
the specified time (window) to be defined as
out of joint. If the left/right motor has moved farther than the defined distance in the defined
time, the seam tracker will determine that it has
lost the joint and terminate the weld.
. After all values have been established, set
the Program screen to Dry Run and verify
the system is functioning properly. Dry
Run setting allows the machine to run
without the torch being energized.
OM-284265 Page 23
5-13. Initial Setup Procedures
Step 1 - Start Position
Define the starting position of the torch by moving it to the desired position (where the search should begin). Access the Config – Start Search
PT screen and then move the joystick to the right. Change the Start Search PT to Yes. If Start Search PT is set to No, the system will search
for the part/work from the current location of the torch.
Step 2 - Find Part/Work
Find Part/Work is defined in the Configuration – To Work screen. There are four options: Down, D/L (Down and Left), D/R (Down and Right)
and None. Skip this step if If None is selected. Define when to move the torch in each direction by using the U/D DLY Work and L/R DLY Work
screens. Select the speed that the torch moves as it looks for the torch in the Work SPD U/D and Work SPD L/R screens. Use the Calibration
screens to define probe deflection. Define the part in a time window by using the Part Window and Part Y screens.
Step 3 - Find Joint/Edge
Find Joint/Edge is defined in the Configuration - To Joint screen. There are three options: Right, Left and None. These options control the
direction the torch will move while looking for the joint. The speed of the torch movement is set in the Weld SPD L/R screen. It is important
to access the Joint Type screen and select the type of joint the seam tracker is looking for. The options are Edge−L, Edge−R and V.
Step 4 - Arc Delay
After the probe finds the joint, additional time is needed for the probe to move to the correct position to start the weld. Define the arc delay
time in Calibration – Arc Delay. If Arc Delay is set to Start, the operator must press the pendant Start button to start the arc. This action allows
the operator to ensure that the torch is in the correct position. The torch position can be changed in Arc Delay by setting the pendant to Jog
and using the joystick. After the weld starts, use Program – Tracking DLY to define the time delay from when the arc starts to when the seam
tracker looks for the probe position. This delay is needed to allow the torch position to stabilize because the torch might touch the part/work
at start up.
Step 5 - Tracking Joint (Tool Offset)
The torch follows the probe after a delay set by Program – Tool Offset. This value is either time or distance as defined by Configuration – Tool
Offset Type.
Step 6 - Out Of Joint
The Configuration – Out of Joint screen determines if the seam tracker is looking for an out of joint condition (enable or disable). This is defined
by the left or right slide moving a distance outside of the value set in Calibration – Out Y within the time frame defined by the Calibration –
Out.
Step 7 - Tacks
To enable automatic tack detection, set Program – Tack Detect to Enable. The size of the tack is determined by Calibration – Tack Y and
Calibration – Tack screens. Tack Y defines how much probe movement is needed within the time defined by Tack Window. The same numbers
are used to determine when the probe moves off the tack. Calibration – Tack Time Out is the maximum time that the Seam Track will remain
in a tack. If after finding a tack the seam tracker does not find the backside of the tack, and the Tack Time Out time is met, then the seam tracker
determines it is off the tack. Calibration − Tack Blackout defines the amount of time after coming off a tack that the seam tracker will not look
for a tack, but will follow the probe.
Step 8 - Return To Home
Set the home position by moving the torch to the desired home position, accessing the Configuration – Set Home PT screen, and moving
the joystick to the right. In Program – RTH DLY, the operator defines how long after the weld ends before the torch starts to move, or if it moves
at all. In Configuration – U/D DLY Home and L/R DLY Home, the operator can specify a time delay before horizontal or vertical motion occurs.
This configuration is useful when the torch must move up to exit the groove before it moves left or right to return to the home position.
OM-284265 Page 24
5-14. Seam Tracker Calibration Screens
Tack Window
Tack Window allows the operator to set a time window (in seconds) for the recognition of a tack.
Tack Delta
Tack Delta allows the operator to set a distance that the unit must
rise in the set Tack Window time for the recognition of a tack.
End Window
End Window allows the operator to set a time window (in seconds) for the recognition of the end of weld.
End Delta
End Delta allows the operator to set a distance that the unit must
move in the End Window time for recognition of the end of weld.
Part Window
Part Window allows the operator to set a time window (in seconds) for recognition of the unit finding the part.
OM-284265 Page 25
5-14. Calibration Screens (Continued)
Part Delta
Part Delta allows the operator to set a distance that the unit
must rise in the set Part Window time for recognition of the unit
finding the part.
Joint Window
Joint Window allows the operator to set a time window (in seconds) for the recognition of the unit finding the joint.
Joint Delta
Joint Delta allows the operator to set a distance that the unit must
move in the set Joint Window time for recognition of the unit finding the joint.
Out Window
Out Window allows the operator to set a time window (in seconds) for out of joint.
Out Delta
Out Delta allows the operator to establish how far the left/right
slide can move in the Out Window time before the Seam Tracker
determines that the torch is out of the joint and stops the weld.
OM-284265 Page 26
5-14. Calibration Screens (Continued)
Tack Timeout
Tack Timeout allows the operator to set a maximum time (in seconds) that the unit will continue welding after recognizing a tack.
Tack Blackout
Tack Blackout allows the operator to set the amount of time after
coming out of an automatic tack before the seam tracker looks
for a tack again.
Units
Units allows the operator to select inches or centimeters for all
distance inputs.
Arc Delay
Arc Delay is the time interval between when the joint is found and
when the arc is struck. Arc Delay allows the torch to move into
the correct position for the weld. If the pendant is set to Start,
press the Start button again to start the weld. This action allows
the operator to ensure the torch is in the correct position. When
in Arc Delay, the operator can change the position of the torch
by setting the pendant to Jog and using the joystick.
High Limit
High limit sets the maximum speed or RPM of the weld process.
OM-284265 Page 27
5-14. Calibration Screens (Continued)
High Out
High Out allows the operator to set the analog voltage output for
maximum speed set in High Limit.
Low Limit
Low Limit allows the operator to set the minimum speed or rpm
of the welding process.
Low Out
Low out allows the operator to set the analog voltage output for
minimum speed set in Low Limit.
