Miller COPILOT COLLABORATIVE WELDING SYSTEM Owners manual

OM-291865A

Processes

MIG (GMAW) Welding
Pulsed MIG (GMAW-P) Welding

Description

Collaborative Robotic Welding System

2023-02

Copilot™Collaborative

Welding System

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

OWNER’S MANUAL

Introduction

Miller Copilot is a portable Collaborative Arc Welding System. The system is
designed to meet applicable North American safety standards listed in the
specifications section of this manual. The system includes a Miller Cobot, controller,
welding power source and welding torch all integrated onto a unified cart, ready for
you to connect power, gas, and wire.

Intended Use Of Miller Copilot

Miller collaborative arc welding systems have been designed for safe operation in a
collaborative production environment. This Collaborative Robot (Cobot) has been
designed to provide you the repetitive precision and endurance of robots, while
working in the same workspace, side by side with the individual skills and ability of
people. To achieve this capability, the safety related control system is designed to
control key parameters such as speed and force to ensure safe operation in the
shared workspace.

The system has a single, fixed cobot workspace shared with and contained within a
larger, single operator workspace.

Working as hard as you do −
every power source from
Miller is backed by the most
hassle-free warranty in the
business.

The cobot performs weld process production tasks on the materials that are loaded
and unloaded by an operator.

During normal production tasks, there is the potential for direct interaction between
the cobot and the operator, however, unintentional direct interaction is possible due
to a lack of a physical barrier separating the cobot workspace from that of the
production personnel. As such, the cobot can only operate under power and force
limited control at slower speeds in accordance with ISO/TS 15066:2016 thereby
reducing risk of unintended contact between the cobot and production personnel.

Miller collaborative arc welding systems are manufactured and shipped as
unapplied welding systems. These systems are designed for welding related
applications. Miller Welding Automation (MWA) has made an assessment to identify
the tasks associated with these applications. These tasks are considered in this risk
assessment at the end of this manual.

Important: Tooling, fixtures, and other equipment added to the robotic cell
after delivery may change the type and number of hazards present in and
around the cobot system. A review of the safety and another risk assessment
must be made after installation of any additional equipment to the robotic cell.

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1 Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-2 Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-3 Additional Hazards For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1-4 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1-5 California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1-6 Principal Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1-7 EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2-1 Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2-2 Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2-3 Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . 8

2-4 Maintenance et réparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2-5 Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2-6 Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2-7 Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 3 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3-1 Additional Safety Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3-2 Miscellaneous Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 4 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4-1 Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4-2 Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4-3 Information About Default Weld Parameters And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4-4 Cobot System Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4-5 System Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4-6 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4-7 Table Platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SECTION 5 – INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5-1 Moving The System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5-2 Cobot Installation Site Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5-3 Leveling The System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5-4 Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5-5 Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5-6 Connecting 120 VAC Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5-7 Shielding Gas And Cooler Connections (CE Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5-8 Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

SECTION 6 – CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6-1 Operation Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6-2 Signal Light Tower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6-3 Puck Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6-4 Moving The Cobot With The Joystick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

SECTION 7 – SAFETY DEVICES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7-1 Operator Station Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7-2 Teach Pendant Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7-3 Lockout/Tagout Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

SECTION 8 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8-1 Powering Up The System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8-2 Logging In To The System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8-3 System Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8-4 Inputs And Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8-5 Auto Mode Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

SECTION 9 – TEACHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9-1 Teach Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9-2 Pre-Teaching Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

SECTION 10 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

SECTION 11 – RISK ASSESSMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

SECTION 12 – WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING

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.

F

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 Principal Safety Standards. 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 the
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.

cuits 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.

l Do not touch live electrical parts.
l Wear dry, hole-free insulating gloves and body protection.
l Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work
or ground.

l Do not use AC weld output in damp, wet, or confined spaces, or if

there is a danger of falling.

l Use AC output ONLY if required for the welding process.
l If AC output is required, use remote output control if present on

unit.

l Additional safety precautions are required when any of the follow-

ing 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

The input power circuit and machine internal cir-

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 these hazards.

(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!

l Disconnect input power or stop engine before installing or servic-

ing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).

l Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

l 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.

l When making input connections, attach proper grounding conduc-

tor first—double-check connections.

l Keep cords dry, free of oil and grease, and protected from hot met-

al and sparks.

l Frequently inspect input power cord and ground conductor for

damage or bare wiring — replace immediately if damaged — bare
wiring can kill.

l Turn off all equipment when not in use.
l Do not use worn, damaged, undersized, or repaired cables.
l Do not drape cables over your body.
l If earth grounding of the workpiece is required, ground it directly

with a separate cable.

l Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

l Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

l Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

l Wear a safety harness if working above floor level.
l Keep all panels and covers securely in place.
l Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

l Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

l Do not connect more than one electrode or work cable to any sin-

gle weld output terminal. Disconnect cable for process not in use.

l Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

OM-291865 Page 1

HOT PARTS can burn.

l Do not touch hot parts bare handed.
l Allow cooling period before working on equipment.
l To handle hot parts, use proper tools and/or wear

heavy, insulated welding gloves and clothing to

prevent burns.

FLYING METAL OR DIRT can injure

eyes.

l Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool, they
can throw off slag.

l Wear approved safety glasses with side shields even under your

welding helmet.

FUMES AND GASES can be

hazardous.

Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.

l Keep your head out of the fumes. Do not breathe the fumes.
l 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.

l If ventilation is poor, wear an approved air-supplied respirator.
l Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners, con­sumables, coolants, degreasers, fluxes, and metals.

l Work in a confined space only if it is well ventilated, or while wear-

ing 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.

l 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.

l Do not weld on coated metals, such as galvanized, lead, or cadmi-

um 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.

BUILDUP OF GAS can injure or kill.

l Shut off compressed gas supply when not in use.
l Always ventilate confined spaces or use approved

air-supplied respirator.

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.

l Wear an approved welding helmet fitted with a proper shade of fil-

ter 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).

l Wear approved safety glasses with side shields under your

helmet.

l Use protective screens or barriers to protect others from flash,

glare, and sparks; warn others not to watch the arc.

l Wear body protection made from leather or flame-resistant cloth-

ing (FRC). Body protection includes oil-free clothing such as leath­er gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

OM-291865 Page 2

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.

l Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

l Do not weld where flying sparks can strike flammable material.
l Protect yourself and others from flying sparks and hot metal.
l Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

l Watch for fire, and keep a fire extinguisher nearby.
l Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

l 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.

l 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 (see Safety Standards).

l Do not weld where the atmosphere can contain flammable dust,

gas, or liquid vapors (such as gasoline).

l 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.

l Do not use welder to thaw frozen pipes.
l Remove stick electrode from holder or cut off welding wire at con-

tact tip when not in use.

l Wear body protection made from leather or flame-resistant cloth-

ing (FRC). Body protection includes oil-free clothing such as leath­er gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

l Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

l After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

l Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

l Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

l Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners, con­sumables, coolants, degreasers, fluxes, and metals.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

l Wear approved ear protection if noise level is high.

ELECTRIC AND MAGNETIC FIELDS
(EMF) can affect Implanted Medical
Devices.

l Wearers of Pacemakers and other Implanted Med-

ical Devices should keep away.

l 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.

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 weld-

ing process, be sure to treat them carefully.

l Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

l Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

l Keep cylinders away from any welding or other electrical circuits.
l Never drape a welding torch over a gas cylinder.
l Never allow a welding electrode to touch any cylinder.

l Never weld on a pressurized cylinder—explosion will result.
l Use only correct compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them
and associated parts in good condition.

l Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the
valve.

l Keep protective cap in place over valve except when cylinder is in

use or connected for use.

l Use the proper equipment, correct procedures, and sufficient

number of persons to lift, move, and transport cylinders.

l Read and follow instructions on compressed gas cylinders, asso-

ciated equipment, and Compressed Gas Association (CGA) publi­cation P-1 listed in Safety Standards.

1-3. Additional Hazards For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

l Do not install or place unit on, over, or near com-

bustible surfaces.

l Do not install unit near flammables.
l Do not overload building wiring — be sure power

supply system is properly sized, rated, and protected to handle
this unit.

FALLING EQUIPMENT can injure.

l Use lifting eye to lift unit only, NOT running gear,

gas cylinders, or any other accessories.

l Use correct procedures and equipment of ad-

equate capacity to lift and support unit.

l If using lift forks to move unit, be sure forks are long enough to ex-

tend beyond opposite side of unit.

l Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

l 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.

l Allow cooling period; follow rated duty cycle.
l Reduce current or reduce duty cycle before start-

ing to weld again.

l Do not block or filter airflow to unit.

FLYING SPARKS can injure.

l Wear a face shield to protect eyes and face.
l Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper
face, hand, and body protection.

l Sparks can cause fires—keep flammables away.

STATIC (ESD) can damage PC

boards.

l Put on grounded wrist strap BEFORE handling

boards or parts.

l Use proper static-proof bags and boxes to store,

move, or ship PC boards.

MOVING PARTS can injure.

l Keep away from moving parts.

l Keep away from pinch points such as drive rolls.

