Miller Electric Welder User Manual

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Page 1

OM-196 188K

July 2003

Processes

MIG (GMAW) Welding Pulsed MIG (GMAW-P) Flux Cored (FCAW) W elding Automatic Welding

Description

Automatic Welding Interface And Arc Welding Power Source

Operating Instructions and

Programming Instructions for

Auto Invision II

Visit our website at

www.MillerWelds.com

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From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.

Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The

Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001:2000 Quality System Standard.

parts list will then help you to decide the exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.

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

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.

Miller offers a Technical Manual which provides more detailed service and parts information for your unit. T o obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMA W-P.

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WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section

25249.5 et seq.)

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 Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . .

1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – DEFINITIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Manufacturer’s Warning Label Definitions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Symbols And Definitions 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Manufacturer’s Rating Label 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Harmonic Data 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Dimensions And Weight 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Selecting A Location 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Connection Diagram 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Weld Output Terminals And Selecting Cable Sizes 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. 115 Volts AC Duplex Receptacle And Circuit Breakers 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Electrical Service Guide 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Connecting Input Power 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Rear Panel Connections 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Peripheral Receptacle Functions 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Touch Sensor Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12. Touch Sensor Board PC18 Switch S1 Settings 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13. Connecting Setup Pendant To Welding Power Source 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – OPERATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Operational Terms 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Lower Front Panel Controls 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Meter Functions 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Upper Front Panel Controls 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Duty Cycle And Overheating 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Volt-Ampere Curves 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Setup Pendant Controls 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – MAINTENANCE & TROUBLESHOOTING 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Blowing Out Inside Of Unit 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Removing Case and Measuring Input Capacitor Voltage 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Voltmeter/Ammeter Help Displays 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Front Panel Error Displays 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Weld Interface Board PC12 Diagnostic LED’s 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Diagnostic LED’s On Weld Interface Board PC12 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Customer Interface Board PC14 Diagnostic LED’s 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Diagnostic LED’s On Customer Interface Board PC14 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Motor Board PC13 Diagnostic LED’s 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11. Diagnostic LED’s On Motor Board PC13 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-12. Troubleshooting 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – ELECTRICAL DIAGRAMS 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – PARTS LIST 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(continued)

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TABLE OF CONTENTS

SECTION 8 – INTRODUCTION TO PROGRAMMING 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Pulse MIG Programs 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Standard Pulse Welding Programs 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Program 1 – 1.2 mm Steel (.045”), 98-2 Argon-Oxy 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Program 2 – 1.0 mm Steel (.040”), 80-20 Argon-CO2 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Program 3 – 1.2 mm Steel (.045”), 80-20 Argon-CO2 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Program 4 – .8 mm 316 (.030”), 98-2 Argon-CO2 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Program 5 – 1.0 mm 316 (.040”), 98-2 Argon-CO2 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8. Program 6 – 1.2 mm 316 (.045”), 98-2 Argon-CO2 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-9. Program 7 – 1.0 mm 308L (.040”), 98-2 Argon-CO2 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-10. Program 8 – 1.2 mm 308L (.045”), 98-2 Argon-CO2 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-11. Program 1 – 1.2 mm Metal Core (.045”), 95-5 Argon-CO2 81. . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-12. Program 2 – 1.4 mm Metal Core (.052”), 95-5 Argon-CO2 81. . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-13. Program 3 – 1.2 mm ER 4043 (.045”), Argon 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-14. Program 4 – 1.0 mm ER 4043 (.040”), Argon 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-15. Program 5 – 1.0 mm 5356 (.040”), Argon 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-16. Program 6 – 1.2 mm ER 5356 (.045”), Argon 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-17. Program 7 – .8 mm Steel (.030”), 98-2 Argon-Oxy 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-18. Program 8 – 1.0 mm Steel (.040”), 98-2 Argon-Oxy 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-19. Setup Pendant Mode Select Button 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-20. Setup Pendant Parameter Select Button 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-21. Setup Pendant Parameter Increase And Decrease Buttons 87. . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – GETTING STARTED FOR PULSE WELDING 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Weld Cycle For Pulse Welding 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Setting Preflow Sequence Display 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Setting Weld Sequence Display 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-4. Setting Crater Sequence Display 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-5. Setting Postflow Sequence Display 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 – TEACHING A PULSE WELDING PROGRAM 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Pulse Waveform Explained 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Teach Points Explained 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Selecting Teach Point Wire Feed Speed For Pulse Welding Program 92. . . . . . . . . . . . . . . . . .