Set Null
Set Null allows the operator to define the null point of the probe.
With no deflection on the probe, move the joystick to the right to
set the null point.
Probe UP/Down
Probe Up/Down shows the calibration number for movement between the probe and movement of the torch in the up/down
direction.
OM-284265 Page 28
5-14. Calibration Screens (Continued)
Probe Left/Right
Probe Left/Right shows the calibration number for movement
between the probe and movement of the torch in the left/right
direction.
Calculate Up/Down
Calculate Up/Down matches the value of torch probe movement
to the actual movement of the motors. Running this function will
change the value of the menu Probe U/D. This function will show
the flex of the probe in the up/down position in reference to the
Null point. At this point the probe is not touching anything so the
reading should be close to 0. Use the joystick to drive the probe
down so it barely touches the work and the value on the screen
changes. Stop the movement of the torch and press the Tack
button. Use the joystick to drive down the probe to obtain a deflection of 0.5 in. (13 mm) on the probe. The value should
change. Press the Tack button again for the second position; the
Calibration screen should be displayed.
. The operator can exit this function and return to the Calibration screen at any time by pressing the Stop button.
Calculate Left/Right
Calculate Left/Right matches the value of the torch probe movement to the actual movement of the motors. Running this function will change the value of the menu Probe L/R. This function
will show the flex of the probe in the left/right position in reference
to the Null point. At this point the probe is not touching anything
so the reading should be close to 0. Use the joystick to drive the
probe either left or right so it barely touches a solid surface and
the value on the screen changes. Stop the movement of the
torch and press the Tack button. Use the joystick to drive the
probe either left or right to obtain a deflection of 0.5 in. (13 mm)
on the probe. The value should change. Press the Tack button
again for the second position; the Calibration screen should be
displayed.
. The operator can exit this function and return to the Calibration screen at any time by pressing the Stop button.
Backup
Select Backup to save all current Calibration settings.
OM-284265 Page 29
5-14. Calibration Screens (Continued)
Restore
Select Restore to return all Calibration settings to the last stored
backup state.
Password
Password allows the operator to change the password required to
access the Calibration screen. The default password is CALIB.
5-15. Configuration Screens
Search Start Point
When Search Start PT in the Program screen is set to Yes, the
operator can establish the location of the start point.
Move the torch to the desired position (where the torch should begin its search for the joint) and in the menu screen move the joystick to the right. The seam tracker will remember this position.
Weld Start Point
The Weld Start PT is the position of the probe in the weld joint.
The probe guides the seam tracker as it tracks a joint during the
welding operation.
To set Weld Start PT, place the probe in the joint and the torch in
the desired position during the weld. For both V and edge joints,
be sure there is enough downward force on the probe. For edge
joints, be sure there is also some lateral force on the probe.
Probe Position
By selecting this function by moving the joystick to the right you
can see the deflection of the probe in both directions. To exit,
press the Stop Button.
OM-284265 Page 30
5-15. Configuration Screens (Continued)
Set Home Point
If RTH DLY (Return to Home Delay) is set in the Program menu
screens, the torch returns to the home location established in the
Set Home PT screen. To set, move the torch to the desired home
position. In the menu screen, move the joystick to the right. The
seam tracker will remember this position.
Tracking Type
Tracking type options are Both, U/D and L/R. The Both option is
tracking in all directions, U/D is tracking only for up down and L/R
tracking only for left right. If Both option is not selected, the operator can manually guide the torch in the direction not controlled
by the seam tracker.
Find Limit
Find Limit enables the seam tracker to find the limit sensors
when the operator moves the joystick to the right.
Limit Side
The encoders on the seam tracker motors are relative encoders,
not absolute encoders. This means that when the system is first
turned on the motors do not know their location in relation to the
limit switches. After the seam tracker is turned on, it relies on the
limit switches to guide it to the defined positions. The Up/Down
command will also move the upper limit switch, but the operator
can define which limit switch is affected. The default setting is the
left side.
. If the limit switch default setting is changed, the Home and
Search Start PT settings will have to be reset.
Tool Offset Type
When tracking the joint, the position correction is based on torch
position rather than probe position. The delay can be done in one
of two ways:
S If the seam tracker is not controlling the speed of the weld,
the approximate time from when the part moves from under
the probe to when it moves under the torch must be determined. Set the Tool Offset Type to Time and then in the Program screen enter the time value.
S If the seam tracker is controlling the speed, set the Tool Offset Type to Dist. In the Program screen enter the linear distance between the probe and torch. The seam tracker will
automatically adjust the time delay based on the speed of
the part.
OM-284265 Page 31
5-15. Configuration Screens (Continued)
Tack Move Average
Tack Move Average defines how the slide for each axis will move
when a tack is found. If Tack Move Average is set to Off, the torch
movement is locked out while on the tack. If it is set to a specific
time, while it is on the tack, the torch will move at the average speed
it was moving in both directions for that time period before the tack
was detected.
Joint Type
Set Joint Type informs the seam tracker of the type of joint to look
for. There are three options: Edge-L (left), Edge-R (right) or V
(depending on the shape of the workpiece to be welded).
To Work
To Work allows the operator to set the direction the probe will
move to auto-find the workpiece, either down, down left, down
right, or none.
To Joint
To Joint allows the operator to set the direction the probe will
move to find the joint after reaching the work, either right, left, or
none.
Tracker
Tracker is only for multi-seam tracker systems and should not be
changed unless instructed by a Miller service technician.
Horizontal Slide
Horizontal Slide allows the operator to control whether the unit
can move in the horizontal direction, and can be set to either Yes
or No.
OM-284265 Page 32
5-15. Configuration Screens (Continued)
Vertical Slide
Vertical Slide allows the operator to control whether the unit can
move in the vertical direction, and can be set to either Yes or No.
Reverse Left/Right
When set to Yes, Reverse Left/Right reverses left and right for
all options and controls. Preferred setting is dependent on where
the operator stands in relation to the seam tracker.