WELDING WIRE can injure.

l Do not press gun trigger until instructed to do so.

l Do not point gun toward any part of the body, other

people, or any metal when threading welding wire.

BATTERY EXPLOSION can injure.

l 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.

l Keep away from moving parts such as fans.
l Keep all doors, panels, covers, and guards closed

and securely in place.

l Have only qualified persons remove doors, panels,
covers, or guards for maintenance and troubleshooting as
necessary.

l Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

l 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.

l Use only genuine replacement parts from the manufacturer.
l Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and lo­cal codes.

H.F. RADIATION can cause

interference.

l High-frequency (H.F.) can interfere with radio navi-

gation, safety services, computers, and communi­cations equipment.

l Have only qualified persons familiar with electronic equipment per-

form this installation.

l The user is responsible for having a qualified electrician promptly

correct any interference problem resulting from the installation.

l If notified by the FCC about interference, stop using the equipment

at once.

l Have the installation regularly checked and maintained.
l 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.

OM-291865 Page 3

ARC WELDING can cause

interference.

l Electromagnetic energy can interfere with sensitive

electronic equipment such as microprocessors,
computers, and computer-driven equipment such

as robots.

l Be sure all equipment in the welding area is electromagnetically

compatible.

1-4. Maintenance and Repair

l To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

l Locate welding operation 100 meters from any sensitive electronic

equipment.

l Be sure this welding machine is installed and grounded according

to this manual.

l 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.

MAINTENANCE and REPAIR WORK
must follow all safety instructions in
this manual.

Maintenance, calibration, and repair work must be
performed in accordance with the latest versions of

Service Manuals.

Follow all regional and national safety requirements and always test
whether all safety functions work properly.

Prior to operating the Cobot manipulator or control box, please follow
the procedures and warnings below:

l Before performing maintenance, follow lockout/tag out

procedures.

l Remove the main input power cable from the control box to ensure

the power is off.

l Check the grounding connection before switching on the power of

the Cobot system.

1-5. 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.

1-6. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org.

Safe Practice For Occupational And Educational Eye And Face Pro­tection, ANSI Standard Z87.1, from American National Standards In-

stitute. Website: www.ansi.org.

Safe Practices for the Preparation of Containers and Piping for Weld­ing and Cutting, American Welding Society Standard AWS F4.1.

Website: http://www.aws.org.

National Electrical Code, NFPA Standard 70 from National Fire Pro­tection Association. Website: www.nfpa.org.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P­1 from Compressed Gas Association. Website: www.cganet.com.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www.

csagroup.org.

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.

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. Website:

www.osha.gov.

OSHA Important Note Regarding the ACGIH TLV, Policy Statement

on the Uses of TLVs and BEIs. Website: www.osha.gov.

Applications Manual for the Revised NIOSH Lifting Equation from the

National Institute for Occupational Safety and Health (NIOSH). Web­site: www.cdc.gov/NIOSH.

OM-291865 Page 4

l Observe ESD (Electro-Static Discharge) procedures when parts

of the Cobot manipulator or control box are disassembled.

l There are no serviceable parts in the controller. If service is re-

quired, please contact Miller Electric.

l Avoid disassembling the power supply connections located inside

the controller. High voltages can be present at the power supply
connections for several hours after the control box has been
switched off.

l Prevent water and dust from entering the Cobot manipulator or

controller.

l Changing torch weight can affect force limits, which can cause in-

jury. Contact Miller Welding Automation Service to determine
safety settings before changing torch weight.

l Reactivate any deactivated safety measures immediately after

maintenance work is completed.

l Document all maintenance operations completed and save for fu-

ture reference.

For more information, go to www.P65Warnings.ca.gov.

American National Standard for Industrial Robots and Robot Systems
– Safety Requirements, ANSI/RIA R15.06-2012, Robotic Industries

Association. Website: www.robotics.org.

Robotic Industries Association Technical Report – supplement to AN­SI/RIA R15.06-2012, RIA TR 15.406-2014, Robotic Industries Associ-

ation. Website: www.robotics.org.

Technical Report for Industrial Robots and Robot Systems – Safety
Requirements, Task-based Risk Assessment Methodology, RIA TR

R15.306-2014. Website: www.robotics.org.

Electrical Standard for Industrial Machinery, NFPA Standard 79, from
National Fire Protection Association. Website: www.nfpa.org.

Safety Standard for Robots and Robotic Equipment, UL 1740. Web­site:www.ulstandards.ul.com.

Industrial robots and robot systems, CAN/CSA-Z434, Canadian
Standards Association (CSA). Website: www.csa.ca.

Technical Specification Robots and Robotic Devices- Collaborative
Robots, ISO/TS 15066:2016.

Safety of Machinery – General Principles for Design – Risk Assess­ment and Risk Reduction, ISO 12100:2010.

Robots and Robotic Devices – Safety Requirements– Part 2: Industri­al Robot Systems and Integration, ISO 10218-2:2011.

Safety of Machinery; General Requirements & Risk Assessment, AN-

SI B11.0-2010.

Low-voltage switchgear and controlgear – Part 5-5: Control circuit de­vices and switching elements – Electrical emergency stop device with
mechanical latching function, IEC 60947-5-5.

Cobot System 2023–02

1-7. 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.

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.

OM-291865 Page 5

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT

UTILISATION

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.

F

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 ce symbole, prendre garde et suivre
les instructions afférentes pour éviter tout risque. Les
consignes de sécurité présentées ci-après ne font que résu­mer l’information contenue dans les Normes de sécurité
principales. Lire et suivre 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.

Au cours de l’utilisation, tenir toute personne à l’écart et
plus particulièrement les enfants.

UNE DÉCHARGE ÉLECTRIQUE peut

entraîner la mort.

Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures

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.

l Ne pas toucher aux pièces électriques sous tension.
l Porter des gants isolants et des vêtements de protection secs et

sans trous.

l 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.

l Ne pas utiliser de sortie de soudage CA dans des zones humides

ou confinées ou s’il y a un risque de chute.

l Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

l 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.

l D’autres consignes de sécurité sont nécessaires dans les condi-

tions suivantes : risques électriques dans un environnement hu­mide ou si l’on porte des vêtements mouillés ; sur des structures

OM-291865 Page 6

graves. Le circuit de l’électrode et de la pièce est

Ce groupe de symboles veut dire Avertissement! Attention! DAN­GER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIE­CES CHAUDES. Reportez-vous aux symboles et aux directives ci­dessous afin de connaître les mesures à prendre pour éviter tout
danger.

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, l’utilisation d’un poste à souder DC à fil à tension constante
est recommandée. En outre, ne pas travailler seul !

l 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).

l Brancher correctement la mise à la terre et utiliser cet appareil

conformément à son manuel d’utilisateur et aux codes nationaux,
provinciaux et municipaux.

l Toujours vérifier la mise à la terre — vérifier et assurez-vous que

le conducteur de mise à la terre du cordon d’alimentation est bien
raccordé à la borne de mise à la terre dans le boîtier de déconne­xion ou que la fiche du cordon est raccordée à une prise correcte­ment mise à la terre.

l En effectuant les raccordements d’entrée, fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

l Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez-les contre les étincelles et les pièces métalliques
chaudes.

l 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 L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
l Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

l Ne pas enrouler les câbles autour du corps.
l Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct.

l Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

l Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide
doublée.

l N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformé­ment à ce manuel.

l Porter un harnais de sécurité si l’on doit travailler au-dessus du

sol.

l S’assurer que tous les panneaux et couvercles sont correctement

en place.

l Fixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près
possible de la soudure.

l Isoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

l 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.

l Utiliser une protection différentielle lors de l’utilisation d’un équipe-

ment auxiliaire dans des endroits humides ou mouillés.

LES PIÈCES CHAUDES peuvent

provoquer des brûlures.

l Ne pas toucher des parties chaudes à mains nues.
l Prévoir une période de refroidissement avant de

travailler à l’équipement.

l Ne pas toucher aux pièces chaudes, utiliser les outils recomman-

dés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.

DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.

l 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.

l Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.

l Eloigner votre tête des fumées. Ne pas respirer les fumées.
l 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.

l Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

l Lire et comprendre les fiches de données de sécurité et les ins-

tructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidisse­ment, les dégraisseurs, les flux et les métaux.

l 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.

l 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.

l 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 ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.

l Fermer l’alimentation du gaz comprimé en cas de

non utilisation.

l Veiller toujours à bien aérer les espaces confinés ou se servir d’un

respirateur d’adduction d’air homologué.

LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses

(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.

l Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pendant le soudage (voir
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).

l Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

l Avoir recours à des écrans protecteurs ou à des rideaux pour pro-

téger les autres contre les rayonnements les éblouissements et
les étincelles ; prévenir toute personne sur les lieux de ne pas re­garder l’arc.

l Porter une protection corporelle en cuir ou des vêtements ignifu-

ges (FRC). La protection du corps comporte des vêtements sans
huile, comme 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.

l 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.

l Ne pas souder dans un endroit là où des étincelles peuvent tom-

ber sur des substances inflammables.

l Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

l Des étincelles et des matériaux chauds du soudage peuvent faci-

lement passer dans d’autres zones en traversant de petites fissu­res et des ouvertures.

l Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

l Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

l Ne pas couper ou souder des jantes ou des roues. Les pneus peu-

vent 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.

l Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les Nor­mes de Sécurité).

l Ne pas souder là où l’air ambiant pourrait contenir des poussières,

gaz ou émanations inflammables (vapeur d’essence, par
exemple).