10-4. Setting Teach Point Parameters For Pulse Welding Program 93. . . . . . . . . . . . . . . . . . . . . . . . .

10-5. Changing To Adaptive Pulse Welding 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 – TEACHING A MIG WELDING PROGRAM 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-1. Weld Cycle For Mig Welding 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-2. Changing To Mig Welding 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-3. Setting Preflow Sequence Display 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-4. Setting Start Sequence Display 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-5. Setting Weld Sequence Display 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-6. Setting Crater Sequence Display 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-7. Setting Retract Sequence Display 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-8. Setting Postflow Sequence Display 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11-9. Setting Run-in Sequence Display 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 12 – SETTING SharpArcE CONTROL 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-1. Selecting And Adjusting SharpArcE Control 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 13 – USING THE OPTIONAL DATA CARD 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-1. Installing Data Card 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-2. Using The Data Card 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-3. Naming Programs And Writing To Card 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-4. Reading From Card 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-5. Reading (Or Deleting) From An Empty Card 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-6. Deleting Programs From Card 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13-7. Selecting Security Lock 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(continued)

Page 5

TABLE OF CONTENTS

SECTION 14 – SETUP 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-1. Setup Flow Chart 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-2. Using Setup Di s p l a y s 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-3. Selecting Or Changing Access Code 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-4. Selecting Voltage Correction 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-5. Selecting Auxiliary Output 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-6. Selecting Voltage Sensing Method 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-7. Selecting Arc Start Method 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-8. Resetting Arc Time 11 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-9. Selecting Units For Wire Feed Speed And Motor Type 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-10. Selecting Wire Type 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-11. Defining Display Value 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-12. Resetting Memory 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-13. Selecting Arc Start/Volt Sense Error Shutdown 114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-14. Selecting Program Name Feature 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-15. Remote Program Select 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-16. Remote Program Setting 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-17. Jog Wire Feed Speed Selection 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-18. Flow Selection 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-19. Arc Voltage Error Selection 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-20. Stick Check Selection 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-21. Setting Ramps Function 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-22. Software Version Number 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14-23. Exiting The Setup Menu 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 15 – CONTROL MENU 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-1. Using Menu Display 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-2. Setting Rise Time Parameter 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-3. Setting Adaptive Parameters 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-4. Setting Auto Configure Parameter 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-5. Setting Retract On/Off 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-6. Setting Sharp Start On/Off 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15-7. Exiting The Control Menu 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES WARRANTY

Page 6

Declaration of Conformity For

European Community (CE) Products

Manufacturer’s Name: Miller Electric Mfg. Co.

Manufacturer’s Address: 1635 W. Spencer Street

Appleton, WI 54914 USA

Declares that the product: Auto Invision II

conforms to the following Directives and Standards:

Directives

Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC

Low Voltage Directive: 73/23/EEC

Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC

Standards

Electromagnetic compatibility (EMC) Product standard for arc welding equipment:

EN50199: December 1995

Arc Welding Equipment part 1: CEI IEC 60974

Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989

Draft IEC 60974-5 Arc Welding Equipment part 5: wire feeders JWG1 (Sec) 158 July 2000

Insulation coordination for equipment within low-voltage systems:

Part 1: Principles, requirements and tests: IEC 664-1: 1992

European Contact: Mr. Danilo Fedolfi, Managing Director

ITW WELDING PRODUCTS ITALY S.r.l. Via Privata Iseo 6/E 20098 San Giuliano Milanese, Italy

dec_con1_11/02

Telephone: 39(02)982901

Fax: 39(02)98290–203

Page 7

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.

som _nd_4/98

Y Marks a special safety message.

. Means “Note”; not safety related.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-4. Read and follow all Safety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input

live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

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

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

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONL Y if required for the welding process. D If AC output is required, use remote output control if present on

unit.

D Disconnect input power or stop engine before installing or

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

D Properly install and ground this equipment according to its

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

D Always verify the supply ground – check and be sure that input

power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first – double-check connections.

D Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

D Turn of f all equipment when not in use. D Do not use worn, damaged, undersized, or poorly spliced cables. D Do not drape cables over your body .

power circuit and machine internal circuits are also

This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

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

or another electrode from a different machine.

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

parts at once. Maintain unit according to manual.

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

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section before touching any parts.

FUMES AND GASES can be hazardous.

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

D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

D If ventilation is poor , use an approved air-supplied respirator. D Read the Material Safety Data Sheets (MSDSs) and the

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

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower th e oxygen level causing injury or death. Be sure the breathing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

OM-196 188 Page 1

Page 8

ARC RAYS can burn eyes and skin.