Probe Left/Right
When set to Rev (Reverse), Probe Left/Right reverses left and
right for controls. Preferred setting depends on the side of the
torch that the probe is on. If the probe is on the other side of the
torch from the slide, select Rev (reverse). If the probe is on the
same side of the torch as the slide, select Norm (normal). Check
operation by setting Program screen to Dry Run and verifying
the torch is following the joint.
Jog Speed Up/Down
Jog Up/Down allows the operator to set the jog speed in the vertical direction in inches or centimeters per second.
Jog Speed Left/Right
Jog Left/Right allows the operator to set the jog speed in the horizontal direction in inches or centimeters per second.
Rapid Speed Up/Down
Rapid Up/Down allows the operator to set the rapid jog speed in the
vertical direction. Rapid jog is achieved by double tapping the joystick in the intended direction.
OM-284265 Page 33
5-15. Configuration Screens (Continued)
Rapid Speed Left/Right
Rapid Left/Right allows the operator to set the rapid jog speed in
the horizontal direction. Rapid jog is achieved by double tapping
the joystick in the intended direction.
Jog Flex
Jog Flex allows the operator to define how much the probe can
flex (when the operator is jogging the wire) before the system will
stop the travel. Press Tack button to override Jog Flex.
Up/Down Delay Home
Up/Down Delay Home allows the operator to set the time delay
(in seconds) for vertical motion after Return to Home action is
initiated.
Left/Right Delay Home
Left/Right Delay Home allows the operator to set the time delay
(in seconds) for horizontal motion after Return to Home action is
initiated.
Up/Down Delay Work
Up/Down Delay Work allows the operator to set the time delay (in
seconds) for vertical motion after Finding Work action is initiated.
OM-284265 Page 34
5-15. Configuration Screens (Continued)
Left/Right Delay Work
Left/Right Delay Work allows the operator to set the time delay
(in seconds) for horizontal motion after Finding Work action is
initiated.
Work Speed Up/Down
Work Speed Up/Down allows the operator to define how fast the
probe moves vertically when Finding Part/Work is initiated.
Work Speed Left/right
Search Speed Left/Right allows the operator to define how fast the
probe moves horizontally when Finding Part/Work is initiated.
Weld Speed Left/Right
Weld Left/Right allows the operator to define how fast the probe
moves horizontally while searching for the joint.
Run Jog Delta
Run Jog Delta is the deflection of the probe from the starting point
that is allowed while the system is welding.
Purge
Select Yes if the Purge ability is available; Select No if Purge is
not available.
OM-284265 Page 35
5-15. Configuration Screens (Continued)
Weld Schedule
Select Yes if a weld schedule is available; Select No if weld
schedule is not available.
Jog Wire
Jog Wire appears only if selected in the Configuration Screen.
Jog Wire allows the operator to move the torch wire in or out to
ensure that it is in the proper place for welding.
Travel Control
Travel Control can be set to Circular, Linear, or No depending on
the type of workpiece to be welded. This setting also dictates
what other relevant options appear on the screens.
Out Of Joint
Out of Joint is either disabled or enabled. If set to Disable, the
Seam Tracker will not look for Out of Joint activity.
Backup
Select Backup to save all current Configuration settings.
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5-15. Configuration Screens (Continued)
Restore
Select Restore to return all Configuration settings to the last
stored backup state.
Service
Select Service to return to the Service screen. Contact a Miller
service technician to obtain service.
Password
Select Password to change the password required to access the
Configuration screen. The default password is CONFI.
Main Version
Main Version is the version of the code in the Seam tracker main
control.
Pendant Version
Pendant Version is the version of the code in the pendant.
OM-284265 Page 37
5-15. Configuration Screens (Continued)
Max Arc Wait
Max Arc Wait allows the operator to define how long the Seam
Tracker will wait for a valid arc before indicating an error
condition.
Arc Dropout
Arc Dropout allows the operator to define how long the arc signal
needs to absent during a weld for the Seam Tracker to determine
that the arc has been lost.
Wait For Arc
Select Yes on Wait For Arc to instruct the unit to wait for the arc
to be struck before beginning movement.
OM-284265 Page 38
SECTION 6 − OPERATION
6-1. Operation Flowchart
Start Pressed
Search Start
Point
Yes
Go to position.
(Config > Search start point)
Tracking
No
Configuration
To Work
Down, D/R, or D/L
Find work at speed config >
Work speed U/D & L/R as defined by
part window / part
End Of Weld
Yes
None
Configuration
To Joint
Right / Left
Stop Tracking
Find joint at speed config >
Weld speed L/R as defined by
joint window / joint
None
Not Done
Settle to position as defined by
config / weld start point
Not Done
No
Done
Return To
Home
Calibration
Arc Delay
No
Yes
Done
Fire Arc
Stop torch movement
Program
Final Weld
Time
Not Done
Return To
Home Delay
Done
Not Done
Program
Tracking Delay
Move to position defined by
Config > Set Home Point
Done
END
OM-284265 Page 39
6-2. Program Menu Screens
Jog Wire
Jog Wire allows the operator to jog the wire by moving the joystick either left or right. Jog Wire (in Configuration menu) must
be set to Yes.
Jog Travel
Jog Travel allows the operator to jog the travel by moving the joystick either left or right. Travel Control (in Configuration menu)
must not be set to None.
Purge
Purge setting only appears if selected under the Configuration
menu. Shielding gas flows when Purge is on; shielding gas does
not flow when Purge is off.
Tracking Delay
Tracking Delay controls the amount of time before tracking is active. Use this setting to prevent torch bounce when the arc is
struck.
Run
Select either Normal, Dry, or Bypass setting. Dry Run setting allows the machine to run without the torch turning on. Bypass is
for multi seam-tracking systems. In Bypass mode, the torch will
not move and the arc will not turn on.
OM-284265 Page 40
6-2. Program Menu Screens (Continued)
Tool Offset
Tool Offset controls the offset from the probe to the torch in either
time or distance as defined in Config – Tool Offset Type.
Tack Detect
Select either Enable or Disable setting. Enabling Tack Detect allows the torch to continue through a tack instead of welding over.
Disabling it turns off this feature.
Weld Schedule
The Weld Schedule setting only appears if it is selected under
the Configuration menu. It can be set to schedule 1−8 in the Auto
Continuum for MIG welding.