OM-291865 Page 7

l 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.

l Ne pas utiliser le poste de soudage pour dégeler des conduites

gelées.

l En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

l Porter une protection corporelle en cuir ou des vêtements ignifu-

ges (FRC). La protection du corps comporte des vêtements sans
huile, comme des gants de cuir, une chemise solide, des panta­lons sans revers, des chaussures hautes et une casquette.

l Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

l Une fois le travail achevé, assurez-vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

l Utiliser exclusivement des fusibles ou coupe-circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

l 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.

l Lire et comprendre les fiches de données de sécurité et les ins-

tructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidisse­ment, les dégraisseurs, les flux et les métaux.

Le BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peut
affecter l’ouïe.

l Porter des protections approuvées pour les oreilles

si le niveau sonore est trop élevé.

Les CHAMPS
ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants
médicaux.

l Les porteurs de stimulateurs cardiaques et autres

implants médicaux doivent rester à distance.

l 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.

Si des BOUTEILLES sont
endommagées, elles pourront
exploser.

Des bouteilles de gaz comprimé protecteur
contiennent du gaz sous haute pression. Si une

bouteille est endommagée, elle peut exploser. Du fait que les bouteil­les de gaz font normalement partie du procédé de soudage, les mani­puler avec précaution.

l 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.

l Placer les bouteilles debout en les fixant dans un support station-

naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.

l Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

l Ne jamais placer une torche de soudage sur une bouteille à gaz.
l Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

l Ne jamais souder une bouteille pressurisée - risque d’explosion.
l 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.

l 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 lerégulateur lors
de l’ouverture de la vanne.

l Maintenir le chapeau de protection sur la soupape, sauf en cas

d’utilisation ou de branchement de la bouteille.

l Utilisez les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever, déplacer et transporter les
bouteilles.

l 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. Symboles de dangers supplémentaires en relation avec l’installation, le

fonctionnement et la maintenance

Risque D’INCENDIE OU

D’EXPLOSION.

l Ne pas placer l’appareil sur, au-dessus ou à proxi-

mité de surfaces inflammables.

l Ne pas installer l’appareil à proximité de produits

inflammables

l Ne pas surcharger l’installation électrique – s’assurer que l’alimen-

tation est correctement dimensionné et protégé avant de mettre
l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT peut

provoquer des blessures.

l Utiliser l’anneau de levage uniquement pour soule-

ver l’appareil, NON PAS les organes de roulement,
les bouteilles de gaz ou tout autre accessoire.

l Utilisez les procédures correctes et des équipements d’une capa-

cité appropriée pour soulever et supporter l’appareil.

l 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.

OM-291865 Page 8

l Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

l 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.

l Laisser l’équipement refroidir ; respecter le facteur

de marche nominal.

l Réduire le courant ou le cycle opératoire avant de

recommancer le soudage.

l Ne pas obstruer les passages d’air du poste.

LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.

l Porter un écran facial pour protéger le visage et

les yeux.

l 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.

l Les étincelles risquent de causer un incendie - éloigner toute sub-

stance inflammable.

LES CHARGES
ÉLECTROSTATIQUES peuvent
endommager les circuits imprimés.

l Établir la connexion avec la barrette de terre

AVANT de manipuler des cartes ou des pièces.

l Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-

placer ou expédier des cartes de circuits imprimes.

Les PIÈCES MOBILES peuvent
causer des blessures.

l Ne pas s’approcher des organes mobiles.
l Ne pas s’approcher des points de coincement tels

que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

l Ne pas appuyer sur la gachette avant d’en avoir

reçu l’instruction.

l Ne pas diriger le pistolet vers soi, d’autres person-

nes ou toute pièce mécanique en engageant le fil de soudage.

L’EXPLOSION DE LA BATTERIE peut
provoquer des blessures.

l 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.

l S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

l Maintenir fermés et verrouillés les portes, pan-

neaux, recouvrements et dispositifs de protection.

l Lorsque cela est nécessaire pour des travaux d’entretien et de dé-

pannage, faire retirer les portes, panneaux, recouvrements ou dis­positifs de protection uniquement par du personnel qualifié.

l Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher l’a­limentation électrique.

LIRE LES INSTRUCTIONS.

l 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.

l N’utiliser que des pièces de remplacement provenant du fabricant.
l 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.

l Le rayonnement haute fréquence (H.F.) peut pro-

voquer des interférences avec les équipements de

radio-navigation et de communication, les services de sécurité et
les ordinateurs.

l Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner
l’installation.

l L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

l Si le FCC signale des interférences, arrêter immédiatement

l’appareil.

l Effectuer régulièrement le contrôle et l’entretien de l’installation.
l 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.

l 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.

l Veiller à ce que tout l’équipement de la zone de soudage soit

compatible électromagnétiquement.

l 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).

l Veiller à souder à une distance de 100 mètres de tout équipement

électronique sensible.

l Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

l 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. Maintenance et réparation

Les TRAVAUX DE MAINTENANCE et
de RÉPARATION doivent respecter
toutes les consignes de sécurité
indiquées dans ce manuel.

Les travaux de maintenance, d’étalonnage et de réparation doivent
être effectués conformément aux indications contenues dans les der­nières versions des manuels d’entretien.

Appliquer toutes les exigences en matière de sécurité régionales et
nationales et toujours vérifier que toutes les fonctions de sécurité sont
en bon état de marche.

Avant d’utiliser le manipulateur Cobot ou le boîtier de commande, sui­vre les procédures et les avertissements ci-dessous :

l Avant d’effectuer des opérations de maintenance, suivre les pro-

cédures de verrouillage/indications de mise hors service.

l Retirer le câble d’alimentation de l’entrée principale du boîtier de

commande pour vous assurer que l’alimentation est coupée.

l Vérifier la connexion à la terre avant de mettre le système Cobot

sous tension.

l Respecter les procédures ESD (Electro-Static Discharge) lorsque

des pièces du manipulateur Cobot ou du boîtier de commande
sont démontées.

l Les pièces situées dans le contrôleur ne sont pas réparables. Si

une réparation est nécessaire, contacter Miller Electric.

OM-291865 Page 9

l Éviter de démonter les connexions d’alimentation électrique situ-

ées à l’intérieur du contrôleur. Des tensions élevées peuvent être
présentes au niveau des connexions d’alimentation pendant plu­sieurs heures après avoir éteint le boîtier de commande.

l Empêcher l’eau et la poussière de pénétrer dans le manipulateur

Cobot ou le contrôleur.

l La modification du poids de la torche peut affecter les limites de

force, ce qui peut provoquer des blessures. Contacter Miller Weld­ing Automation Service pour déterminer les paramètres de sécu­rité avant de changer le poids de la torche.

l Rallumer toutes les mesures de sécurité désactivées immédiate-

ment après la fin des travaux de maintenance.

l Consigner toutes les opérations de maintenance effectuées et les

conserver pour consultation ultérieure.

2-5. 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.

2-6. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org.

Safe Practice For Occupational And Educational Eye And Face Pro­tection, ANSI Standard Z87.1, from American National Standards Ins-

titute. Website: www.ansi.org.

Safe Practices for the Preparation of Containers and Piping for Weld­ing and Cutting, American Welding Society Standard AWS F4.1.

Website: http://www.aws.org.

National Electrical Code, NFPA Standard 70 from National Fire Pro­tection Association. Website: www.nfpa.org.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P­1 from Compressed Gas Association. Website: www.cganet.com.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www. csa-

group.org.

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.

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. Website:

www.osha.gov.

OSHA Important Note Regarding the ACGIH TLV, Policy Statement

on the Uses of TLVs and BEIs. Website: www.osha.gov.

Applications Manual for the Revised NIOSH Lifting Equation from the

National Institute for Occupational Safety and Health (NIOSH). Web­site: www.cdc.gov/NIOSH.

American National Standard for Industrial Robots and Robot Systems
– Safety Requirements, ANSI/RIA R15.06-2012, Robotic Industries

Association. Website: www.robotics.org.

Robotic Industries Association Technical Report – supplement to AN­SI/RIA R15.06-2012, RIA TR 15.406-2014, Robotic Industries Asso-

ciation. Website: www.robotics.org.

Technical Report for Industrial Robots and Robot Systems – Safety
Requirements, Task-based Risk Assessment Methodology, RIA TR

R15.306-2014. Website: www.robotics.org.

Electrical Standard for Industrial Machinery, NFPA Standard 79, from
National Fire Protection Association. Website: www.nfpa.org.

Safety Standard for Robots and Robotic Equipment, UL 1740. Web­site:www.ulstandards.ul.com.

Industrial robots and robot systems, CAN/CSA-Z434, Canadian Stan­dards Association (CSA). Website: www.csa.ca.