BUILDUP OF GAS can injure or kill.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

D Wear a welding helmet fitted with a proper shade of filter to protect

your face and eyes when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (leather and wool) and foot protection.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot

burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

D Protect yourself and others from flying sparks and hot metal. D Do not weld where flying sparks can strike flammable material. D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

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

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

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

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see Safety Standards).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

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

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

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

from your person before doing any welding.

workpiece, and hot equipment can cause fires and

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

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

D Wear approved safety glasses with side

shields even under your welding helmet.

D Shut off shielding gas supply when not in use. D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed. D Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away. D Wearers should consult their doctor before

going near arc welding, gouging, or spot welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

D Wear approved ear protection if noise level is

high.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully .

D Protect compressed gas cylinders from excessive heat, mechani-

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

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

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits. D Never drape a welding torch over a gas cylinder . D Never allow a welding electrode to touch any cylinder . D Never weld on a pressurized cylinder – explosion will result. D Use only correct shielding gas cylinders, regulators, hoses, and fit-

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

D Turn face away from valve outlet when opening cylinder valve. D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety Standards.

OM-196 188 Page 2

Page 9

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

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring – be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle. D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

MOVING PARTS can cause injury.

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

closed and securely in place.

H.F. RADIATION can cause interference.

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

navigation, safety services, computers, and communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained. D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts. D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading welding wire.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as computers and computer-driven equipment such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according t o this manual.

D 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.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W1 17.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New Y ork, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-196 188 Page 3

Page 10

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency Electric And Ma g netic Fields

Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.” However, studies are still going forth and evidence continues to be examined. Until the final conclusions of the research are reached, you may wish to minimize your exposure to electromagnetic fields when welding or cutting.

To reduce magnetic fields in the workplace, use the following procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from operator as practical.

5. Connect work clamp to workpiece as close to the weld as possible.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor, then following the above procedures is recommended.

OM-196 188 Page 4

Page 11

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT

UTILISATION

som _nd_fre 4/98

1-1. Signification des symboles

Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives.

Y Identifie un message de sécurité particulier.

. Signifie NOTA ; n’est pas relatif à la sécurité.

1-2. Dangers relatifs au soudage à l’arc

Y Les symboles présentés ci-après sont utilisés tout au long du

présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ci-après ne font que résumer l’information contenue dans les normes de sécurité énumérées à la section 1-4. Veuillez lire et respecter toutes ces normes de sécurité.

Y L’installation, l’utilisation, l’entretien et les réparations ne doi-

vent être confiés qu’à des personnes qualifiées.

Y Au cours de l’utilisation, tenir toute personne à l’écart et plus par-

ticulièrement les enfants.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous tension dès que l’appareil est sur ON. Le circuit d’entrée et les

tension à ce moment-là. En soudage semi-automatique ou automatique, le fil, le dévidoir, le logement des galets d’entraînement et les pièces métalliques en contact avec le fil de soudage sont sous tension. Des matériels mal installés ou mal mis à la terre présentent un danger.

D Ne jamais toucher les pièces électriques sous tension. D Porter des gants et des vêtements de protection secs ne comportant

pas de trous.

D S’isoler de la pièce et de la terre au moyen de tapis ou d’autres

moyens isolants suffisamment grands pour empêcher le contact physique éventuel avec la pièce ou la terre.

D Ne pas se servir de source électrique àcourant électrique dans les zones

humides, dans les endroits confinés ou là où on risque de tomber.

D Se servir d’une source électrique àcourant électrique UNIQUEMENT si le

procédé de soudage le demande.

D Si l’utilisation d’une source électrique àcourant électrique s’avère néces-

saire, se servir de la fonction de télécommande si l’appareil en est équipé.

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’instal-

lation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).

D Installer et mettre à la terre correctement cet appareil conformément à

son manuel d’utilisation et aux codes nationaux, provinciaux et municipaux.

D Toujours vérifier la terre du cordon d’alimentation – Vérifier et s’assu-

rer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

D En effectuant les raccordements d’entrée fixer d’abord le conducteur

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

D Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est pas

endommagé o u dénudé – remplacer le cordon immédiatement s’il est endommagé – un câble dénudé peut provoquer une électrocution.

D Mettre l’appareil hors tension quand on ne l’utilise pas. D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

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

câble distinct.

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

terre ou une électrode provenant d’une autre machine.

circuits internes de l’appareil sont également sous

Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.

