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Manual Miller Electric Welder

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  • Miller Electric Welder - page 1

    Auto Invision II V isit our website at www.MillerWelds.com Processes OM-196 188K July 2003 Description MIG (GMAW ) W elding Pulsed MIG (GMAW -P) Flux Cored (FCA W ) W elding Automatic W elding Automatic Welding Interface And Arc Welding Power Source Operating Instructions and Programming Instructions for ...

  • Miller Electric Welder - page 2

    Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld ...

  • Miller Electric Welder - page 3

    T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Welder - page 4

    T ABLE OF CONTENTS SECTION 8 – INTRODUCTION T O PROGRAMMING 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Pulse MIG Programs 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Standard Pulse Welding Programs 76 . . . . . . . . . . . . ...

  • Miller Electric Welder - page 5

    T ABLE OF CONTENTS SECTION 14 – SETUP 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1. Setup Flow Chart 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2. Using S e t u p D i s ...

  • Miller Electric Welder - page 6

    dec_con1_1 1/02 Declaration of Conformity For European Community (CE) Products Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W . Spencer Street Appleton, WI 54914 USA Declares that the product: Auto Invision II conforms to the following Directives and Standards: Directives Electromagnetic compatibility Directives: ...

  • Miller Electric Welder - page 7

    OM-196 188 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means W arning! Wat ...

  • Miller Electric Welder - page 8

    OM-196 188 Page 2 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. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and ...

  • Miller Electric Welder - page 9

    OM-196 188 Page 3 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. ...

  • Miller Electric Welder - page 10

    OM-196 188 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However , after examining more than 500 studies spanning 17 yea ...

  • Miller Electric Welder - page 11

    OM-196 188 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier . . Sig ...

  • Miller Electric Welder - page 12

    OM-196 188 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS DE L ’ARC peuvent pro- voquer des brûlures dans les yeux et sur ...

  • Miller Electric Welder - page 13

    OM-196 188 Page 7 1-3. 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 proxi- mité de surfaces infllammables. D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’install ...

  • Miller Electric Welder - page 14

    OM-196 188 Page 8 1-4. Principales normes de sécurité Safety in W elding and Cutting, norme ANSI Z49.1, de l’American Wel - ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Safe Practice for the ...

  • Miller Electric Welder - page 15

    OM-196 188 Page 9 SECTION 2 – DEFINITIONS 2-1. Manufacturer ’ s W arning Label Definitions W arning! W atch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill. 1.1 W ear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yo ...

  • Miller Electric Welder - page 16

    OM-196 188 Page 10 > 60 s V S-179 190-A V V 1 W arning! W atch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Disconnect input plug or power before working on machine. 4 Hazardous voltage remains on input capacitors after power is turned off. Do not touch fully charged capacitors. 5 Always wait ...

  • Miller Electric Welder - page 17

    OM-196 188 Page 1 1 2-2. Symbols And Definitions A Amperage Positive Remote V V oltage Output Circuit Breaker Negative On Of f Inductance Protective Earth (Ground) V oltage Input 2-3. Manufacturer ’ s Rating Label S-184 765 2-4. Harmonic Data HARMONIC DA T A per IEC 61000-3-12, draft 2000-9-29 PRIMARY ; 400V/30.5A/60hz LOAD; 450A/38Vdc/390IPM/,MA ...

  • Miller Electric Welder - page 18

    OM-196 188 Page 12 SECTION 3 – INST ALLA TION 3-1. Specifications Input Rated Welding V oltage Wire Feed Speed Wire Maximum Open- Amperes Input At Rated Load Input Power Rated W elding Output V oltage Range Wire Feed Speed Range* Wire Diameter Range Maximum Open- Circuit Amperes Input At Rated Load Output 60 Hz, KV A KW Power Output Range Range* ...

  • Miller Electric Welder - page 19

    OM-196 188 Page 13 3-3. Selecting A Location loc_2 3/96 - 801 958 / 801 914-A 1 Lifting Forks Use lifting forks to move unit. Extend forks beyond opposite side of unit. 2 Lifting Handles Use handles to lift unit. 3 Hand Cart Use cart or similar device to move unit. 4 Rating Label Use rating label to determine input power needs. 5 Line Disconnect De ...

  • Miller Electric Welder - page 20

    OM-196 188 Page 14 3-5. W eld Output T erminals And Selecting Cable Sizes T otal Cable (Copper) Length In W eld Circuit Not Exceeding 30 m (100 ft) Or Less 45 m (150 ft) 60 m (200 ft) 70 m (250 ft) 90 m (300 ft) 105 m (350 ft) 120 m (400 ft) W elding Amperes 10 – 60% Duty Cycle 60 – 100% Duty Cycle 10 – 100% Duty Cycle 100 25 25 25 35 35 50 5 ...

  • Miller Electric Welder - page 21

    OM-196 188 Page 15 3-7. Electrical Service Guide Three-Phase Input V oltage 400 Input Amperes At Rated Output 31 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 45 Min Input Conductor Size In A WG/Kcmil 10 Max Recommended Input Conductor Length In Feet (Meters) 264 (80) Min Grounding Conductor Size In A WG/Kcmil 10 Reference: 199 ...