Technical Specification Robots and Robotic Devices- Collaborative
Robots, ISO/TS 15066:2016.

Safety of Machinery – General Principles for Design – Risk Assess­ment and Risk Reduction, ISO 12100:2010.

Robots and Robotic Devices – Safety Requirements– Part 2: Indus­trial Robot Systems and Integration, ISO 10218-2:2011.

Safety of Machinery; General Requirements & Risk Assessment, AN-

SI B11.0-2010.

Low-voltage switchgear and controlgear – Part 5-5: Control circuit de­vices and switching elements – Electrical emergency stop device with
mechanical latching function, IEC 60947-5-5.

Cobot System_cfr 2023–02

2-7. 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: par exemple,
des restrictions d’accès pour les passants ou une évaluation indivi­duelle des risques 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 câ­bles d’un côté et à distance de l’opérateur.

OM-291865 Page 10

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 – DEFINITIONS

U

se ventilating fan to remove fumes.

Safe10 2012 05

Use ventilating fan to remove fumes.

Safe11 2012 05

Keep flammable

s away from welding. Do not weld near flammables.

Safe12 2012 05

Keep flammable

s away from cutting. Do not cut near flammables.

Safe13 2012 05

W

elding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Safe14 2012 05

Cutting sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Safe15 2012 05

D

o not weld on drums or any closed containers.

Safe16 2017 04

D

o not cut on drums or any closed containers.

Safe17 2017 04

D

o not grip material near cutting path.

Safe18 2017 10

T

urn off power before disassembling torch.

Safe19 2012 05

Do not remove or paint over (cover) the label.

Safe20 2017 04

3-1. Additional Safety Symbol Definitions

3-2. Miscellaneous Symbols

Warning! Watch Out! There are possible hazards as shown by the
symbols.

Do not remove or paint over (cover) the label.

Hazardous voltage; electric shock can kill.

Hazardous voltage; electric shock can kill.

Moving parts can injure. Keep away from positioning arm when it is
being moved.

Amperage

Rated Supply

Current

Voltage

Hertz

Single Phase

Three Phase

Rated Maximum

Supply Current

Maximum Effective

Supply Current

Ground

On

Rated Supply

Voltage

Power On/Off

Pushbutton In

Pushbutton Out

Isolating Switch

Disconnector

Off

Lockout

OM-291865 Page 11

SECTION 4 – SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the back of the work table, above the input power connections. Use rating
label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on cover of this
manual.

4-2. Software Licensing Agreement

The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at

https://www.millerwelds.com/eula and are incorporated by reference herein.

4-3. Information About Default Weld Parameters And Settings

NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical
welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are
for reference purposes only; and final weld results can be affected by other variables and application-specific circumstances. The appropriate­ness of all parameters and settings should be evaluated and modified by the end user as necessary based upon application-specific require­ments. The end user is solely responsible for selection and coordination of appropriate equipment, adoption or adjustment of default weld
parameters and settings, and ultimate quality and durability of all resultant welds. Miller Electric expressly disclaims any and all implied warran­ties including any implied warranty of fitness for a particular purpose.

4-4. Cobot System Specifications

Input Power 3-phase 240-575 VAC

Welder Specifications Auto Continuum 350

System Dimensions (HxWxD) 84 in. x 48 in. x 52 in. (2134 mm x 1219 mm x 1321 mm)
Payload capacity with feet 1500 lb (680 kg)

Payload capacity with casters 750 lb (340 kg)

Load Height 37 in. (940 mm)
System Weight 1700 lb (771 kg)
Torch Specifications Tregaskiss CA3 Torch

Table Specifications 5/8 in. diameter holes on 2 in. grid spacing 48 x 48 in (1219 x 1219 mm).

Cobot requires separate 110 VAC input

350A at 31.5 VDC at 100% duty cycle

(Assuming evenly spread across table)

(Assuming evenly spread across table)

350A Air Cooled

Table is nitride hardened and reversible

OM-291865 Page 12

4-5. System Component Identification

1

3

10

2

11

4

7

5

9

8

6

A. Front Of System

1 System Status Light Bar

2 Auto Continuum Power Source

3 Cobot Teach Pendant

4 Weld Platen

5 Torch Puck

6 Cobot Manipulator

7 Welding Torch And Mount

8 Torch Cable Management Bracket

9 Joystick

10 Operation Box

11 Spatter Trays

Do not use spatter trays for
storage.

OM-291865 Page 13

B. Rear Of System

3

1

2

7

6

5

4

1 Cobot Controller

2 Auto Continuum Feeder

3 Lower Torch Cable Management Bracket

4 Wire Spool Hub And Spool Cover

Assembly

5 Switched 110V Outlet (To Power Cobot

Controller)

6 Main Disconnect

7 Modbus To EiP Gateway

OM-291865 Page 14

4-6. Dimensions

A. Front View

All dimensions in inches.

F

OM-291865 Page 15

B. Side View

All dimensions in inches.

F

OM-291865 Page 16

C. Top View

All dimensions in inches.

F

OM-291865 Page 17

4-7. Table Platen

2

2 X 21 = 42

48

3

2

2 X 15 = 30

48

3

1.5 X 45

TYP

352 X .625 TOOLING HOLES
(MAXIMUM USABLE DEPTH 3")

MANUFACTURING FEATURES

90°

.63

Tooling holes are 2 in. apart.

There are 3 inches between edge of table
and first tooling holes.

There are 15 rows of holes front to back and
21 rows of holes left to right, for a total of
325 holes.

The holes have diameter 0.625 in and maxi­mum usable depth of 3 in.

OM-291865 Page 18

SECTION 5 – INSTALLATION

5-1. Moving The System

Use correct procedures and equip­ment of adequate capacity to lift
and support unit.

If using lift forks to move unit, be
sure forks are long enough to ex­tend beyond opposite side of unit.

Keep equipment (cables and
cords) away from moving vehicles
when working from an aerial
location.

Use lifting eye to lift unit only, NOT
running gear, gas cylinders, or any
other accessories.

Miller Copilot is shipped in a crate capable of
being moved as a single unit. This not only
makes moving the system easy; it also
means a quick startup time once the ma­chine is placed. Power, welding wire, and
welding gas are generally all that are re­quired to have the system ready to program
and run production.

The cobot system and shipping crate weigh
less than 4500 pounds (1818 kg). An 8000
pound (3636 kg) capacity fork truck is recom­mended for safely moving and lifting the
system.

Uncrating The System

Tools needed: ladder, crowbar, dead blow
hammer

Reference video at MillerWelds. com/

copilotsupport.

Step 1. Start uncrating from top of the crate.
Remove the clips with crowbar.

Step 2. Remove support beams under top of
crate.

Step 3. Remove front clips and front panel.
Step 4. Remove rear clips and rear panel.
Step 5. Remove bottom side clips and side

panels (one side at a time).
Step 6. Follow procedure for lifting table us-

ing lifting straps.

Lifting Table

Use only eye bolts with shoulders
to lift the cobot system.

NOTICE – The Cobot system is not designed
to be lifted from underneath. Lifting from the
bottom may result in damage to the system.

Remove spatter trays.

Install eye bolts with shoulders through tool­ing holes as shown.

Attach nuts to eye bolts from underside of ta­ble. Hand tighten eye bolts.

Use correct procedures and equipment of
adequate capacity to lift and support the unit.

Do not move or operate unit where
it could tip.

Special installation may be re­quired where gasoline or volatile
liquids are present - see NEC Ar­ticle 511 or CEC Section 20.

OM-291865 Page 19

5-2. Cobot Installation Site Requirements

R72.44

RESTR

I

C

TE

D

SP

ACE

2

0.0

R92.44

Other Equipment

Building Structure

Do not move or operate unit where
it could tip.

Special installation may be re­quired where gasoline or volatile
liquids are present - see NEC Ar­ticle 511 or CEC Section 20.

A risk assessment of the specific installation
location shall be performed to determine
possible trapping or pinch points within the
cobot restricted space.

A minimum of 20 in. (508 mm) of clearance
beyond the restricted space (72.44 in. from
the base of the cobot arm) shall be main­tained. This includes perimeter barriers, arc
screens, buildings, structures, utilities, other
machines, and equipment not specifically
supporting the cobot function.

Failure to maintain the required
clearance can result in
entrapment.

OM-291865 Page 20

5-3. Leveling The System

1

2

3

1

2

3

NGO’s

tools/

trashcan continuitytester

Grinder left

PAPR

Grinder right

Raising Leveling Mounts

Lowering Leveling Mounts

1 Leveling Mount

2 5/8 in. (16 mm) Jam Nut

3 Wheel

Leveling the system is recommended.

Lowering Leveling Mounts For Welding
Operation

Spin leveling mount down until it contacts
the floor.

Using wrench, continue to spin the leveling
mount until cart is raised off the wheels. Do
not raise wheels by more than 0.75 in. (19
mm).

Repeat on all four corners. Check the table
level and adjust as required to level table.

Use wrench to secure 5/8 in. jam nuts.