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

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

D Porter un harnais de sécurité quand on travaille en hauteur. D Maintenir solidement en place tous les panneaux et capots. D Fixer le câble de retour de façon à obtenir un bon contact métal-métal

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

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

avec tout objet métallique.

Il y a DU COURANT CONTINU IMPORT ANT dans les convertisseurs après la suppression de l’alimentation électrique.

D Arrêter les convertisseurs, débrancher le courant électrique, et dé-

charger les condensateurs d’alimentation selon les instructions indiquées dans la partie entretien avant de toucher les pièces.

LES FUMÉES ET LES GAZ peuvent être dangereux.

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

D Eloigner votre tête des fumées. Ne pas respirer

D A l’intérieur, ventiler la zone et/ou utiliser un échappement au niveau

de l’arc pour l’évacuation des fumées et des gaz de soudage.

D Si la ventilation est insuffisante, utiliser un respirateur à alimenta-

tion d’air homologué.

D Lire les spécifications de sécurité des matériaux (MSDSs) et les

instructions du fabricant concernant les métaux, les consommables, les revêtements, les nettoyants et les dégraisseurs.

D Travailler dans un espace fermé seulement s’il est bien ventilé ou en

portant un respirateur à alimentation d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels. S’assurer que l’air de respiration ne présente aucun danger.

D Ne pas souder dans des endroits situés à proximité d’opérations de

dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l ’ arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

D Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage.

les fumées.

OM-196 188 Page 5

Page 12

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

des brûlures dans les yeux et sur la peau. Des étincelles sont projetées

pendant le soudage.

D Porter un casque de soudage muni d’un écran de filtre approprié pour

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

D Porter des protections approuvés pour les oreilles si le niveau sondre est

trop élevé.

D Utiliser des écrans ou des barrières pour protéger des tiers de l’éclair

et de l’éblouissement; demander aux autres personnes de ne pas regarder l’arc.

D Porter des vêtements de protection constitué dans une matière dura-

ble, résistant au feu (cuir ou laine) et une protection des pieds.

(ultraviolets et infrarouges) susceptibles de provoquer

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

D Fermer l’alimentation du gaz protecteur en cas de

non utilisation.

D Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi-

rateur d’adduction d’air homologué.

DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.

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

d’utiliser le pistolet ou la torche.

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

les, 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 o u u n incendie. A vant de commencer le soudage, vérifier et s’assurer que l’endroit ne présente pas de danger.

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

métal chaud.

D Ne pas souder dans un endroit là où des étincelles peuvent tomber sur

des substances inflammables.

D Déplacer toutes les substances inflammables à une distance de 10,7

m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

D Des étincelles et des matériaux chauds du soudage peuvent facile-

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

D Surveiller tout déclenchement d’incendie et tenir un extincteur à proxi-

mité.

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

peut déclencher un incendie de l’autre côté.

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

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

D Brancher le câble sur la pièce le plus près possible de la zone de sou-

dage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution et d’incendie.

D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

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

électrode ou couper le fil à la pointe de contact.

D Porter des vêtements de protection dépourvus d’huile tels que des

gants en cuir, une chemise en matériau lourd, des pantalons sans revers, des chaussures hautes et un couvre chef.

D Avant de souder, retirer toute substance combustible de vos poches

telles qu’un allumeur au butane ou des allumettes.

projetées de l’arc de soudure. La projection d’étincel-

DES PARTICULES VOLANTES peuvent blesser les yeux.

D Le soudage, l’écaillement, le passage de la pièce

à la brosse en fil de fer, et le meulage génèrent

lantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.

D Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

des étincelles et des particules métalliques vo-

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, restez à distance. D Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

LE BRUIT peut affecter l’ouïe.

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

D Porter des protections approuvés pour les oreilles si

le niveau sondre est trop élevé.

Si des BOUTEILLES sont endommagées, elles pourront exploser.

Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser . Du fait que les bouteilles de gaz

manipuler avec précaution.

D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, du laitier, des flammes ouvertes, des étincelles et des arcs.

D Placer les bouteilles debout en les fixant dans un support stationnai-

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

D T enir les bouteilles éloignées des circuits de soudage ou autres cir-

cuits électriques.

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

bouteille.

D Ne jamais souder une bouteille pressurisée – risque d’explosion. D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,

tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.

D Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la

bouteille.

D Maintenir le chapeau de protection sur la soupape, sauf en cas d’uti-

lisation ou de branchement de la bouteille.

D Lire et suivre les instructions concernant les bouteilles de gaz com-

primé, les équipements associés et les publications P-1 CGA énumérées dans les normes de sécurité.

font normalement partie du procédé de soudage, les

OM-196 188 Page 6

Page 13

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance

Risque D’INCENDIE OU D’EXPLOSION.