Travel Stop Delay
Travel Stop Delay allows the operator to establish the time (in
seconds) that travel continues after end-of-weld conditions are
met.
Travel IPM
Travel IPM controls the speed of the weld in inches per minute.
. Travel speed can be changed to centimeters per minute as
defined in Calib – Units.
OM-284265 Page 41
6-2. Program Menu Screens (Continued)
Diameter
Diameter allows the operator to input the diameter of round
workpieces.
Travel Stop Delay
Travel Stop Delay allows the operator to set the time in seconds
that travel continues after end-of-weld conditions are met.
End Of Weld
The End of Weld setting can be set to three different options: Off
Part, Overlap, or Time. When set to Off Part, the weld will finish
when the probe falls off; use this setting for linear pieces. When
set to Overlap, the weld will finish when the probe hits the weld
again; use this setting for circular pieces. When set to Time, the
operator can set the time duration for the weld.
Value
If End of Weld is set to Time, Value indicates the duration of the
weld in seconds.
Final Weld Time
Final Weld Time defines the time (in seconds) that the torch will
continue welding after the probe reaches the set end conditions.
OM-284265 Page 42
6-2. Program Menu Screens (Continued)
Return To Home Delay
The RTH DLY setting defines the length of time after the beginning of down−slope before the system performs a Return to
Home action. Return to home is not done If RTH DLY is set to
Off. Minimum value is Off and Maximum value is 10.0.
Search Start Point
If Search Start Point is set to Yes, after the Start button has been
pressed the torch will move to the predefined position as defined
in Config – Search Start PT. The move is bypassed If setting is
set to No.
Calibrate
Select Calibrate to access the Calibration screen. The default
password for the calibrate screen is CALIB. The password can
be changed in the Calibration Password screen.
Configuration
Select Configure to access the Configuration screen. The default password for the configure screen is CONFI. The password
can be changed in the Configure Password screen.
Go Home
Select Go Home to have the unit return to the Home position.
OM-284265 Page 43
6-3. Service Screens
. Obtain approval from a Miller service technician before making these adjustments.
I Term Up/Down
I Term Up/Down indicates up/down activity during seam
tracking.
Error Term Up/Down
Error Term Up/Down indicates an up/down error during seam
tracking.
I Term Left/Right
I Term Left/Right indicates left/right activity during seam
tracking.
Error Term Left/Right
Error Term Left/Right indicates a left/right error during seam
tracking.
Up/Down
Up/Down indicates an up/down error when jogging.
Left/Right
Left/Right indicates a left/right error when jogging.
OM-284265 Page 44
6-4. Weld Screens
. The active channel is the channel that is highlighted. To
make the current channel active, Press the up arrow. To
make the travel channel active, press the down arrow.
Line 1
LINE 1
LINE 2
LINE 3
LINE 4
Line 1 shows the weld status: Run, Dry Run or Bypass. In Run
mode, all weld functions are operational. In Dry Run mode, all
weld functions are operational with the exception of the welding
arc. The purpose of Dry Run is to ensure that everything is set
correctly for the system to find and track the welding joint. In Bypass mode, only travel is active if selected. The purpose of this
mode is to be able to turn off this seam tracker if there is more
than one seam tracker on the welding fixture.
Line 2
Line 2 shows the current weld schedule status: Weld Start PT,
Find Part, Find Joint, Arc DLY, Wait For Arc, Tracking, End Weld,
Home DLY, or Home. If the number is counting down it is providing information on how long that segment of the weld schedule
remains. If the number is counting up, it is providing information
on how long the schedule has been in that segment. This information is useful because some segments have defined durations while other segments run as long as necessary until they
are complete. See Section 5-13 for more information on how to
set up the seam tracker to find and follow the seam.
Line 3
Line 3 shows the status of various inputs and outputs. If Jog is
highlighted, the joystick will be able to move the torch in the
seam. Jogging the torch with Auto turned on will change how
much flex is on the probe. The operator is limited in the changes
that can be made as defined by Run Jog Y in the Configuration
menu. If Jog is not highlighted the operator can use the joystick
to change Line 2 to Trav IPM, Trav CPM, or Trav RPM and then
be able to change the speed by using the dial. If PS is highlighted,
the output to turn on the power supply is active. If FT is highlighted, the seam tracker has found the end of the weld and is in the
weld final time. If RTH is highlighted, the seam tracker is performing a Return to Home action.
Line 4
Line shows the status of various inputs and outputs. If Arc is
highlighted, the seam tracker is receiving a valid arc on signal.
If Auto is highlighted, the seam tracker is in automatic mode and,
if following the seam, using the probe. If Man is highlighted, the
torch will only move if set to Jog and by using the joystick. If Tack
is highlighted, a tack has been found by the seam tracker or by
the operator pressing the tack button on the pendant.
OM-284265 Page 45
6-5. Error/E Stop Screens
E Stop
An E Stop message indicates the E Stop button was pressed
and the motors have been disabled. The E stop on the pendant
or an external E Stop must be cleared before the seam tracker
will function.
Arc Error
If the Wait for Arc screen (in Configuration mode) is set to Yes and
the arc goes out during the weld, the weld process stops and the
Arc Error message is displayed. Press the Stop button to exit.
Arc STR Error
If the time required to start the weld exceeds the Max Arc Wait
setting (in Configuration Mode) welding stops and the Arc STR
ERR message is displayed. Press the Stop button to exit.
Hit Probe
The Hit Probe message is displayed if, while jogging the torch,
the probe has been deflected more than defined in the Jog Flex
menu (in Configuration mode). Press the Stop button to exit or
press the Tach button to override.
LMT Switch 1
The LMT Switch 1 message is displayed when the upper limit
switch is activated while the system is tracking a joint. Press the
Stop button to exit.
OM-284265 Page 46
6-5. Error/E Stop Screens (Continued)
Limit Switch 2
The Limit Switch 2 message is displayed when the right limit
switch is activated while the system is tracking a joint. Press the
Stop button to exit.
Limit Switch 3
The Limit Switch 3 message is displayed when the lower limit
switch is activated while the system is tracking a joint. Press the
Stop button to exit.