NOTICE – Cart must be supported by level­ing mounts to support rated load of 1500 lb
(680 kg).

Raising Leveling Mounts For Transit

Remove tooling from cart before transit.
Maximum transit load is 750 lb (340 kg).

Loosen 5/8 in. jam nut enough to allow rais­ing of leveling mount.

Spin leveling mount to raise it off the floor by
at least 1/4 in. (6 mm). Do not raise mounts
past 1 inch (25 mm).

Repeat on all four corners.

OM-291865 Page 21

5-4. Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommen­dations are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual
branch circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and

630.12.

NOTICE – INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply
of input power at rated frequency ±10%) and voltage ±10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use
a generator with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.

NOTICE – Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual in­put voltage is outside this range, output may not be available.

350 Amp Model 60 Hz 3-Phase
Rated Supply Voltage (V) 230 380 400 460 575
Rated Maximum Supply Current I
Rated Effective Supply Current I
Maximum Recommended Standard Fuse Rating In Amperes
Time Delay Fuses
Normal Operating Fuses

2

3

Maximum Recommended Supply Conductor Length In Feet (Meters)
Raceway Installation
Minimum Supply Conductor Size In AWG (mm
Minimum Grounding Conductor Size In AWG (mm

Reference: 2020 National Electrical Code (NEC) (including article 630)

(A) 43.7 26.2 24.6 21.4 17.1

1max

(A) 36.7 21.8 28.8 18.8 14.6

1eff

1

50 30 30 25 20
60 35 35 30 25

4

119 (36) 215 (66) 241 (74) 193 (59) 196 (60)

2)5

2)5

8 (10) 10 (6) 10 (6) 12 (4) 14 (2.5)
8 (10) 10 (6) 10 (6) 12 (4) 14 (2.5)

OM-291865 Page 22

5-5. Connecting 3-Phase Input Power

8

7

9

10

1

6

3

5

4

2

230-575 VAC, 3 Phase

120 VAC, 1 Phase

Installation must meet all National
and Local Codes—have only quali­fied persons make this installation.

Disconnect and lockout/tagout input
power before connecting input con­ductors from unit. Follow estab­lished procedures regarding the
installation and removal of lockout/
tagout devices.

Make input power connections to
the cobot system first.

Always connect green or green/yel­low conductor to supply grounding
terminal first, and never to a line
terminal.

See rating label on unit and check input volt­age available at site.

1 Input Power Conductors (Customer Sup-

plied Cord)

Select size and length of conductors using
Electrical Service Guide. Conductors must

comply with national, state, and local electri­cal codes.

Cobot System Input Power Connections

2 Strain Relief Installed On Disconnect OR

Strain Relief (Customer Supplied)

Install strain relief of proper size for unit and
conductors. Route conductors (cord)
through strain relief. Tighten strain relief.

3 Cobot System Grounding Terminal

4 Green Or Green/Yellow Grounding

Conductor

Connect green or green/yellow grounding
conductor to machine grounding terminal
first.

5 Cobot System Line Terminals

6 Input Conductors (L1, L2, And L3)

Connect input conductors L1, L2, and L3 to
cobot system line terminals.

Disconnect Device Input Power
Connections

7 Disconnect Device (switch shown in the

OFF position)

8 Disconnect Device Grounding Terminal

9 Disconnect Device Line Terminals

Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.

Connect input conductors L1, L2, and L3 to
disconnect device line terminals.

10 Over-Current Protection

Select type and size of over-current protec­tion using Electrical Service Guide (fused
disconnect switch shown).

Close and secure door on disconnect de­vice. Follow established lockout/tagout pro­cedures to put unit in service.

OM-291865 Page 23

5-6. Connecting 120 VAC Input Power

2

1

Installation must meet all National
and Local Codes—have only quali­fied persons make this installation.

NOTICE – Do not modify the power cord.
The power cord plugs will work with standard
NEMA receptacles. Use only the power
cords supplied with this unit. Modifying the
power cord (s) and/or plugs, or using cords
not intended for use with this product will
void warranty.

For 120 volts AC input power, a 15 or 20 am­pere individual branch circuit protected by
time-delay fuses or circuit breaker is
required.

1 Power Cord, 120 VAC

120 VAC cord with NEMA type 5-15P plug
and SDG plug.

2 Plug - NEMA Type 5-15P

3 Receptacle - NEMA Type 5-15R (Not

Shown)

Connect plug to receptacle.

OM-291865 Page 24

5-7. Shielding Gas And Cooler Connections (CE Model)

1

2

3

4

Turn off power before making
connections.

1 Jog/Retract Switch

2 10 Socket Control Receptacle RC3

3 Gas Purge Switch

Connect control cable from rear of welding
power source to wire drive assembly.

To make connections, align keyway, insert
plug, and tighten threaded collar.

4 Shielding Gas Valve Fitting

Requires hose fitting with 5/8–18 right-hand
threads.

For guns requiring external gas connections,
remove hose from barbed fitting near gun/
feeder opening and connect to gun.

Shielding gas pressure not to exceed

F

100 psi (689 kPa).

OM-291865 Page 25

5-8. Installing And Threading Welding Wire

6 in.

(150 mm)

WOOD

3

1

2

3

4

5

6

7

2

1

4

5

allen_wrench

NGO’s

tools/

flathead philips head wrench

allen_set

crescent wrench

15/16 in.

Verify correct drive rolls are installed.

F

1 Example Of No Wire Slippage
2 Nonconducting Surface
3 Pressure Adjust Knob
4 Pressure Indicator Scale
5 Drive Rolls
6 Back Of Gun
7 End Of Liner

Step 1. Turn power switch to “ON” position,
located on front of power source.

Step 2. Pull and hold wire. Cut off end of
wire.

Hold wire tightly to keep it from

F

unraveling.

Step 3. Push wire through guides up to drive
rolls; continue to hold wire.

Install gun. Lay gun cable out straight. Cut
off end of wire. Push wire through guides up
to drive rolls; continue to hold wire. Press
Jog button to feed wire out gun.

F

Step 4. To adjust drive roll pressure, begin
by holding nozzle about 2 in. (51 mm) from

For best wire feeding performance, be

sure that the outlet cable has the prop­er size liner for the welding wire size
being used. Also, when the gun is in­stalled, the liner extending from the
back of the gun should be as close to
the drive rolls as possible, without
touching.

nonconducting surface and pressing gun
trigger to feed wire against surface.

Step 5. Cut wire off.

For soft wire or small diameter stain-

F

less steel wire, reduce drive roll pres­sure on the rear roll to half that of the
front rolls.

OM-291865 Page 26

6-1. Operation Box

EMERGENCY

STOP

AUTO TEACH REVERSE FORWARD

WIRE JOG

ON OFF

WELD ENABLESTARTEND

PROGRAM PAUSE

/

1 2

3

4

5

6

293166-A

1

2

3

4

SECTION 6 – CONTROLS

1 Emergency Stop Button

Press this button to stop cobot and welding
and to remove drive power from cobot.

2 Auto/Teach Key Switch

Auto Mode allows playback of active pro­gram. Teach Modes allow creation and edit­ing of programs.

3 End Program Button

Press this button to stop the cobot and force
an end to program in auto mode.

6-2. Signal Light Tower

4 Start/Pause Button

Pressing this button in Auto Mode will start
the active program in auto mode.

Pressing this button while cobot is running a
program will cause cobot to pause.

Pressing this button while cobot is paused
will cause the cobot to resume from paused
position.

5 Wire Jog Forward/Reverse Switch

Rotate switch counterclockwise to retract
the weld wire.

Rotate switch clockwise to jog the weld wire
forward.

6 Weld Enable Switch

Rotate switch counterclockwise to enable
welding arc.

Rotate switch clockwise to disable welding
arc.

1 Red Light

2 Amber Light

3 Green Light

4 Blue Light

Light Definition

Red — Steady
State

Red — Flashing Grip Error or Cobot

Amber — Steady
State

Amber — Flashing Cobot is welding
Green — Steady

State
Blue — Steady

State

Emergency Stop
condition

Error
Cobot is moving

Cobot is in collabo­rative mode

Cobot is in Auto
mode

OM-291865 Page 27

6-3. Puck Buttons

1

2

3

4

1 Free Drive Enable 3–Position Switch

The switch enables the programmer to move
the robot to a position by dragging the robot
while this switch is in the ON (Middle)
position.

In the normal (not depressed) state, the
switch is typically used to prevent the cobot
from operating. In the middle position, the
switch allows the operator to manually drive
the cobot arm into position. When the switch
is fully depressed, it locks the arm in place.

2 Air Point Store

Pressing this button stores a non-weld posi­tion point and a weld end point.

3 Weld Point Store

Pressing this button stores a weld position
point.

4 Linear/Circular

Press this button to toggle between a linear
weld point and a circular weld point.

OM-291865 Page 28

6-4. Moving The Cobot With The Joystick

Z

Y

X

1

2

3

4

5

1 Joystick

2 Roll

3 Pitch

4 Yaw

5 World Frame

Grasp the joystick with fingers

Moving the joystick up/down, left/right, or for­ward/backward will cause the manipulator to
move in that direction in the world frame.