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

mité de surfaces infllammables.

D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique – s”assurer que l’alimen-

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

LA CHUTE DE L’APPAREIL peut blesser.

D Utiliser l’anneau de levage uniquement pour sou-

lever l’appareil, NON PAS les chariot, les bouteilles de gaz ou tout autre accessoire.

D Utiliser un engin d’une capacité appropriée pour

D En utilisant des fourches de levage pour déplacer l’unité, s’assurer

que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

soulever l’appareil.

L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement, respec-

ter le cycle opératoire nominal.

D Réduire l e courant ou le cycle opératoire avant de

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

recommancer le soudage.

DES ORGANES MOBILES peuvent provoquer des blessures.

D Rester à l’écart des organes mobiles comme le

ventilateur.

D Maintenir fermés et fixement en place les portes,

panneaux, recouvrements et dispositifs de protection.

LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences.

D Le rayonnement haute frequence peut provoquer

des interférences avec les équipements de radio–navigation e t d e communication, les services

D Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installation.

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

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’appa-

reil.

D Effectuer régulièrement le contrôle et l’entretien de l’installation. D Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et et un blindage pour réduire les interférences éventuelles.

de sécurité et les ordinateurs.

LE SOUDAGE À L’ARC risque de provoquer des interférences.

LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antistatiques

pour stocker, déplacer ou expédier des cartes de circuits imprimes.

DES ORGANES MOBILES peuvent provoquer des blessures.

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

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

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

reçu l’instruction.

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

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

D L’énergie électromagnétique risque de provoquer

des interférences pour l’équipement électronique sensible tel que les ordinateurs et l’équipement

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

patible électromagnétiquement.

D Pour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).

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

électronique sensible.

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

conformément à ce mode d’emploi.

D En cas d’interférences après avoir pris les mesures précédentes, il

incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

commandé par ordinateur tel que les robots.

LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques.

D Porteurs de stimulateur cardiaque, restez à dis-

tance.

D Les porteurs d’un stimulateur cardiaque doivent

d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

OM-196 188 Page 7

Page 14

1-4. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme A WS

F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126

National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Règles de sécurité en soudage, coupage et procédés connexes, norme CSA W117.2, de l’Association canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Pra ctices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les effets, pour l’organisme, des champs magnétiques basse fréquence

Le courant de soudage, pendant son passage dans les câbles de soudage, causera des champs électromagnétiques. Il y a eu et il y a encore un certain souci à propos de tels champs. Cependant, après avoir examiné plus de 500 études qui ont été faites pendant une période de recherche de 17 ans, un comité spécial ruban bleu du National Research Council a conclu: “L’accumulation de preuves, suivant le jugement du comité, n’a pas démontré que l’exposition aux champs magnétiques et champs électriques à haute fréquence représente un risque à l a santé humaine”. Toutefois, des études sont toujours en cours et les preuves continuent à être examinées. En attendant que les conclusions finales de la recherche soient établies, il vous serait souhaitable de réduire votre exposition aux champs électromagnétiques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur. 3 Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

4 Garder le poste de soudage et les câbles le plus loin possible de

vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il e st alors recommandé de respecter les consignes ci–dessus.

OM-196 188 Page 8

Page 15

SECTION 2 – DEFINITIONS

2-1. Manufacturer’s Warning Label Definitions

1 1.1 1.2 1.3

2 2.1

3 3.1 3.2 3.3

4 4.1

2.2

2.3

S-179 310

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

1 Electric shock from welding

electrode or wiring can kill.

1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

1.2 Protect yourself from electric shock by insulating yourself from work and ground.

1.3 Disconnect input plug or power before working on machine.

2 Breathing welding fumes can

be hazardous to your health.

2.1 Keep your head out of the fumes.

2.2 Use forced ventilation or local exhaust to remove the fumes.

2.3 Use ventilating fan to remove fumes.

3 Welding sparks can cause

explosion or fire.

3.1 Keep flammables away from welding. Do not weld near flammables.

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

3.3 Do not weld on drums or any closed containers.

4 Arc rays can burn eyes and

injure skin.

4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection.

5 Become trained and read the

instructions before working on the machine or welding.

6 Do not remove or paint over

(cover) the label.