  • Miller Electric Welder - page 22

    OM-196 188 Page 16 3 5 6 4 1 Receptacle 2 Keyway 3 4-Pin Receptacle (Optional External V oltage Sensing Connection) T o connect interconnecting cord to receptacle, align keyway , insert plug, and tighten threaded collar . Secure ring terminal on remaining end of cord to work. 4 Peripheral Receptacle Receptacle provides connection to touch sensor , ...

  • Miller Electric Welder - page 23

    OM-196 188 Page 17 3-10. Peripheral Receptacle Functions Function Socket Socket Information Programmable Output Relay Con- A Contact closure to B dependent upon state of programmed output (see Section 14-5). The closure between A and B can carry a maximum of 0.6 amps at 125 V AC; or a maximum of 0.6 amps at 1 10 VDC. AK J Output Relay Con- tacts B ...

  • Miller Electric Welder - page 24

    OM-196 188 Page 18 3-1 1. T ouch Sensor Operation Th e touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source. Voltage sense leads provide a path for touch sensor voltage when this feature is turned on at the peripheral r eceptacle. T urning on touch sensor causes a dc voltage to be present on ...

  • Miller Electric Welder - page 25

    OM-196 188 Page 19 3-13. Connecting Setup Pendant T o W elding Power Source 802 816 Y T urn Off welding power source and weld control. 1 W elding Power Source 2 Interconnecting Cord 3 Setup Pendant T o make connections, align plug with receptacle, insert plug, and use thumb screws on receptacle to secure plug. 1 2 3 . Disconnect the setup pendant f ...

  • Miller Electric Welder - page 26

    OM-196 188 Page 20 SECTION 4 – OPERA TION 4-1. Operational T erms The following is a list of terms and their definitions as they apply to this interface unit: General T erms: Adaptive Pulse W elding When the “adaptive pulse” welding process is selected, the unit will attempt to automatically regulate pulse frequency in order to maintain a con ...

  • Miller Electric Welder - page 27

    OM-196 188 Page 21 System Reset By selecting system reset in the memory reset mode, the unit defaults to original factory settings for all programs and all set up excluding System, Arc Time, and Model T ype. V oltage (Control Feedback) Allows voltage to be monitored at the output terminals by two methods. This can be selected through the internal c ...

  • Miller Electric Welder - page 28

    OM-196 188 Page 22 4-4. Upper Front Panel Controls 1 Setup Pendant Receptacle Receptacle for connecting pendant interconnecting cord. 2 Jog Forward Push Button Advances wire out of the gun. 3 Wirefeed Indicator LED LED lights when wire feed motor is energized. 4 Jog Reverse Push Button Retracts wire up into the gun. 5 Gas Indicator LED LED lights w ...

  • Miller Electric Welder - page 29

    OM-196 188 Page 23 4-5. Duty Cycle And Overheating Duty Cycle is percentage of 10 min - utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. W ait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. Y Exceeding duty cycle can damage unit an ...

  • Miller Electric Welder - page 30

    OM-196 188 Page 24 4-7. Setup Pendant Controls 1 Increase Button W orks with security feature on welding power source to allow increasing weld parameter values within the allowable range. 2 Decrease Button W orks with security feature on welding power source to allow decreasing weld parameter values within the allowable range. 3 Parameter Select Bu ...

  • Miller Electric Welder - page 31

    OM-196 188 Page 25 SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. 3 Months Replace damaged or unreadable label. Repair or replace cracked cables. Replace cracked torch body . Repair or replace cracked cables and cords. 6 Months Clean and ...

  • Miller Electric Welder - page 32

    OM-196 188 Page 26 5-3. Removing Case and Measuring Input Capacitor V oltage Turn Of f welding power source, a n d disconnect input power . 1 Outside Handle Screws T o loosen top, remove two outside handle screws from both handles and all side bolts. 2 Interconnect Board PC2 3 V oltmeter Measure the dc voltage across th e screw terminals on PC2 as ...

  • Miller Electric Welder - page 33

    OM-196 188 Page 27 5-4. V oltmeter/Ammeter Help Displays . Al l directions are in reference to th e front of the unit. All circuitry referred to is located inside the unit. 1 Help 1 Display Indicates a malfunction in the primary power circuit. If this display is shown, contact a Factory Authorized Service Agent. 2 Help 2 Display Indicates a malfunc ...

  • Miller Electric Welder - page 34

    OM-196 188 Page 28 1 Memory CRC Error Display Corrupted program data has been detected or loaded. The “X” value indicates the pro- gram number . May be caused by incompatible information on the data card or bad memory . 2 Memory Range Error Display Improper welding power source range is selected. The “X” value indicates the pro- gram number ...

  • Miller Electric Welder - page 35

    OM-196 188 Page 29 1 W eld Interface Board PC12 Diagnostic LED’s are visible inside unit, located on PC12 (see illustration for board location). Refer to Section 5-7 for information on diagnostic LED’ s . Reinstall cover and left side panel after checking diagnostic LED’s. 191 842 1 5-6. W eld Interface Board PC12 Diagnostic LED’ s LED12 LE ...