Rotate or twist the joystick in pitch/yaw/roll
directions about the world frame.

Cobot motion controlled by the joystick

F

is slow and precise. Joystick adjust­ments are generally used for fine tun­ing the cobot position and orientation.

OM-291865 Page 29

SECTION 7 – SAFETY DEVICES

EMERGENCY

STOP

AUTO TEACH REVERSE FORWARD

WIRE JOG

ON OFF

WELD ENABLESTARTEND

PROGRAM PAUSE

/

1

293166-A

The cobot system is equipped with several safety devices that protect both personnel working around the system and the equip­ment in the system. Personnel working with the cobot system must check for proper operation of the safety devices on a regular
basis.

Two emergency stop (E-stop) buttons are provided on the cobot welding system. These are latching type switches that stay in the pressed posi­tion until the button is twisted to release the latch.

7-1. Operator Station Emergency Stop

1 Operator Station Emergency Stop

The E-stop located on the operator station is
a large mushroom type button.

l Press the E-stop button in to stop all co-

bot functions and turn off cobot servo
power.

l Twist the red portion of the button clock-

wise to release the emergency stop

7-2. Teach Pendant Emergency Stop

condition and allow servo power to be
turned back on. The button pops out
when turned.

The cobot teach pendant has an E-stop push
button in the upper right corner of the
pendant.

l Press the E-stop button in to stop all co-

bot functions and turn off cobot servo
power.

l Twist the red portion of the button clock-

wise to release the emergency stop con­dition and allow servo power to be
turned back on. The button pops out
when turned.

OM-291865 Page 30

7-3. Lockout/Tagout Point

DANGER! – Disconnect input
power or stop engine before instal­ling or servicing this equipment.
Lockout/tagout input power ac­cording to safety standards (see
Section 1-2).

1 Lockout Tab

The disconnect switch provides a lockout tab
with hole to insert a padlock.

Turn switch to Off.

Pull out lockout tab.

Insert padlock.

OM-291865 Page 31

SECTION 8 – OPERATION

1

2

3

4

5

The cobot system is operated from the front of the system using the operator station push buttons. In most cases welding operation only requires
the operator to load a part to be welded, press the “start” push button.

All personnel that will be operating the system must be familiar with the safety features of the system and know how to stop the
cobot in the case of an emergency.

8-1. Powering Up The System

1 Turn On disconnect power switch.

2 Turn On welder power switch.

3 Turn On cobot controller switch.

4 Wait until cobot standby light is On.

5 Turn On teach pendant power switch.

8-2. Logging In To The System

When you power up the system, you automatically be logged in as an Operator. The Operator level does not require a password. If you need to
change default settings, log in as an Administrator. See the Manipulator Owner’s Manual.

8-3. System Settings

A cobot system has many settings that are configured when the system is assembled. Most are one-time settings that will never need to be
changed for the life of the system. This section introduces a few key concepts for basic setup and operation. This is not a comprehensive list of
all the settings that each system has. Refer to the Manipulator Owner’s Manual for more detailed information.

You can view these settings when you are logged in as an Operator.

You can change some settings not related to safety if you are logged in as an Administrator.

OM-291865 Page 32

A. Home Position

1 Move to Position Button
2 Save Button

Press and holding the Move to Position but­ton to move the cobot to the defined Home
position.

The Home position is automatically inserted
as the first line of any new program.

The Home position can be updated by mov­ing the cobot to a new Home position and
pressing the Save button.

It is a good practice when creating programs
to start and end programs at the Home posi­tion so operators can understand when the
cobot has completed a task.

B. Tool Center Point (TCP) Check

The TCP definition tells the cobot where the end of the torch is—the point where welding occurs (at least under ideal conditions). It is a reference
point that is used to control the motion of the cobot and to define the location of the wire tip in relation to the cobot's base or other reference
frame.

A pointer is mounted inside the system to be used as a quick reference to verify the torch and/or arm alignment. This can be a valuable tool to
determine if the welding torch is no longer in alignment because of a “crash” (when the torch or arm collides with something solid in the system
such as the tool, the part being welded, or the system frame).

To check the TCP using the reference pointer:

Step 1. Check the contact tip and replace it.
Step 2. Check the welding wire stick-out length (typically 12-15 mm) and straightness of the wire. Consistency is more important than how

straight the wire is; if the wire has a natural “cast” or bend, that is acceptable as long as the bend is consistent.

Step 3. Press the Move to Position button.
Step 4. Be prepared to stop the movement if the torch looks like it is going to crash with the TCP pointer.
Step 5. Move forward to the TCP Checkpoint.
Step 6. If the wire aligns with the pointer, TCP is confirmed and the system is ready for operation.
Step 7. If the wire does not align with the pointer, the torch may need straightening or adjustment, or it is possible that the cobot origin position is

no longer correct.
Step 8. If the wire aligns with the pointer but the part program is still not tracing or running correctly, the tool or parts to be welded may not be re-

peating correctly.

The position can be updated by moving the cobot to a new TCP position and pressing the Save button.

Be careful updating this position after you have created programs. Programs created before the revised TCP Check position may be shifted
based on an incorrect/damaged TCP point.

OM-291865 Page 33

8-4. Inputs And Outputs

Cobot inputs and outputs are used to operate the system and understanding where to view these and what they mean can make running and
troubleshooting the system much easier.

To view the inputs and outputs go to Settings/IO Tab.

A. Cobot Inputs

Input signals from the different buttons and safety devices let the cobot know what operation to perform, and when it is safe for the cobot to start
moving. The following list covers the basic inputs to the cobot.

Input # Name Description

DI00 Auto Auto Mode Input. Changes operational mode to Auto
DI01 Teach Teach Mode Input. Changes operational mode to Teach
DI02 Start/Pause When cobot is in Auto Mode, Start/Pause Inputs Starts and Pauses Active Program
DI03 End Program When cobot is in Auto Mode End Program Stops cobot at current position and ends

DI04 Position Store When cobot is in teach Mode, Puck mounted Position Store Button adds non-weld po-

DI05 Weld Store When cobot is in teach Mode, Puck mounted Weld Store Button adds weld position

DI06 Linear/Circular When cobot is in teach Mode, Puck mounted Linear/Circular Button toggles weld posi-

DI07 Weld Enable/Disable When Weld Enable/Disable Switch is set to Enable, Welding commands are valid.

DI10 Wire Jog Fwd When wire jog fwd input is valid weld wire is feed forward. If input is held valid for 3 sec

DI11 Wire Jog Rev When the wire jog rev input is valid weld wire will retract. If input is held valid for 3 se

SI00 Emergency Stop input CH1 External Emergency Stop Input (At Operator Station) CH1
SI01 Emergency Stop input CH2 External Emergency Stop Input (At Operator Station) CH2
SI06 Force Enable CH1 Lead Through Teach Enable Switch (Located at torch puck) CH1
SI16 Force Enable CH2 Lead Through Teach Enable Switch (Located at torch puck) CH2

Active program

sition points.

points.

tion points between linear and circular.

When Switch is set to disable, welding commands are invalid.

wire will jog forward at high speed.

wire will retract at high speed.

B. Cobot Outputs

Cobot outputs tell the cobot when to run a tip change and let the system know when the cobot is clear of the work and at the home position.

Output#Name Description

DO00 Cobot Moving/Welding Output is valid without flashing when cobot is moving. Output is valid and flashing

DO01 Auto Mode Output is valid when cobot is in auto mode (Blue)
DO02 E-Stop/Error State Output is valid without flashing when cobot is in e-stop. Output is flashing when cobot

DO03 Collaborative Mode Output is valid when cobot is in collaborative mode

when the cobot is welding (Amber)

is in error state

8-5. Auto Mode Start-Up

Once the weld programs have been created, follow the steps below to run the cobot automatically.

Option 1: Running the program Active in Teach

Step 1. Turn the operation box Auto/Teach key switch to Auto.
Step 2. Load and secure the part for welding.
Step 3. If cobot is not at first point in active program, Press and hold start button until cobot is at first point. Releasing button prior to reaching first

point will stop cobot.
Step 4. In case something is in the way of the cobot while moving to first position of program, switch Auto/Teach switch to teach and hand guide

cobot around obstacle and then switch back to Auto.

Step 5. Once cobot has reached first point in program. Press the START/PAUSE push button once. This will start the program.
Step 6. Pressing the start/pause button while the cobot is running the active program will cause the cobot to pause.
Step 7. Pressing the Start/Pause after the cobot has paused will resume the active program at the point it paused.
Step 8. Pressing the end program button while the cobot is running the active program will cause the cobot to stop and end the active program
Step 9. Pressing e-stop (or if the cobot generates an error while running the active program) will cause the cobot to stop and end the active

program.

OM-291865 Page 34

SECTION 9 – TEACHING

Cobot systems are shipped with all the necessary system configuration installed so end users only need to program the welding that they want
the cobot to perform. This section makes recommendations and outlines the programming structure; this manual is not intended to instruct users
on the operation of the cobot teach pendant and explain the commands used in cobot programs. Please refer to the cobot operations manual for
specific information on using the teach pendant.