1/96

OM-196 188 Page 9

Page 16

1 Warning! Watch Out! There

2 Electric shock from wiring can

3 Disconnect input plug or

1234 5 6

4 Hazardous voltage remains

> 60 s

S-179 190-A

5 Always wait 60 seconds after

6 Check input capacitor voltage,

1 Warning! Watch Out! There

2 When power is applied failed

1 23 4 5

3 Flying pieces of parts can

4 Always wear long sleeves and

S-179 304-A

5 After taking proper

are possible hazards as shown by the symbols.

kill.

power before working on machine.

on input capacitors after power is turned off. Do not touch fully charged capacitors.

power is turned off before working on unit, OR

and be sure it is near 0 before touching any parts.

4/96

are possible hazards as shown by the symbols.

parts can explode or cause other parts to explode.

cause injury. Always wear a face shield when servicing unit.

button your collar when servicing unit.

precautions as shown, connect power to unit.

2345

OM-196 188 Page 10

∠ = <60

∠

4/96

1 Warning! Watch Out! There

are possible hazards as shown by the symbols.

2 Falling equipment can cause

injury and damage to unit.

3 Always lift and support unit

using both handles. Keep angle of lifting device less than 60 degrees.

4 Use a proper cart to move

unit.

5 Do not use one handle to lift

or support unit.

S-179 309-A

1/96

Page 17

2-2. Symbols And Definitions

Amperage Positive Remote

Output Circuit Breaker Negative On

Off Inductance

2-3. Manufacturer’s Rating Label

Protective Earth

(Ground)

Voltage

Voltage Input

2-4. Harmonic Data

HARMONIC DATA per IEC 61000-3-12, draft 2000-9-29

PRIMARY; 400V/30.5A/60hz LOAD; 450A/38Vdc/390IPM/,MAXIMUM OUTPUT, GMAW.

R sce = 227.28

THD

PWHD Table 4, balanced three phase equipment.

S-184 765

61 Amps 35 Amps

OM-196 188 Page 11

Page 18

3-1. Specifications

Wire

Maximum

Amperes Input

Power

Output

Range

Range*

Diameter

Circuit

Output 60 Hz,

KVA

450 A @ 38 Volts DC,

Three

450 A @ 38 Volts DC,

100% Duty Cycle;

Standard:

.030 To .062 in

Three

100% Duty Cycle;

10 – 38

50 To 780 ipm

.030 To .062 in

)

953121.6

19.4

Phase

565 A @ 43 Volts DC,

(1.3 To 19.8 mpm)

(0.8 To 1.6 mm)

(660 mm)

Input

Rated Welding

SECTION 3 – INSTALLATION

Voltage

Wire Feed Speed

Diameter

Range

Maximum

Open-

Voltage DC

Amperes Input

At Rated Load

Three-Phase

KVA KW

Phase

*Wire feed speed ranges are for GMAW welding. While pulse welding, wire feed speed ranges may be more limited (see Section 9) **While idling

565 A @ 43 Volts DC

60% Duty Cycle

(0.8 To 1.6 mm

3-2. Dimensions And Weight

Hole Layout Dimensions

A 14-21/64 in (363.9 mm)

B 20-3/4 i n (527.1 mm)

C 23-27/64 in (594.9 mm)

D 24-31/32 in (634.2 mm)

E 12-3/8 i n (314.3 mm)

F 9/32 in (7.1 mm) Dia.

Weight

26 in

(660 mm)

14-1/2 i n

(368 mm)

23-3/4 in

(603 mm)

130 lb (59 kg)

801 914-A

OM-196 188 Page 12

Page 19

3-3. Selecting A Location

Movement

Location

18 in

(460 mm)

Tipping

Y Special installation may be required where gasoline or volatile

liquids are present – see NEC Article 511 or CEC Section 20.

18 in

(460 mm)

Y Do not move or operate

unit where it could tip.

1 Lifting Forks Use lifting forks to move unit. Extend forks beyond opposite side

of unit. 2 Lifting Handles Use handles to lift unit. 3 Hand Cart Use cart or similar device to move

unit. 4 Rating Label Use rating label to determine input

power needs. 5 Line Disconnect Device Locate unit near correct input

power supply.

loc_2 3/96 - 801 958 / 801 914-A

3-4. Connection Diagram

2 3

11 12

. The proper interface kit must

be installed in the interface unit to allow it to be connected to the robot.

1 Robot (Will Vary According T o

Application) 2 Motor/Drive Assembly 3 Gas Cylinder 4 Gas Hose 5 Robot Control 6 Robot Input/Output Cable 7 Remote Program Select

Cable (Optional) 8 Gas And Motor Control Cable 9 Welding Power

Source/Interface Unit 10 Negative (–) Weld Cable 11 Workpiece 12 Voltage Sensing Lead

. Positive (+) voltage sensing

lead is contained in the motor

cable.