  • Miller Electric Welder - page 36

    OM-196 188 Page 30 5-7. Diagnostic LED’ s On Weld Interface Board PC12 LED Status Diagnosis 1 On Indicates auxiliary output relay is not energized. Of f Indicates auxiliary output relay is energized. 2 On Indicates gas valve is not energized. Of f Indicates gas valve is energized. 3 On Indicates +24 volts dc is present for gas valve. Of f Indicat ...

  • Miller Electric Welder - page 37

    OM-196 188 Page 31 1 Customer Interface Board PC14 Diagnostic LED’s are visible inside unit, located on PC14 (see illustration for board location). Refer to Section 5-9 for information on diagnostic LED’ s . Reinstall top cover after checking diagnostic LED’s. 1 5-8. Customer Interface Board PC14 Diagnostic LED’ s LED1 LED6 LED3 LED2 LED4 L ...

  • Miller Electric Welder - page 38

    OM-196 188 Page 32 5-9. Diagnostic LED’ s On Customer Interface Board PC14 LED Status Diagnosis 1 On Indicates –15 volts dc RA supply is present on customer interface board PC14. 1 Of f Indicates –15 volts dc RA supply is not present on customer interface board PC14. 2 On Indicates +15 volts dc RA supply is present on customer interface board ...

  • Miller Electric Welder - page 39

    OM-196 188 Page 33 LED Diagnosis Status 23 On Input signal On from peripheral for jog advance. Of f Input signal Off from peripheral for no jog advance. 24 On Input signal On from peripheral for jog retract. Of f Input signal Off from peripheral for no jog retract. 25 On Input signal On from peripheral for shielding gas purge. 25 Of f Input signal ...

  • Miller Electric Welder - page 40

    OM-196 188 Page 34 5-1 1. Diagnostic LED’ s On Motor Board PC13 LED Status Diagnosis 1 On Indicates motor reverse relay is energized. Red Of f Indicates motor reverse relay is not energized. 2 On LED should be On. Indicates 1 15 volts ac input is sufficiently charging +170 volts dc bus for motor . Red Of f If LED is Of f, check 1 15 volts ac inpu ...

  • Miller Electric Welder - page 41

    OM-196 188 Page 35 Notes ...

  • Miller Electric Welder - page 42

    OM-196 188 Page 36 SECTION 6 – ELECTRICAL DIAGRAMS Figure 6-1. Circuit Diagram For Welding Power Source ...

  • Miller Electric Welder - page 43

    OM-196 188 Page 37 203 505-A ...

  • Miller Electric Welder - page 44

    OM-196 188 Page 38 Figure 6-2. Circuit Diagram For Control Board PC1 (Part 1 of 3) ...

  • Miller Electric Welder - page 45

    OM-196 188 Page 39 203 31 1 (1 of 3) ...

  • Miller Electric Welder - page 46

    OM-196 188 Page 40 Figure 6-3. Circuit Diagram For Control Board PC1 (Part 2 of 3) ...

  • Miller Electric Welder - page 47

    OM-196 188 Page 41 203 31 1 (2 of 3) ...

  • Miller Electric Welder - page 48

    OM-196 188 Page 42 Figure 6-4. Circuit Diagram For Control Board PC1 (Part 3 of 3) ...

  • Miller Electric Welder - page 49

    OM-196 188 Page 43 203 31 1 (3 of 3) ...

  • Miller Electric Welder - page 50

    OM-196 188 Page 44 Figure 6-5. Circuit Diagram For Function/Meter Board PC3 ...

  • Miller Electric Welder - page 51

    OM-196 188 Page 45 190 696 ...

  • Miller Electric Welder - page 52

    OM-196 188 Page 46 184 183 Figure 6-6. Circuit Diagram For Interconnect Board PC2 188 015 Figure 6-7. Circuit Diagram For Gate Boards PC4 And PC5 ...

  • Miller Electric Welder - page 53

    OM-196 188 Page 47 Notes ...

  • Miller Electric Welder - page 54

    OM-196 188 Page 48 Figure 6-8. Circuit Diagram For Interface Module ...

  • Miller Electric Welder - page 55

    OM-196 188 Page 49 193 709-A ...

  • Miller Electric Welder - page 56

    OM-196 188 Page 50 Figure 6-9. Circuit Diagram For Microprocessor Board PC1 1 ...

  • Miller Electric Welder - page 57

    OM-196 188 Page 51 191 838 ...

  • Miller Electric Welder - page 58

    OM-196 188 Page 52 Figure 6-10. Circuit Diagram For Motor Board PC13 ...

  • Miller Electric Welder - page 59

    OM-196 188 Page 53 212 354-A ...

  • Miller Electric Welder - page 60

    OM-196 188 Page 54 Figure 6-1 1. Circuit Diagram For Switch Board PC15 182 996 ...

  • Miller Electric Welder - page 61

    OM-196 188 Page 55 200 739 Figure 6-12. Circuit Diagram For Junction Board PC16 ...