It is strongly recommended that new cobot users go through our basic operations training class before attempting to create or
modify programs on the cobot system. The cobot can potentially injure personnel or damage itself if not programmed properly.

9-1. Teach Mode

To teach new programs the cobot must be in Teach Mode. This means the key switch located on the operation box must be set to Teach.

Do not switch the Auto/Teach key switch while the cobot is actively running a program. If you wish to interrupt auto mode operation, press the
Start/Puse button first, then turn the key switch to Teach.

9-2. Pre-Teaching Checks

Any time an operator or programmer has an opportunity to inspect the system is a good time to look for normal wear that may need to be ad­dressed. This is even more critical when a programmer is in the process of correcting a weld or creating a new program. Failure to check the co­bot hardware before touching up points could result in lost time.

l Cobot torch alignment—crashes happen and many times no adjustment is needed but it is good programming practice to check the cobot

torch position against a fixed reference point to see if anything has moved since the last time the cobot was programmed. If it has, correcting
the hardware misalignment may solve any welding problems.

l Cables—the torch cable (whip), power cables, and liners sometimes get caught up on equipment. Twisted cables cause short circuits or bro-

ken wires. Welding wire liners forced to bend in a very small radius can keep wire from passing freely through the liner. Replace or service
any cable or liner that is visibly damaged or has reached the end of its useful service life.

OM-291865 Page 35

SECTION 10 – TROUBLESHOOTING

This troubleshooting list addresses only potential system problems and does not cover the cobot error and alarm codes. For a comprehensive
list of cobot errors see the cobot operations manual.

Problem Probable Cause Remedy

No drive power .

Emergency Stop Error displayed on pendant.

Solid red light.
Red light flashing. Free Drive Grip Error or Cobot internal error. Release free-drive enable switch and wait for

Cobot does not turn on. 120V cord not plugged into wall outlet or wall

Cobot does not weld. Weld Enable switch on Operation Box is set

Welder does not turn on. Customer supplied disconnect is switched to

Cobot displays welder communication error
or can’t feed wire or purge gas from teach
pendant.

Operation ESTOP, Pendant Estop was
activated.

outlet has no power.

to Off.

off or fuses are blown.

Communication error between cobot and
welder.

Check both E-Stop switches for activation.
Check Teach Pendant cable.
Check Operation Box cable.

flashing red light to turn off.
Clear error on pendant. If error does not pop

back up, then wait for red light to turn off for
about one minute.

If error does not clear, cycle power on the
cobot.

Check to see if 120V cord coming from cobot
system main disconnect is plugged into wall
outlet receptacle.

Have qualified personnel check to see if 120
VAC is available at wall outlet.

Set Weld Enable switch to On.

Check to see if customer supplied disconnect
is in ON position.

Have qualified personnel check to see if cus­tomer supplied disconnect has blown fuses.

Cycle system power at disconnect located on
back side of system (see Section 8-1).

OM-291865 Page 36

SECTION 11 – RISK ASSESSMENT

Operator

Task

Process
Hazard

All Users Reference Section 1-2.

Process
Hazard

All Users Reference Section 1-2.

Process
Hazard

All Users Reference Section 1-2.

Process
Hazard

All Users Reference Section 1-2.

Process
Hazard

All Users Reference Section 1-2.

Mechanical
Hazard –
Crush/Pinch

All Users

Mechanical
Hazard -En­tanglement

All Users

Mechanical
Hazard –
Puncture/
Stabbing

All Users Reference Section 1-2.

Workpiece
Loading/
Unloading

Operator/
Programmer

Hazard

Arc welding
(Radiation
hazard -Eye
arc flash)

Arc welding
(Radiation
hazard -Skin
arc flash)

Welding
fumes/
smoke

Arc welding
(thermal
hazard)

Weld Spatter
and Sparks

Robot
motion

Moving
Elements

Welding
Wire/Torch

Hot parts
(thermal
hazard)

Exposure (E1, E2)

Severity (S1, S2, S3)

S2 E2 A2 Medium

S2 E2 A2 Medium

S2 E1 A1 Medium

S2 E1 A1 Medium

S2 E2 A1 Medium

S2 E2 A1 Medium

S2 E2 A1 Medium

S2 E2 A1 Medium

S1 E2 A2 Low

Avoidance (A1, A2, A3)

Risk Category

Risk Reduction

Recommendations

Barriers and
Arc Screens

Barriers and
Arc Screens

Local Ex­haust Venti­lation (LEV)

Barriers and
Arc Screens

Barriers and
Arc Screens

Elimination,
Safeguard­ing, Visual
Warning and
Awareness
Means, Ad­ministrative
Controls

Elimination,
Safeguard­ing, Visual
Warning and
Awareness
Means, Ad­ministrative
Controls

Elimination,
Safeguard­ing, Visual
Warning and
Awareness
Means, Ad­ministrative
Controls

Barriers and
Arc Screens

Safeguards Used

Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Robot Safety Software,
Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Reference Manipulator
Owner’s Manual.

Robot Safety Software,
Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Reference Manipulator
Owner’s Manual.

Robot Safety Software,
Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Reference Section 1-2.

Exposure (E1, E2)

Avoidance (A1, A2, A3)

E1 A1 S2 Low

E1 A1 S2 Low

E1 A1 S1

E1 A1 S2 Low

E1 A1 S2 Low

E2 A1 S1

E2 A1 S1

E2 A1 S1 Low

E2 A1 S1 Low Low

Risk Category

Severity (S1, S2, S3)

Low
risk of
arc
flash

Low
risk of
arc
flash

Negligi­ble

Low
Risk of
Burn

Negligi­ble

Negligi­ble

Low
Risk of
Punc­ture/
Stab­bing

Residual Risk Level

OM-291865 Page 37

Operator

Task

Hazard

Programming
and
verification

Operator/
Programmer

Programming
and
verification

Operator/
Programmer

Programming
and
verification

Operator/
Programmer

Programming
and
verification

Operator/
Programmer

Programming
and
verification

Operator/
Programmer

Brief opera­tor interven­tion not
requiring
disassembly

Tip change

Operator/
Programmer

Robot mo­tion (me­chanical
hazard ­pinching,
impact)

Arc welding
(thermal
hazard)

Arc welding
(radiation
hazard - arc
flash)

Welding
wire/Torch
(mechanical

- puncture/
stabbing)

Tripping
hazard

Welding
wire/Torch
(mechanical

- puncture/
stabbing)

Welding
wire/Torch
(mechanical

- puncture/
stabbing)

Risk Category

Severity (S1, S2, S3)

Exposure (E1, E2)

Avoidance (A1, A2, A3)

S2 E1 A1 Medium

S2 E1 A1 Low

S2 E1 A2 High

S1 E1 A1 Low

S1 E1 A1

Negligi­ble

S1 E1 A1 Low

S1 E2 A1 Low

Risk Reduction

Recommendations

Elimination,
Safeguard­ing, Visual
Warning and
Awareness
Means, Ad­ministrative
Controls

Barriers and
Arc Screens

Barriers and
Arc Screens

Elimination,
Safeguard­ing, Visual
Warning and
Awareness
Means, Ad­ministrative
Controls

Elimination,
Safeguard­ing, Visual
Warning and
Awareness
Means, Ad­ministrative
Controls

Elimination,
Safeguard­ing, Visual
Warning and
Awareness
Means, Ad­ministrative
Controls

Safeguards Used

Robot Safety Software,
Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Reference Manipulator
Owner’s Manual.

Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Reference Section 1-2.

Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Reference Section 1-2.

Robot Safety Software,
Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Reference Section 1-2.

Robot Safety Software,
Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Reference Section 1-2.

Robot Safety Software,
Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Reference Section 1-2.

Exposure (E1, E2)

Avoidance (A1, A2, A3)

Risk Category

Severity (S1, S2, S3)

E2 A1 S1 Low Low

E1 A1 S2 Low Low

Low

E2 A2 S1 Low

risk to
a pro­gramm­er,
while
welding
in test
mode
around
the ro­bot and
work­piece.

E1 A1 S1

E1 A1 S1

E1 A1 S1

E1 A1 S1

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Residual Risk Level

OM-291865 Page 38

Operator

Task

Hazard

Tip change

Operator/
Programmer

Tip change

Operator/
Programmer

Nozzle
cleaning

Operator/
Programmer

Nozzle

cleaning

Operator/
Programmer

Wire change

Operator/
Programmer

Trouble­shooting

Programm­er/Mainte­nance

Trouble-

shooting

Programm­er/Mainte­nance

Trouble-

shooting

Equipment
jams

Welding
wire/Torch
(thermal
hazard - hot
nozzle/tip)

Thermal
hazard - hot
torch

Welding
wire/Torch
(mechanical

- puncture/
stabbing)

Welding
wire/Torch
(thermal
hazard - hot
nozzle/tip)

Welding
wire/Torch
(mechanical

- puncture/
stabbing)

Electrical
hazard
(shock, elec­trocution,
burn)

Unexpected
robot motion
(mechanical
hazard ­crush, im­pact,
stabbing)

Mechanical
hazard
(tripping)

Mechanical
(stored
energy)

Risk Category

Severity (S1, S2, S3)

Exposure (E1, E2)

Avoidance (A1, A2, A3)

S1 E2 A1 Low

S1 E2 A1 Low

S1 E2 A1 Low

S1 E2 A1 Low

S1 E2 A1 Low

S3 E1 A1 High

S3 E1 A1 High

S1 E1 A1

Negligi­ble

S2 E1 A1 Medium

Risk Reduction

Recommendations

Administra­tive Control,
Visual Warn­ing and
Awareness
Means.