Limit Switch 4
The Limit Switch 4 message is displayed when the left limit
switch is activated while the system is tracking a joint. Press the
Stop button to exit.
Need Limits
The Need Limits message is displayed when the seam tracker
has been commanded or will be commanded to move to a location during or after the weld and the limit switches have not been
found since the system was turned on. Press the Stop button to
exit.
Out Of Seam
The Out Of Seam message is displayed, the arc is turned off, and
the seam tracker stops when the seam tracker has determined
that the probe in no longer in the joint. Pressing the Stop button
to exit.
OM-284265 Page 47
6-5. Error/E Stop Screens (Continued)
Communication Errors
These screens indicate communication errors between the pendant and seam tracker control module, or between the seam
tracker control module and other connection boxes.
OM-284265 Page 48
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
7-1. Routine Maintenance
!
Disconnect power before maintaining.
3 Months
Clean and
tighten
weld
terminals.
Replace
unreadable
labels.
Replace
cracked
parts.
Repair or
replace
cracked
weld
cable.
Check cords
and cables.
Check gas
hose and
fittings.
Check gun
cable.
6 Months
Blow out or vacuum
inside. During heavy
service, clean
monthly.
Clean
drive rolls.
Or
7-2. Troubleshooting
!
Disconnect power before troubleshooting.
A. Seam Tracking System
Trouble
Pendant display Off; pendant screen is
blank/off.
Remedy
Verify AC power cord is connected to controller and appropriate AC power source.
Circuit breaker tripped. Use Power switch to cycle power on and off. Have Factory Authorized Service Agent replace power switch w/circuit breaker if necessary.
120 volt AC input power not present. Have Factory Authorized Service Agent check TB2 terminals 15
and 16 inside controller.
+12 Volt DC power not present. Have Factory Authorized Service Agent check TB1 terminals 1 and 2
inside controller. Replace DC power supply if necessary.
Pendant cable may be faulty. Have Factory Authorized Service Agent remove cable from pedant and
check pins A and B for +12 volts DC. Replace cable if necessary.
System does not operate; pendant displays start Limit/Stop Skip.
System needs to find encoder start points. Press the start button to find encoder start point.
No menu selection; pendant joystick
does not change menu screen.
Pendant joystick may be faulty. Press the start button to find encoder start point.
Pendant Jog/Nav switch is set to Jog. Change Jog/Nav switch to Nav position. Pendant should display Pro−Nav.
If pendant does not display Pro−Nav, Jog/Nav switch may be faulty. Have Factory Authorized Service
Agent check connector J3 pin 12 (Gnd) to pin 16 (Nav).
OM-284265 Page 49
Trouble
No jog drive motion; pendant joystick
does not move the slides.
Remedy
Pendant joystick may be faulty. Have Factory Authorized Service Agent open pendant and check
connector J3 pin 7 (GND) to pin 8 (JoyD), pin 9 (JoyU), pin 10 (JoyL), and pin 11 (JoyR).
Pendant Jog/Nav switch is set to Nav. Change Jog/Nav switch to Jog position. Pendant should display Pro−Jog.
If pendant does not display Pro−Jog, Jog/Nav switch may be faulty. Have Factory Authorized Service
Agent check connector J3 pin 12 (Gnd) to pin 15 (Man).
E−Stop button pressed. Release the E−Stop button to clear E−stop condition.
Slide cables disconnected. Connect slide cables to controller and slides.
Brake release voltage missing. Have Factory Authorized Service Agent check J11 pins 9 and 10
inside controller for 24volts DC.
Drive power missing. Have Factory Authorized Service Agent check TB1 terminals 3 and 4 inside
controller for 24 volts DC. Replace DC power supply if necessary.
Pendant displays Hit Probe during jog
moves.
Probe deflection is greater than defined Jog Flex value. Check Jog Flex value in Configuration menu.
Press stop button to clear message. Press and hold down Tach button and then press Jog to move.
Probe cable is disconnected. Connect probe cable to controller and probe.
Probe cable may be faulty. Have Factory Authorized Service Agent check J11 pin 6 to Amphenol pin
B, J11 pin 4 to Amphenol pin C, J11 pin 2 to Amphenol pin D, and J11 pin 1 to Amphenol pin A.
Probe may be faulty. Have Factory Authorized Service Agent check J11 pin 6 (Gnd) to pin 2(U/D)
up/down range of 0.7 to 7.8 volts DC, and pin 4(L/R) left/right range of 0.7 to 7.8 volts DC.
Operator can jog slides in three out of
four directions.
Limit switch may be faulty. Have Factory Authorized Service Agent check limit switch on the slide:
Up/Down slide Amphenol pin J to pin K, and pin J to pin L; Left/Right slide Amphenol pin J to pin K,
pin J to pin L.
Motor cable may be faulty. Check Up/Down cable J9 pin 8 to Amphenol pin J, J9 pin 7 to Amphenol
pin K, and J9 pin 9 to Amphenol pin L.
Check Left/Right cable J10 pin 8 to Amphenol pin J, J10 pin 7 to Amphenol pin K, and J10 pin 9 to
Amphenol pin L.
Interface board may be faulty. Check Up/Down input terminal J9 pin 8 to pin 7, J9 pin 8 to pin 9.
Check Left/Right input terminal J10 pin 8 to pin 7, and J10 pin 8 to pin 9.
B. Voltage Readings
Connector J11 pins 7 and 8
+ 5 volts DC
TB1 Terminals 1 and 2
+12 volts DC
TB1 Terminals 3 and 4
+24 volts DC
TB2 Terminals 15 and 16
120 volts AC
OM-284265 Page 50
Notes
TM-284265 Page 51
SECTION 8 − ELECTRICAL DIAGRAMS
Figure 9-1. Seam Tracker Interconnection Diagram
OM−284265 Page 52
TM-284265 Page 53
Figure 9-2. Seam Tracker Main Module
OM−284265 Page 54
TM-284265 Page 55
Figure 9-3. Seam Tracker Pendant
OM−284265 Page 56
TM-284265 Page 57
SECTION 9 − PARTS LIST
12
11
13
10
9
8
14
7
15
6
16
5
4
17
18
19
3
20
2
1
21
Figure 9-1. ST-Main Box-EV Assembly
OM-284265 Page 58
Item
No.