  • Miller Electric Welder - page 62

    OM-196 188 Page 56 Figure 6-13. Circuit Diagram For Interface Board PC12 (Part 1 of 2) ...

  • Miller Electric Welder - page 63

    OM-196 188 Page 57 191 843-A (Part 1 of 2) ...

  • Miller Electric Welder - page 64

    OM-196 188 Page 58 Figure 6-14. Circuit Diagram For Interface Board PC12 (Part 2 of 2) ...

  • Miller Electric Welder - page 65

    OM-196 188 Page 59 191 843-A (Part 2 of 2) ...

  • Miller Electric Welder - page 66

    OM-196 188 Page 60 Figure 6-15. Circuit Diagram For Customer Interface Board PC14 (Part 1 of 3) ...

  • Miller Electric Welder - page 67

    OM-196 188 Page 61 Pensar 86147s03 (Part 1 of 3) ...

  • Miller Electric Welder - page 68

    OM-196 188 Page 62 Figure 6-16. Circuit Diagram For Customer Interface Board PC14 (Part 2 of 3) ...

  • Miller Electric Welder - page 69

    OM-196 188 Page 63 Pensar 86147s03 (Part 2 of 3) ...

  • Miller Electric Welder - page 70

    OM-196 188 Page 64 Figure 6-17. Circuit Diagram For Customer Interface Board PC14 (Part 3 of 3) ...

  • Miller Electric Welder - page 71

    OM-196 188 Page 65 Pensar 86147s03 (Part 3 of 3) ...

  • Miller Electric Welder - page 72

    OM-196 188 Page 66 Figure 6-18. Circuit Diagram For T ouch Sensor Board PC18 174 578-A ...

  • Miller Electric Welder - page 73

    OM-196 188 Page 67 200 739-A Figure 6-19. Circuit Diagram For Setup Pendant ...

  • Miller Electric Welder - page 74

    OM-196 188 Page 68 Figure 6-20. Circuit Diagram For Setup Pendant Centronix Junction Board PC3 200 739 ...

  • Miller Electric Welder - page 75

    OM-196 188 Page 69 191 531 Figure 6-21. Circuit Diagram For Power Distribution Board PC20 ...

  • Miller Electric Welder - page 76

    OM-196 188 Page 70 SECTION 7 – P ARTS LIST . Hardware is common and not available unless listed. 802 872-D 1 2 5 6 7 8 9 10 44 45 46 55 59 60 62 63 64 65 66 67 68 70 75 71 72 73 74 76 77 78 79 80 81 82 83 84 85 81 86 87 13 15 11 9 48 47 58 57 56 12 14 49 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 88 89 61 ...

  • Miller Electric Welder - page 77

    OM-196 188 Page 71 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Complete Assembly Quanti ty 1 185 970 COVER, top 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 195 585 HANDLE, carrying rubber 2 . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Welder - page 78

    OM-196 188 Page 72 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Complete Assembly (Continued) Quanti ty 47 T2 185 231 TRANSFORMER, control 200/400 V AC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RC10 166 679 HOUSING RECEPT ACLE PINS & SOCKETS 1 . . . . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Welder - page 79

    OM-196 188 Page 73 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Complete Assembly (Continued) Quanti ty 144 844 ST AND-OFF , No. 6-32 x .875 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 091 772 ST AND-OFF , No. 6-32 x .625 4 . . . . . . . . . . . . . . . . . . . . ...

  • Miller Electric Welder - page 80

    OM-196 188 Page 74 Notes ...

  • Miller Electric Welder - page 81

    Auto Invision II OM-196 188K July 2003 Programming Instructions for ...

  • Miller Electric Welder - page 82

    OM-196 188 Page 76 SECTION 8 – INTRODUCTION TO PROGRAMMING The interface unit is designed for us e in pulse MIG welding (adaptive or standard), or MIG welding. The unit is factory-equipped with eight programs for pulse MIG welding. The unit also provides memory for the creation of up to eight MIG programs (see Section 1 1). Th e weld programs req ...

  • Miller Electric Welder - page 83

    OM-196 188 Page 77 8-3. Program 1 – 1.2 mm Steel (.045”), 98-2 Argon-Oxy Wire Size/T ype: 1.2 mm (.045”) Steel Gas: Ar - Oxy / 19 L/min (40 CFH) MPM / IPM Apk Abk PPS PWms Vpk COMMENTS 19.1 / 750 540 159 263 3.1 34.5 17.8 / 700 530 150 250 3.0 33.9 16.5 / 650 520 141 237 2.9 33.3 15.2 / 600 510 133 225 2.9 32.7 14.0 / 550 500 124 212 2.8 32.0 ...

  • Miller Electric Welder - page 84

    OM-196 188 Page 78 8-5. Program 3 – 1.2 mm Steel (.045”), 80-20 Argon-CO 2 Wire Size/T ype: 1.2 mm (.045”) Steel Gas: Ar - CO 2 / 19 L/min (40 CFH) MPM / IPM Apk Abk PPS PWms Vpk COMMENTS 19.1 / 750 570 134 246 2.9 41.2 17.8 / 700 560 130 235 2.9 40.6 16.5 / 650 550 126 224 2.9 40.0 15.2 / 600 540 123 213 2.9 39.5 14.0 / 550 530 11 9 201 2.8 ...