Administra­tive Control,
Visual Warn­ing and
Awareness
Means.

Elimination,
Safeguard­ing, Visual
Warning and
Awareness
Means, Ad­ministrative
Controls

Administra­tive Control,
Visual Warn­ing and
Awareness
Means.

Elimination,
Safeguard­ing, Visual
Warning and
Awareness
Means, Ad­ministrative
Controls

Safeguard­ing, Adminis­trative Con­trols, and
Warning and
Awareness
Means.

Elimination,
Safeguard­ing, Visual
Warning and
Awareness
Means, Ad­ministrative
Controls

Safeguard­ing, Adminis­trative Con­trols, and
Warning and

Safeguards Used

Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Reference Section 1-2.

Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Reference Section 1-2.

Robot Safety Software,
Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Reference Section 1-2.

Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Reference Section 1-2.

Robot Safety Software,
Safety Precautions,
Personal Protective
Equipment, Operator
Training.

Reference Section 1-2.

Safety Precautions,
Troubleshooting to be
performed only by
trained personnel, and
Lockout/Tagout
Procedures

Reference Section 1-2.

Robot Safety Software,
Troubleshooting to be
performed only by
trained personnel,
Lockout/Tagout Proce­dures, and Safety
Precautions.

Reference Manipulator
Owner’s Manual.

Robot Safety Software,
Safety Precautions,
Troubleshooting to be
performed only by
trained personnel, and

Exposure (E1, E2)

Avoidance (A1, A2, A3)

E1 A1 S1

E1 A1 S1

E1 A1 S1

E1 A1 S1

E1 A1 S1

E1 A1 S1

E1 A1 S1

E1 A1 S1

E1 A1 S1

Severity (S1, S2, S3)

Risk Category

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Residual Risk Level

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

OM-291865 Page 39

Operator

Task

Hazard

Dropped
parts (unap­plied system)

Event recov­ery (wire
stick, no arc,
etc.)

Event recov­ery (wire
stick, no arc,
etc.)

Abnormal
condition
(process is­sues - part
burn thru)

Control of
hazardous
energy (in­cluding fix­tures,
clamps, and
other
equipment)

Changing
torch weight
or cobot
payload

Mainte­nance and
repair

Maintenance
and repair

Maintenance
and repair

Equipment
cleaning

Equipment
cleaning

Mechanical
(impact,
cutting)

Mechanical
(crushing,
stabbing,
cutting)

Thermal
hazard
(burn)

Thermal
hazard
(burn)

Stored
energy

Robot mo-

tion (me­chanical

hazard -im-

pact force)

Mechanical
hazard
(tripping)

Ergonomic
hazards (dif­ficult
access)

Mechanical
hazard
(tripping)

Ergonomic
hazards (dif­ficult
access)

Risk Category

Severity (S1, S2, S3)

Exposure (E1, E2)

Avoidance (A1, A2, A3)

S2 E1 A1 Low

S2 E2 A2 High

S1 E2 Low

S1 E1 A2 Low

S3 E2 A2 High

S2 E2 A1 Medium

S1 E1 A1 Negligi-

ble

S1 E1 A1 Negligi-

ble

S1 E1 A1 Negligi-

ble

S1 E1 A1 Negligi-

ble

Risk Reduction

Recommendations

Awareness
Means.

Personal
Protective
Equipment,
Administra­tive Controls

Safeguard­ing, Adminis­trative Con­trols, and
Warning and
Awareness
Means.

Administra­tive Control,
Visual Warn­ing and
Awareness
Means.

Administra­tive Control,
Visual Warn­ing and
Awareness
Means.

Safeguard­ing, Adminis­trative Con­trols, Per­sonal Pro­tective
Equipment

Elimination,

Safeguard-

ing, Visual

Warning and

Awareness
Means, Ad­ministrative

Controls

Safeguards Used

Lockout/Tagout
Procedures
Reference Manipulator
Owner’s Manual.

Personal protection
equipment - Operator
training.

Robot Safety Software,
Safety Precautions,
Personal Protective
Equipment, Operator
Training.
Reference Manipulator
Owner’s Manual.

Safety Precautions,
Personal Protective
Equipment, Operator
Training.
Reference Section 1-2.

Safety Precautions,
Personal Protective
Equipment, Operator
Training.
Reference Section 1-2.

Robot Safety Software,
Safety Precautions,
Personal Protective
Equipment, Operator
Training.
Reference Manipulator
Owner’s Manual.

Contact Miller Welding

Automation Service to

determine safety set­tings before changing

torch weight, Personal

Protective Equipment,

Operator Training.

Exposure (E1, E2)

Avoidance (A1, A2, A3)

Risk Category

Severity (S1, S2, S3)

Unap­plied
sys­tems -

E1 A1 S1

Negligi­ble

no tool­ing
sup­plied
by
MWA

E1 A1 S1

E1 A1 S1

E1 A1 S1

E1 A1 S1

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

E2 A1 S1 Low Low

E1 A1 S1 Negligi-

ble

E1 A1 S1 Negligi-

ble

E1 A1 S1 Negligi-

ble

E1 A1 S1 Negligi-

ble

Negligi­ble

Negligi­ble

Negligi­ble

Negligi­ble

Residual Risk Level

OM-291865 Page 40

Operator

Task

Hazard

Equipment
cleaning

Passing by
System

Passing by
System

Load/Unload
Parts
Operator

Placement of
the
equipment

Environmen­tal hazards
(dirt, oil)

Arc welding
(Radiation
hazard - arc
flash)

Weld Spatter
and Sparks

Electrical
hazard
(shock, elec­trocution,
burn)

Robot mo­tion (me­chanical
hazard ­pinching,
impact)

Exposure (E1, E2)

Severity (S1, S2, S3)

S1 E1 A1 Negligi-

S2 E2 A2 Medium

S2 E2 A2 Medium

S1 E1 A1

S1 E1 A1 Low

Avoidance (A1, A2, A3)

Risk Category

ble

Negligi­ble

Risk Reduction

Recommendations

Barriers and
Arc Screens

Barriers and
Arc Screens

Administra­tive Control,
Visual Warn­ing and
Awareness
Means.

Safeguards Used

Safety Precautions,
Personal Protective
Equipment, Operator
Training.
Reference Section 1-2.

Safety Precautions,
Personal Protective
Equipment, Operator
Training.
Reference Section 1-2.

Safety Precautions,
Personal Protective
Equipment.
Reference Manipulator
Owner’s Manual.

Exposure (E1, E2)

Avoidance (A1, A2, A3)

E1 A1 S1 Negligi-

E1 A1 S2 Low

E1 A1 S2 Low

E1 A1 S1

S1 E1 A1 Low

Risk Category

Severity (S1, S2, S3)

ble

Negligi­ble

Residual Risk Level

Negligi­ble

Negligi­ble

OM-291865 Page 41

SECTION 12 – WARRANTY

Miller Welding Automation Cobot Welding System Warranty Information

Warranty Table

This table consists of the warranty coverage periods for a variety of MWA supplied components.

Please consult this table prior to calling the service department or your integration partner with a warranty claim.

Warranty Coverage Periods (Effective 1/1/2023) 90 Days 1 Year 3 Years

Mig Inverter Welding Power Supplies X
Mig Conventional Welding Power Supplies X
Tig Welding Power Supplies X
Robotic Wire Feeder X
Robotic Torches X
Wire Feeder Extension Cable X
Cobots and Teaching Pendent X
Systems Components — Non-Miller X
Systems Components — Customer Supplied N/A
*Systems warranty coverage begins from ship date to the MWA

customer.
*Robot warranty coverage begins from the ship date to the MWA

customer.

NOTE: Warranty terms and conditions are subject to change without notice.

Warranty Registration Effective from 01/01/2023

Revised 12/15/2022

OM-291865 Page 42

Notes

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date

Distributor

Address

City

State Zip

(Date which equipment was delivered to original customer.)

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 Protective Equipment (PPE)

Contact the Delivering Carrier to:

Service and Repair Replacement Parts

Training (Schools, Videos, Books)

Welding Process Handbooks

To locate a Distributor or Service Agency visit

www.millerwelds.com or call 1-800-4-A-Miller

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.

Miller Electric Mfg. LLC

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters–USA

USA Phone: [phone]
USA & Canada FAX: [phone]
International FAX: [phone]

For International Locations Visit
www.MillerWelds.com

ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2023-02