13 Positive (+) Weld Cable

801 915-B

OM-196 188 Page 13

Page 20

3-5. Weld Output Terminals And Selecting Cable Sizes

Positive

Negative

3-6. 115 Volts AC Duplex Receptacle And Circuit Breakers

Total Cable (Copper) Length In Weld Circuit Not Exceeding

30 m (100 ft) Or Less

Welding

Amperes

100 25 25 25 35 35 50 55 55 150 35 35 35 50 55 70 95 95 200 35 35 50 55 70 95 120 120 250 35 50 55 70 95 120 2-70 2-70 300 50 55 70 95 120 2-70 2-95 2-95 350 55 70 95 120 2-70 2-95 2-95 2-120

(+)

*Weld cable size (mm2) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007E

Negative

(–)

Ref. 801 914-A

400 55 70 95 120 2-70 2-95 2-120 2-120 500 70 95 120 2-70 2-95 2-120 3-95 3-95 600 95 120 2-70 2-95 2-120 3-95 3-120 3-120

10 – 60%

Duty Cycle

60 – 100%

Duty Cycle

45 m

(150 ft)

60 m

(200 ft)

2 3

70 m

(250 ft)

10 – 100% Duty Cycle

90 m

(300 ft)

1 115 V 10 A AC Receptacle Power is shared between duplex

receptacle and internal 14 socket receptacle.

2 Circuit Breaker CB1 3 Circuit Breaker CB2 CB1 protects duplex receptacle

and 115 volts ac portion of internal 14 socket receptacle from overload.

Press button to reset breaker. CB2 protects 24 volts ac portion of

internal 14 socket receptacle from overload.

Press button to reset breaker. 4 Circuit Breaker CB1 CB1 protects the motor control

circuitry from overload. If CB1 trips, the wire drive motor is inoperative.

Press button to reset breaker.

105 m

(350 ft)

120 m

(400 ft)

OM-196 188 Page 14

802 748

Page 21

3-7. Electrical Service Guide

Three-Phase

Input Voltage 400 Input Amperes At Rated Output 31 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 45 Min Input Conductor Size In AWG/Kcmil 10 Max Recommended Input Conductor Length In Feet (Meters) 264 (80) Min Grounding Conductor Size In AWG/Kcmil 10

Reference: 1993 National Electrical Code (NEC). S-0092J

3-8. Connecting Input Power

Input Fi l t e r

Board

Tools Needed:

5/16 in

Y Always connect

L1 L2

=GND/PE

grounding conductor first.

Y Turn Off welding power source, and

check voltage on input capacitors according to Section 5-3 before proceeding.

Check input voltage available at site. Remove left side panel.

1 Input And Grounding Conductors See Section 3-7. Install ring terminals of proper size onto input

conductors for connection to input filter board terminals (see illustration).

2 Line Disconnect Device

ssb2.4* 1/94 – ST-801 718 / ST-801 946

Select type and size of overcurrent protection using Section 3-7. Connect input and grounding conductors to a deenergized line disconnect device.

Reinstall left side panel.

OM-196 188 Page 15

Page 22

3-9. Rear Panel Connections

C D

Example Receptacle

L K

1 Receptacle 2 Keyway 3 4-Pin Receptacle (Optional

External Voltage Sensing Connection)

To connect interconnecting cord to receptacle, align keyway, insert plug, and tighten threaded collar.

Secure ring terminal on remaining end of cord to work.

4 Peripheral Receptacle Receptacle provides connection to

touch sensor, water flow switch, jog +/–, and n/o relay contacts circuitry.

5 Robot Control Receptacle

(Remote Program Select Connection To Robot Control)

To connect matching interconnecting cord to one of the above receptacles, align keyway, insert plug, and tighten threaded collar. Connect remaining end of cord to matching receptacle on applicable equipment (see Section 3-4).

6 10-Socket Receptacle (Wire

Feed/Shielding Gas Control Connection To Motor Drive Assembly)

Ref. S-0003-A / 802 748

OM-196 188 Page 16

Page 23

3-10. Peripheral Receptacle Functions

Output Relay Con-

Signal

Touch Sensor ON

Programmable

Coolant Flow

Switch Input

Function Socket Socket Information

A Contact closure to B dependent upon state of

programmed output (see Section 14-5). The closure between A and B can carry a maximum of 0.6 amps at 125 VAC; or a maximum of 0.6 amps at 110 VDC.

tacts

Purge

B Contact closure to A dependent upon state of

programmed output (see Section 14-5). See socket A information for current carrying capacity of closure.