  • Miller Electric Welder - page 85

    OM-196 188 Page 79 8-7. Program 5 – 1.0 mm 316 (.040”), 98-2 Argon-CO 2 Wire Size/T ype: 1.0 mm (.040”) 316 Gas: Ar - CO 2 / 19 L/min (40 CFH) MPM / IPM Apk Abk PPS PWms Vpk COMMENTS 19.1 / 750 443 144 183 2.6 34.0 17.8 / 700 425 130 175 2.5 33.8 16.5 / 650 407 11 6 167 2.4 33.6 15.2 / 600 390 103 160 2.3 33.4 14.0 / 550 372 89 152 2.2 33.1 1 ...

  • Miller Electric Welder - page 86

    OM-196 188 Page 80 8-9. Program 7 – 1.0 mm 308L (.040”), 98-2 Argon-CO 2 Wire Size/T ype: 1.0 mm (.040”) 308L Gas: Ar - CO 2 / 19 L/min (40 CFH) MPM / IPM Apk Abk PPS PWms Vpk COMMENTS 19.1 / 750 436 120 183 2.5 34.2 17.8 / 700 425 11 5 175 2.4 33.7 16.5 / 650 414 11 0 167 2.3 33.2 15.2 / 600 403 105 160 2.3 32.7 14.0 / 550 391 100 152 2.2 32 ...

  • Miller Electric Welder - page 87

    OM-196 188 Page 81 8-1 1. Program 1 – 1.2 mm Metal Core (.045”), 95-5 Argon-CO 2 The next 8 programs are available after changing software wiretype (see Section 14-10). Note Wire Size/T ype: 1.2 mm (.045”) Metal Core Gas: Ar - CO 2 / 19 L/min (40 CFH) MPM / IPM Apk Abk PPS PWms Vpk COMMENTS 19.1 / 750 525 160 21 1 2.9 31.6 17.8 / 700 515 155 ...

  • Miller Electric Welder - page 88

    OM-196 188 Page 82 8-13. Program 3 – 1.2 mm ER 4043 (.045”), Argon Wire Size/T ype: 1.2 mm (.045”) ER 4043 Gas: Ar / 19 L/min (40 CFH) MPM / IPM Apk Abk PPS PWms Vpk COMMENTS 17.9 / 705 492 160 190 2.9 31.6 17.8 / 700 490 160 190 2.9 31.5 16.5 / 650 451 167 195 2.8 30.1 15.2 / 600 412 174 200 2.8 28.8 14.0 / 550 373 180 205 2.7 27.4 12.7 / 50 ...

  • Miller Electric Welder - page 89

    OM-196 188 Page 83 8-15. Program 5 – 1.0 mm 5356 (.040”), Argon Wire Size/T ype: 1.0 mm (.040”) 4043 Gas: Ar / 19 L/min (40 CFH) MPM / IPM Apk Abk PPS PWms Vpk COMMENTS 18.6 / 735 410 75 156 1.3 27.0 18.5 / 730 410 75 156 1.3 27.0 17.7 / 695 407 69 152 1.3 26.9 16.9 / 665 405 64 148 1.3 26.8 16.1 / 630 402 58 144 1.3 26.6 15.2 / 600 400 52 14 ...

  • Miller Electric Welder - page 90

    OM-196 188 Page 84 8-17. Program 7 – .8 mm Steel (.030”), 98-2 Argon-Oxy Wire Size/T ype: .8 mm (.30”) Steel Gas: Ar - Oxy / 19 L/min (40 CFH) MPM / IPM Apk Abk PPS PWms Vpk COMMENTS 19.7 / 775 384 121 143 2.0 33.9 17.8 / 700 375 11 0 135 1.9 33.6 15.9 / 625 366 99 127 1.8 33.3 14.0 / 550 358 88 120 1.7 33.0 12.1 / 475 349 76 11 2 1.6 32.6 10 ...

  • Miller Electric Welder - page 91

    OM-196 188 Page 85 8-19. Setup Pendant Mode Select Button 1 Mode Disp l a y 2 Mode Select Button Press Mode Select button to move indicator in left window display . Go to Section 8-20. Ref. 154 109 > Process Sequence SharpArc Card Process > Sequence SharpArc Card 1 2 > Prg 1 Pulse 035” Steel Argon – Oxy ...

  • Miller Electric Welder - page 92

    OM-196 188 Page 86 Ref. 154 109 1 Parameter Displ a y 2 Moving Line Moving line is under value that can be changed. 3 Pulse Panel Parameter Select Button Press pulse panel parameter select button to move indicator in right win- dow display . 1 > Process Sequence SharpArc Card > Prg 1 Pulse 035” Steel Argon – Oxy 2 3 Prg 1 > Pulse 035? ...

  • Miller Electric Welder - page 93

    OM-196 188 Page 87 Ref. 154 109 Use mode select button to select mode to b e changed (see 8-19). Use pulse panel parameter select button to select parameter to be changed (see 8-20). 1 Increase Button Press button to increase value that is underlined by the moving line. 2 Decrease Button Press button to decrease value that is underlined by the movi ...