Part
No.
Description
Quantity
Figure 9-1. ST-Main Box-EV Assembly
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
. . . . . . . . . . . . . . . A14128CH . . . . . . .
. . . . . . . . . . . . . . . . . . 240D10 . . . . . . .
. . . . . . . . . . . . . . . . . . . . . TB1 . . . . . . .
. . . . . . . . . . . . . . CFM40D-01 . . . . . . .
. . . . . . . . . . . . . . . . . ST-MB-1 . . . . . . .
. . . . . . . . . . . . . . . . . . . ST-MB . . . . . . .
. . . . . . 8961K150_DIN RAIL . . . . . . .
. . . . . OUTSIDE−SH4B−05B . . . . . . .
. . . . . . . . . . OUTSIDE−RH4B . . . . . . .
. . . . . . . . . . . . NDR−BKT−1B . . . . . . .
. . . . . . . . . . . . . . . . NDR−480 . . . . . . .
. . . . . . . . . . . . . . . 99607A152 . . . . . . .
. . . . . . . . . . . . NDR−BKT−1C . . . . . . .
. . . . . . . . . . 24V13−POLOLU . . . . . . .
. . . . . . . . . . . . . . . . . . . . . TB2 . . . . . . .
. . . . . . . . 97−3102A−14S−5P . . . . . . .
. . . . . . . . . 97−3102A−18−1S . . . . . . .
. . . . . . . . 97−3102A−20−27P . . . . . . .
. . . . . . . . . . . . . . . 3302M_TB . . . . . . .
. . . . . . . . . . . . . . . . . . 10EJT1 . . . . . . .
. . . . . . . TA35−CFTRF100C0 . . . . . . .
Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solid State Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Block 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ST-Main Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Din Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Socket Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket 1B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply 24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knurled Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket 1C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Block 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector To Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector To Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector To Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cord Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
1
1
1
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.
Notes
OM-284265 Page 59
19
18
17
18
12
17
14
11
15
13
16
20
21
10
9
8
7
6
22
5
23
4
3
2
1
Figure 9-2. MM MIDI Assembly
Item
No.
Part
No.
Description
Quantity
Figure 9-2. MM MIDI 150 HD
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
. . . . . . . . . . . . . . . . . T.10.005 . . . . . . .
. . . . . . . . . . . . . . . . HI HGH20 . . . . . . .
. . . . . . . . . . . . . . . T.06.009−4 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.014 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.012 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.004 . . . . . . .
. . . . . . HI HGR20T398E19C . . . . . . .
. . . . . . . . . . . . . . . . . T.06.013 . . . . . . .
. . . . . . . . . . . . . . . . . T.10.008 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.006 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.002 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.003 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.001 . . . . . . .
. . . CU60002RS1 – 10x26x8 . . . . . . .
. . . . . RI RMI28 IR20 56B14 . . . . . . .
. . . . . . . . 97−3102A−14S−5P . . . . . . .
. . . . . . . . . 97−3102A−18−1S . . . . . . .
. . . . . . . . . . . . AT220−001−A . . . . . . .
. . . . . . . . . . . . . . . . T.06.007D . . . . . . .
. . . . . . . . AT220−002.PIN10 . . . . . . .
. . 56PL015FE01EH30M500Z5 . . . . .
. . . . . DM−VMS15−05N−250 . . . . . . .
. . . . . . . . . . . . . . TMVT16P10 . . . . . . .
Backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hiwin Sliding Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sliding Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit Switch Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hiwin Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit Switch Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball Bearing SKF6000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox Size 28 IR 1/20 56B14 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector 14P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flat Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14P Connector Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Motor With Brake, Encoder 500 . . . . . . . . . . . . . . . . . . . . . . . .
Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
4
1
2
2
1
2
2
1
1
4
1
1
3
1
1
2
1
1
1
1
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-284265 Page 60
Item
No.
Part
No.
Description
Quantity
Figure 9-2. MM MIDI 150 HD
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
. . . . . . . . . . . . . . . . . T.10.005 . . . . . . .
. . . . . . . . . . . . . . . . HI HGH20 . . . . . . .
. . . . . . . . . . . . . . . T.06.009−4 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.014 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.012 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.004 . . . . . . .
. . . . . . HI HGR20T398E19C . . . . . . .
. . . . . . . . . . . . . . . . . T.06.013 . . . . . . .
. . . . . . . . . . . . . . . . . T.10.008 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.006 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.002 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.003 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.001 . . . . . . .
. . . CU60002RS1 – 10x26x8 . . . . . . .
. . . . . RI RMI28 IR20 56B14 . . . . . . .
. . . . . . . . . . . 3102A−20−27P . . . . . . .
. . . . . . . . . . . . . . . . . T.10.010 . . . . . . .
. . . . . . . . . . . . AT220−001−A . . . . . . .
. . . . . . . . . . . . . . . . T.06.007D . . . . . . .
. . . . . . . . AT220−002.PIN10 . . . . . . .
. . . . . 56PL015EH30M500Z5 . . . . . . .
. . . . . DM−VMS15−05N−250 . . . . . . .
. . . . . . . . . . . . . . TMVT16P10 . . . . . . .
Backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hiwin Sliding Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sliding Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit Switch Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hiwin Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit Switch Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball Bearing SKF6000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox Size 28 IR 1/20 56B14 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector 14P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flat Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14P Connector Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Motor With Encoder 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
4
1
2
2
1
2
2
1
1
4
1
1
3
1
1
2
1
1
1
1
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.
Item
No.
Part
No.
Description
Quantity
Figure 9-2. MM MIDI 250 HD With Brake
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
. . . . . . . . . . . . T.06.005.1M-A . . . . . . .
. . . . . . . . . . . . . . . . HI HGH20 . . . . . . .
. . . . . . . . . . . . . . . T.06.009−4 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.014 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.012 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.004 . . . . . . .
. . . . . . HI HGR20T518E19C . . . . . . .
. . . . . . . . . . . . . . . . . T.06.013 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.008 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.006 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.002 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.003 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.001 . . . . . . .