  • Miller Electric Welder - page 94

    OM-196 188 Page 88 SECTION 9 – GETTING ST ARTED FOR PULSE WELDING Ref. S-0271 9-1. W eld Cycle For Pulse Welding Wire Speed W eld Start Start Power Start Speed Preflow T ime Arc Strike W eld Speed W eld T ime W eld Stop Crater Time Crater Speed Arc Out Retract Time Postflow T ime T ime Run-In Setting Robot Motion . The type of robot connected det ...

  • Miller Electric Welder - page 95

    OM-196 188 Page 89 9-3. Setting W eld Sequence Display 1 W eld Parameters Display Parameter ranges are as follows: Trim (Arc Length), 0-99 Wire Feed Speed, 50-780 Inches Per Minute, IPM Go to Section 9-4. W eld 60 Trim > 200 IPM > W eld 60 Trim 300 IPM 1 W eld >5 0 T rim 200 IPM Increase/ Decrease Set Desired Weld Sequence Trim Parameter S ...

  • Miller Electric Welder - page 96

    OM-196 188 Page 90 9-5. Setting Postflow Sequence Display 1 Postflow Parameters Display Postflow can be adjusted from 0-9.9 seconds. If value set is zero (0), there is no Postflow sequence. 1 > Poflw 0.0 Sec Poflw > 0.0 Sec > Poflw 1.2 Sec Parameter Select Parameter Select Set Desired Time Increase/ Decrease Increase Proceed to next Sectio ...

  • Miller Electric Welder - page 97

    OM-196 188 Page 91 The teach mode allows the user to create custom pulse MIG welding programs. The teach mode has 15 teach points. At each teach point, the user can adjust five parameters: peak amperage (Apk), back- ground amperage (Abk), pulses per second (PPS), pulse width in milliseconds (PWms), and peak voltage (Vpk) to shape the pulse waveform ...

  • Miller Electric Welder - page 98

    OM-196 188 Page 92 10-3. Selecting T each Point Wire Feed Speed For Pulse Welding Program 1 Process Di s p l a y When unit is first turned On, Process is the default screen, at other times use mode select button to select Process. 2 T each Display Use parameter select button to select T each. Use increase/decrease buttons to select O n . 3 IPM (T e ...

  • Miller Electric Welder - page 99

    OM-196 188 Page 93 Pulse 035” Steel Argon – Oxy > T each Of f When the Process T each mode is On, and one of the following pulse parameters is se- lected: Apk, Abk, PPS, PWms, or Vpk, the pulse panel displays the selected pulse pa- rameter instead of Trim (arc length). When the pulse parameter is selected, the value ca n be changed with the ...

  • Miller Electric Welder - page 100

    OM-196 188 Page 94 Make copies of this chart for future use. NOTE Program # Wire Size/T ype Gas Program Name Card # Gun Model Flowrate CFH IPM Apk Abk PPS PWms Vpk COMMENTS Preflow: Sec. Run-In T rim: IPM: Sec.: Crater T rim: IPM: Sec.: Postflow: Sec. ...

  • Miller Electric Welder - page 101

    OM-196 188 Page 95 > Process Sequence SharpArc Card Prg 1 > Adapt Pulse 035” Steel Argon – Oxy W elding parameters are the same for both a Pulse and an Adaptive Pulse welding program. While welding adaptively , the unit uses feedback to attempt to maintain a constant arc length. T o change to Adaptive Pulse welding, proceed as shown: 1 Se ...

  • Miller Electric Welder - page 102

    OM-196 188 Page 96 1 Setup Pendant Display Default display when unit is first turned On, at other times use mode select button to select Process. Go to Section 1 1-3. 1 > Process Sequence SharpArc Card > Process Sequence SharpArc Card > Process Sequence SharpArc Card Prg 1 > MIG 1 1-2. Changing T o Mig Welding Mode Select Parameter Sele ...

  • Miller Electric Welder - page 103

    OM-196 188 Page 97 1 Start Parameters Display Parameter ranges are as follows: Seconds, 0-2.5 Sec. If value set is zero (0), there is no Run-In se- quence. With zero (0) time value, programmed values for volts and wire feed speed are used until a val- id arc condition is detected. V olts, 10.0-38.0 V olts Wire Feed Speed, 50-780 inches per minute, ...

  • Miller Electric Welder - page 104

    OM-196 188 Page 98 1 Crater Parameters Display Parameter ranges are as follows: Seconds, 0-2.50 Sec. If value set is zero (0), there is no Crater sequence. V olts, 10.0-38.0 V olts. Wire Feed Speed, 50 to 780 inches per minute, IPM. Go to Section 1 1-7. > Cratr 0.02 Sec 24.0 V ol t 90 IPM Cratr 0.12 Sec > 18.0 V olt 90 IPM Cratr 0.12 Sec 18.0 ...

  • Miller Electric Welder - page 105

    OM-196 188 Page 99 1 Postflow Parameters Display Postflow can be adjusted from 0-9.9 seconds. If value set is zero (0), there is no Postflow sequence. 1 > Poflw 0.0 Sec Poflw > 0.0 Sec > Poflw 1.2 Sec 1 1-8. Setting Postflow Sequence Display Set Desired T ime Parameter Select Increase/ Decrease Parameter Select . Run-in parameters are not ...

  • Miller Electric Welder - page 106

    OM-196 188 Page 100 SECTION 12 – SETTING SharpArc E CONTROL 12-1. Selecting And Adjusting SharpArc E Control 1 SharpArc SharpArc  is used to adjust arc cone width and arc characteristics. Use mode select button to move > to select SharpArc. Use Display Control to adjust Arc setting. SharpArc  setting range is from 0 to 20. The factory de ...

  • Miller Electric Welder - page 107

    OM-196 188 Page 101 SECTION 13 – USING THE OPTIONAL DA T A CARD 1 Label Peel backing from label and apply to data card with THIS SIDE UP by metal pins. W rite the names of the programs stored on the card on the label. W rite the name of the piece of equipment the card is used with on the label. 2 Data Card 3 Card Slot Insert card into slot. T o f ...

  • Miller Electric Welder - page 108

    OM-196 188 Page 102 Use Mode Select button to select Card. 1 Card Display 2 W rite Used t o transfer program data from unit to card. The program card can hold up to 32 programs. When writing to the card, the next available program number is automatically assigned. 3 Read Used t o transfer program data from card t o unit. 4 Delete Used to delete pro ...

  • Miller Electric Welder - page 109

    OM-196 188 Page 103 13-3. Naming Programs And Writing T o Card All program types (Pulse, Adaptive Pulse, and MIG) can be stored on a data card and retrieved. Setup and Control menus do not save to the card. NOTE 1 Card Display Use Mode Select button to select Card. 2 Moving Line Moving line is under value that can be changed. Use increase or decrea ...

  • Miller Electric Welder - page 110

    OM-196 188 Page 104 13-4. Reading From Card Programs developed on the Auto Invision will not run the same on Auto Invision II. NOTE Use Mode Select button to select Card. 1 Card Display 2 Moving Line Moving line is under value that can be changed. Use increase or decrease button to select program number to read from card to feeder . 3 Read Display ...

  • Miller Electric Welder - page 111

    OM-196 188 Page 105 1 W arning Display If there are no programs on the card, t h i s s e r i e s o f displays appear . W rite > Read Delete Done W ARNING: Card Empty Press Below W rite Read Delete > Done Press >Process Sequence SharpArc Card > Prg 2 MIG 1 13-5. Reading (Or Deleting) From An Empty Card Parameter Select Parameter Select O ...

  • Miller Electric Welder - page 112

    OM-196 188 Page 106 13-7. Selecting Security Lock Security lock works only when a data card is inserted. NOTE 1 Security Display Us e this display to lock a program’s weld parameters so that changes ca n not be made using pulse panel controls. 2 Program Number Choose the program number (1 through 8) to be locked. 3 Program Lock Display When lock ...

  • Miller Electric Welder - page 113

    OM-196 188 Page 107 SECTION 14 – SETUP 14-1. Setup Flow Chart >Memory No Reset No Re set 14-12 Program Reset System Reset T otal Reset >Wiretype Wire T ype Hardwire/ Hardwire 14-10 Softwire >Arc Start Arc Start Standard Standard 14-7 T ype Hot Start Soft Start >Monitor Arc V olts Of f/On Of f 14-19 Range 0.1 - 9.9 2.0 V olts Sec 0.1 - ...

  • Miller Electric Welder - page 114

    OM-196 188 Page 108 1 Front Panel Setup Display Front panel display during setup. 2 Pulse Panel Mode And Parameter Select Buttons 3 Power Switch On Rear Panel Press and hold down both buttons while turning On unit. 4 Setup Pendant Display Follow this procedure any time access is required. Once in the set- up displays, use the Mode Select button to ...

  • Miller Electric Welder - page 115

    OM-196 188 Page 109 14-3. Selecting Or Changing Access Code Access code works only when a data card is inserted (see Section 13). NOTE 1 Code Display With code off, access to the setup displays is not restricted. With code on, the operator must know and enter the access code to access or change any of the setup displays. 2 Access Display With a cod ...

  • Miller Electric Welder - page 116

    OM-196 188 Page 1 10 1 Mig T ype Display With DVC V oltage Correction On, the unit uses closed-loop feedback or voltage sensing leads to maintain set voltage parameters. With DVC V oltage Correction Off, feedback from the arc is not used for closed-loop feedback to maintain voltage parameters. Feedback from the arc is still used for other functions ...

  • Miller Electric Welder - page 117

    OM-196 188 Page 1 1 1 14-7. Selecting Arc Start Method Arc Start selection is not used when welding in non-pulsed MIG. Do not use the Hot Start setting for .035 in (9 mm) or smaller wire. NOTE ArcStart T ype > Hot Start 1 Standard Start W elding operation is performed at set values for welding parameters. 2 Hot Start Use the Hot Start mode for p ...