. . . CU60002RS1 – 10x26x8 . . . . . . .
. . . . . RI RMI28 IR20 56B14 . . . . . . .
. . . . . . . . . . . 3102A−20−27P . . . . . . .
. . . . . . . . . . . . . . . . . T.06.010 . . . . . . .
. . . . . . . . . . . . AT220−001−A . . . . . . .
. . . . . . . . . . . . . . . . T.06.007D . . . . . . .
. . . . . . . . AT220−002.PIN10 . . . . . . .
. . 56PL015FE01EH30M500Z5 . . . . .
. . . . . DM−VMS15−05N−250 . . . . . . .
. . . . . . . . . . . . . . TMVT16P10 . . . . . . .
Backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hiwin Sliding Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sliding Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit Switch Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hiwin Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit Switch Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball Bearing SKF6000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox Size 28 IR 1/20 56B14 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector 14P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flat Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14P Connector Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Motor With Brake, Encoder 500 . . . . . . . . . . . . . . . . . . . . . . . .
Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
4
1
2
2
1
2
2
1
1
4
1
1
3
1
1
2
1
1
1
1
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-284265 Page 61
Item
No.
Part
No.
Description
Quantity
Figure 9-2. MM MIDI 250 HD
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
. . . . . . . . . . . . T.06.005.1M-A . . . . . . .
. . . . . . . . . . . . . . . . HI HGH20 . . . . . . .
. . . . . . . . . . . . . . . T.06.009−4 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.014 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.012 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.004 . . . . . . .
. . . . . . HI HGR20T518E19C . . . . . . .
. . . . . . . . . . . . . . . . . T.06.013 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.008 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.006 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.002 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.003 . . . . . . .
. . . . . . . . . . . . . . . . . T.06.001 . . . . . . .
. . . CU60002RS1 – 10x26x8 . . . . . . .
. . . . . RI RMI28 IR20 56B14 . . . . . . .
. . . . . . . . . . . 3102A−20−27P . . . . . . .
. . . . . . . . . . . . . . . . . T.06.010 . . . . . . .
. . . . . . . . . . . . AT220−001−A . . . . . . .
. . . . . . . . . . . . . . . . T.06.007D . . . . . . .
. . . . . . . . AT220−002.PIN10 . . . . . . .
. . . . . 56PL015EH30M500Z5 . . . . . . .
. . . . . DM−VMS15−05N−250 . . . . . . .
. . . . . . . . . . . . . . TMVT16P10 . . . . . . .
Backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hiwin Sliding Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sliding Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit Switch Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hiwin Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit Switch Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ball Bearing SKF6000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox Size 28 IR 1/20 56B14 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector 14P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flat Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14P Connector Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Motor With Encoder 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
4
1
2
2
1
2
2
1
1
4
1
1
3
1
1
2
1
1
1
1
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.
Notes
OM-284265 Page 62
24
23
22
21
25
20
19
18
17
16
15
14
13
12 11
10
9
8
1
7
4
6
3
2
5
Figure 9-3. Probe Assembly
OM-284265 Page 63
Item
No.
Part
No.
Description
Quantity
Figure 9-3. Probe Assembly
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1 . . . . . . . . . . . . . . . . . . . IGP30
2 . . . . . . . . . . . . . . . . . . . IGP20
3 . . . . . . . . . . . . . . . . . . . IGP15
4 . . . . . . . . . . . . . . . . . . . IGP10
5 . . . . . . . . . . . . . . . . . . . IGP06
6 . . . . . . . . . . . . . . . . . . . IGP03
7 . . . . . . . . . . . . . . . IG MTJ002
8 . . . . . . . . . . . . . . . IG T03-BR
9 . . . . . . . . . . UNI5923 M3x16
10 . . . . . . . . . . . . . IG T03-100/1
11 . . . . . . . . . . . . . . . IG T03-102
12 . . . . . . . . . . . . . . . CU 686 ZZ
13 . . . . . . . . . . . . . . . . . IG C-002
14 . . . . . . . . . . . . . . EN T03-104
15 . . . . . . . . . . . IG T03-036 D70
16 . . . . . . . . . . . . . . IG JP00B00
17 . . . . . . . . . . . . . . . . . IGSOFF
18 . . . . . . . . . . IG9SY40R06504
19 . . . . . . . . . . . . . . . IG T03-035
20 . . . . . . . . . . . . . ISO 4032 M3
21 . . . . . . . . . . CN 3102E145P
22 . . . . . . . . . . . . . . . IG T03-034
23 . . . . . . . EN ISO 7045 M3x12
24 . . . . . . . JIS B 1111-A M3x10
25 . . . . . . . . . . . . . . . . . IGJOY80
Item
Part
No.
No.
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.......
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.......
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.......
.......
.......
.......
.......
.......
.......
.......
.......
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.......
Tip 030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip 020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip 015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip 010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bakelite Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip For Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plastic Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Case Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Close Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joystick + Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
4
4
1
Quantity
IGS001 (Standard Probe)
..
..
..
..
..
..
..
..
..
..
1
5
9
10
15
16
17
19
21
22
. . . . . . . . . . IG9SY40R06504
. . . . . . . . . . . . . . . . . . . IGP06
. . . . . . . . . . UNI5923 M3x16
. . . . . . . . . . . . . IG T03-100/1
. . . . . . . . . . . IG T03-036 D70
. . . . . . . . . . . . . . IG JP00B00
. . . . . . . . . . . . . . . . . IGSOFF
. . . . . . . . . . . . . . . IG T03-035
. . . . . . . . . . CN 3102E145P
. . . . . . . . . . . . . . . IG T03-034
.......
.......
.......
.......
.......
.......
.......
.......
.......
.......
Joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tip 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plastic Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Case Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Close Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
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-284265 Page 64
1
1
2
2
3
Replacement Probe Shaft
(Breakaway) - JTSTPRS01
Probe Insulator - JTSTPTI
Replacement Probe shaft End
Screw - JTSTPRS02
Figure 9-4. Recommended Spare Parts
1
1
Probe Tips
S JTSTPT3
2
3
3 mm probe ball
S JTSTPT6
6 mm probe ball
S JTSTPT10
10 mm probe ball
S JTSTPT15
15 mm probe ball
S JTSTPT20
20 mm probe ball
S JTSTPT30
30 mm probe ball
2
3
4
Copper Wheel Probe - JTSTPTWH
Probe Extension - JTST100PE
(100 mm)
Extension Rods
Extension rods define the distance between the torch holder and probe. The
standard system includes a 200 mm rod.
4
S JMS115R
115 mm
S JMS200R
200 mm
S JMS300R
300 mm
Figure 9-5. Accessories
OM-284265 Page 65
Effective January 1, 2019
(Equipment with a serial number preface of MK or newer)
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.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
* Subarc Wire Drive Assemblies
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to
* TIG Torches (No Labor)
authorized distributors that new Miller equipment sold after the
* Tregaskiss Guns (No Labor)
effective date of this limited warranty is free of defects in material
* Water Cooling Systems
and workmanship at the time it is shipped by Miller. THIS
* Wireless Remote Foot/Hand Controls and Receivers
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Work Stations/Weld Tables (No Labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
5. 6 Months — Parts
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Batteries
Within the warranty periods listed below, Miller will repair or replace 6. 90 Days — Parts
any warranted parts or components that fail due to such defects in
* Accessories (Kits)
material or workmanship. Miller must be notified in writing within
* Canvas Covers
thirty (30) days of such defect or failure, at which time Miller will
* Induction Heating Coils and Blankets, Cables, and
provide instructions on the warranty claim procedures to be
Non-Electronic Controls
followed. Notifications submitted as online warranty claims must
* M-Guns
provide detailed descriptions of the fault and troubleshooting steps
* MIG Guns, Subarc (SAW) Torches, and External
taken to diagnose failed parts. Warranty claims that lack the
Cladding Heads
required information as defined in the Miller Service Operation
* Remote Controls and RFCS-RJ45
Guide (SOG) may be denied by Miller.
* Replacement Parts (No labor)
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
below in the event of a defect within the warranty coverage time
periods listed below. Warranty time periods start on the delivery Miller’s True Blue Limited Warranty shall not apply to:
date of the equipment to the end-user purchaser, or 12 months 1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
after the equipment is shipped to a North American distributor, or
station table tops and welding curtains, or parts that
18 months after the equipment is shipped to an international
fail due to normal wear. (Exception: brushes and
distributor, whichever occurs first.
relays are covered on all engine-driven products.)
1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs, 2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
Diodes, and Discrete Rectifier Modules
covered by the manufacturer’s warranty, if any.
2. 3 Years — Parts and Labor Unless Specified
* Auto-Darkening Helmet Lenses (No Labor) (See 3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
Classic Series Exception Below)
improperly operated or misused based upon industry
* Engine Driven Welder/Generators
standards, or equipment which has not had reasonable
(NOTE: Engines are Warranted Separately by the
and necessary maintenance, or equipment which has
Engine Manufacturer.)
been used for operation outside of the specifications for
* Insight Welding Intelligence Products
the equipment.
* Inverter Power Sources
4. Defects caused by accident, unauthorized repair, or
* Plasma Arc Cutting Power Sources
improper testing.
* Process Controllers
MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL
* Semi-Automatic and Automatic Wire Feeders
AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN
* Transformer/Rectifier Power Sources
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
3. 2 Years — Parts and Labor
The exclusive remedies for warranty claims are, at Miller’s
* Auto-Darkening Helmet Lenses − Classic Series Only option, either: (1) repair; or (2) replacement; or, if approved in
(No Labor)
writing by Miller, (3) the pre-approved cost of repair or
* Auto-Darkening Weld Masks (No Labor)
replacement at an authorized Miller service station; or (4)
* Fume Extractors − Capture 5, Filtair 400 and Industrial payment of or credit for the purchase price (less reasonable
Collector Series
depreciation based upon use). Products may not be returned
4. 1 Year — Parts and Labor Unless Specified
without Miller’s written approval. Return shipment shall be at
* AugmentedArc and LiveArc Welding Systems
customer’s risk and expense.
* Automatic Motion Devices
The above remedies are F.O.B. Appleton, WI, or Miller’s
* Bernard BTB Air-Cooled MIG Guns (No Labor)
authorized service facility. Transportation and freight are the
* CoolBelt and CoolBand Blower Unit (No Labor)
customer’s responsibility. TO THE EXTENT PERMITTED BY
LAW, THE REMEDIES HEREIN ARE THE SOLE AND
* Desiccant Air Dryer System
EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL
* Field Options
(NOTE: Field options are covered for the remaining THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR
SPECIAL,
INCIDENTAL OR
warranty period of the product they are installed in, DIRECT, INDIRECT,
or for a minimum of one year — whichever is CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY
greater.)
WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
* RFCS Foot Controls (Except RFCS-RJ45)
WARRANTY, GUARANTY, OR REPRESENTATION,
* Fume Extractors − Filtair 130, MWX and SWX Series
INCLUDING
ANY
IMPLIED
WARRANTY
OF
* HF Units
MERCHANTABILITY OR FITNESS FOR PARTICULAR
* ICE/XT Plasma Cutting Torches (No Labor)
PURPOSE, ARE EXCLUDED AND DISCLAIMED BY
* Induction Heating Power Sources, Coolers
MILLER.
(NOTE: Digital Recorders are Warranted
Some US states do not allow limiting the duration of an implied
Separately by the Manufacturer.)
warranty or the exclusion of certain damages, so the above
* Load Banks
limitations may not apply to you. This warranty provides
* Motor-Driven Guns (except Spoolmate Spoolguns)
specific legal rights, and other rights may be available
* PAPR Blower Unit (No Labor)
depending on your state. In Canada, some provinces provide
* Positioners and Controllers
additional warranties or remedies, and to the extent the law
* Racks (For Housing Multiple Power Sources)
prohibits their waiver, the limitations set out above may not
* Running Gear/Trailers
apply. This Limited Warranty provides specific legal rights, and
* Spot Welders
other rights may be available, but may vary by province.
mil dom warr 2019-01
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
Contact 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. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
 2019 Miller Electric Mfg. LLC
2019−01
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