  • Miller Electric Welder - page 118

    OM-196 188 Page 1 12 1 Wire Feed Display The displayed unit of wire speed (IPM or MPM) can be changed along with the wire feed motor type (Standard, Low Speed, or High Speed). ArcStart Arc T ime > Wirefeed Wiretype Display > IPM Motor T yp e Standard Display > MPM Motor T yp e Standard 1 Display IPM Motor T yp e > Standard Display IPM M ...

  • Miller Electric Welder - page 119

    OM-196 188 Page 1 13 14-10. Selecting Wire T ype If wire type is changed, perform a system reset (see Section 14-12) immediately after selecting wire type to bring up the correct welding programs. NOTE 1 Wire T ype Display Select soft wire when using aluminum wire in the wire feeder . Select hard wire when using any other kind of wire. Wire T ype & ...

  • Miller Electric Welder - page 120

    OM-196 188 Page 1 14 1 No Reset Press Parameter Select button to exit memory reset parameter with- out resetting any data. 2 Program Reset Press Parameter Select button to reset last active program to original factory program settings. All other program and setup information remains the same. If setup card is in card slot, program will be loaded fr ...

  • Miller Electric Welder - page 121

    OM-196 188 Page 1 15 1 Name Display When a data card is used, the pro- grams written from the unit to the card can be named. Memory Shutdown > Name Program Card Programs >O n Card Programs >O f f 1 14-14. Selecting Program Name Feature Press Mode Select Increase Access Setup Display 14-15. Remote Program Select 1 Program Display When Progr ...

  • Miller Electric Welder - page 122

    OM-196 188 Page 1 16 1 Jog IPM Display Jog wire feed speed can be varied between 50 and 780 inches per minute, IPM. When not welding, a Robot Jog local setting will jog wire at the Local Jog ipm setting, even if robot pro- vides wire jog signal. A Robot Jog remote setting requires that the robot provide a jog command and jog speed signal. Auxiliary ...

  • Miller Electric Welder - page 123

    OM-196 188 Page 1 17 1 Monitor Display Provides a means to enable/dis- able the arc voltage error feature and to set an acceptable range of deviation from set arc voltage or arc length ( trim) before the error will ac- tuate. When this feature is off, arc voltage or arc length variations will not cause an error or shut the unit down. When this feat ...

  • Miller Electric Welder - page 124

    OM-196 188 Page 1 18 1 Ramps Display The ramps function allows output power to be tapered from start to weld and/or from weld to crater . 2 Program Number Choose the desired program num- b er (1 through 8). T urns start and/or crater ramping On or Off a s desired. 3 Start Display T urns start ramping On or Of f as de- fined. 4 Crater Display T urns ...

  • Miller Electric Welder - page 125

    OM-196 188 Page 1 19 SECTION 15 – CONTROL MENU The control menu allows the user access to rise time setting that controls rise and fall time of the pulse square wave. Changing the rise time setting changes the square wave shape by rounding off the corners, and makes it possible to quiet the pulse arc by just changing the rise time. 1 Front Panel ...

  • Miller Electric Welder - page 126

    OM-196 188 Page 120 15-2. Setting Rise T ime Parameter Maximum Rise Time setting will make the welding power source go to its maximum output in the maximum amount of time (1250 amperes per millisecond). NOTE 1 Rise Time Display Setting is depend on desired arc characteristics. Make a sample weld after each setting until desired arc characteristics ...

  • Miller Electric Welder - page 127

    OM-196 188 Page 121 15-4. Setting Auto Configure Parameter 1 Auto Configure Display Setting allows user to do manual configuration or automatic configuration by welding power source/interface. Us e Increase or Decrease button to change setting. Press Mode Select button to go to next parameter or cycle power of f an d back on at power switch to sav- ...

  • Miller Electric Welder - page 128

    OM-196 188 Page 122 15-5. Setting Retract On/Off 1 Retract Display Settings allow user to turn the re- tract feature On or Of f. The retract feature allows the user to set a time and wire feed speed to pull wire away from work when the weld is done. Us e Increase or Decrease button to change setting. If the retract feature is turned On, a weld sequ ...

  • Miller Electric Welder - page 129

    OM-196 188 Page 123 1 Exit Control Menu Display Allows the user to leave the control menu. 1 AutoConfig Retract ShrpStrt > Exit Exit Cntrl Menu Now Press 15-7. Exiting The Control Menu Access Control Display Press Mode Select ...

  • Miller Electric Welder - page 130

    ...

  • Miller Electric Welder - page 131

    Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 6/03 Y o ur distributor also gives you ... Service Y ou 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 ...

  • Miller Electric Welder - page 132

    PRINTED IN USA  2003 Miller Electric Mfg. Co. 1/03 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Company 1635 W es t Spencer St reet Applet on, W I 5 4914 USA International He adquarte rs–USA USA Phone: 920-735-4505 Auto-A t t ended USA & C anada F A X: 920-735-4134 Int ernational F A X : 9 20-735-4125 European Headquarte rs – Un ...

Manufacturer Miller Electric Category Welding System

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A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Miller Electric Welder by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Miller Electric Welder.

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