C* Circuit common.

D Contact closure to C completes 24 volts dc

solenoid circuit to purge shielding gas line.

E Contact closure to F indicates coolant flow switch is

closed and recirculating coolant system is operational.

F* Circuit common.

Jog + H** Contact closure to circuit common advances

Jog – J** Contact closure to circuit common retracts welding

802 748

Touch Sensor ON

And Output Signa

*Circuit common is same electrical reference point. **Speed of Jog + and Jog – is at setup value for Jog IPM parameter. { Socket M can be changed to 0 volts dc (common) for part touched output signal (see Section 3-12). Note: A customer supplied matching amphenol plug [Miller Part No. 194 847 (Amphenol Part No. MS3106A20-33P and strain relief clamp

AN3057-12)] is required to use peripheral receptacle.

M{ Part touched is selectable for either 0 volts dc

welding wire at wire drive assembly.

wire at wire drive assembly.

K Contact closure to L energizes Touch Sensor

circuitry.

L* Circuit common.

(common) or +24 volts dc (see Section 3-12). Part touched +24 volts dc output signal referenced to circuit common is factory default setting.

OM-196 188 Page 17

Page 24

3-11. Touch Sensor Operation

The touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source. Voltage sense leads provide a path for touch sensor voltage when this feature is turned on at the peripheral receptacle. Turning on touch sensor causes a dc voltage to be present on the welding wire. When welding wire touches the weldment, the voltage sensing circuit closes, and a +24 volts dc output signal is sent to the robot control indicating weldment detection. Touch sensor dc voltage on the welding wire will vary from 60 to 150 volts dc depending on the welding power source. As soon as touch sensor turns on, DANGER SENSOR ON appears on the front panel display.

3-12. Touch Sensor Board PC18 Switch S1 Settings

Top View

Front

Y WARNING: One of S1 switches must be ON and

the other must be OFF.

1 Touch Sensor Board PC18 2 Switch S1 When S1 switch 1 is On, output is

+24 volts dc (factory default). When S1 switch 2 is On, output is

common.

212 321-A

OM-196 188 Page 18

Page 25

3-13. Connecting Setup Pendant To Welding Power Source

. Disconnect the setup pendant from the welding

power source before welding.

Y Turn Off welding power

source and weld control.

1 Welding Power Source 2 Interconnecting Cord 3 Setup Pendant To make connections, align plug

with receptacle, insert plug, and use thumb screws on receptacle to secure plug.

802 816

OM-196 188 Page 19

Page 26

SECTION 4 – OPERATION

4-1. Operational Terms

The following is a list of terms and their definitions as they apply to this interface unit:

General Terms: Adaptive Pulse Welding When the “adaptive pulse” welding process is selected, the unit will attempt to automatically regulate

Abk (Background Amperage) Abk is the low weld current. Background current preheats welding wire and maintains the arc. When

Apk (Peak Amperage) Apk is the high pulse of welding current. Peak current melts the welding wire and forms a droplet. The

Vpk (Peak Voltage) Arc voltage during peak current phase of the pulse waveform. This determines arc length during

Inductance In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit

PPS (Pulses Per Second) PPS, pulse rate, and frequency (Hz) are used interchangeably. A PPS or pulse rate of 60 Hz means

PWms (Pulse Width in Milliseconds) PWms is the time spent at peak current (1.2 ms is .0012 seconds). This time must be long enough to

Synergic Synergic refers to the unit’s ability to use preprogrammed pulse parameters to determine the actual

Trim Term used to represent arc length adjustments in pulse programs. Increasing trim increases the ac-

pulse frequency in order to maintain a constant arc length, regardless of change in welding wire stickout.

background current is too low, the arc is unstable and hard to maintain.

droplet is forced into the weld puddle.

adaptive pulse welding.

metal transfers per second (provided no other changes are made) and increase the arc-on time. The increased arc-on time makes the pool more fluid.

60 pulses of current are produced each second.

form a droplet of welding wire. The stiffness or fluidity of the molten weld puddle is controlled by PWms.

pulse settings of Peak Amperage, Background Amperage, Pulse Frequency and Pulse Width at any specific wire feed speed setting.

tual arc length. Likewise, decreasing trim shortens arc length. Trim is replaced by volts in MIG programs.

Setup Pendant Terms: Card Mode Is used to select use of the optional data card storage and retrieval capabilities. Process Mode Is used to select the type of process to be used, including Pulse, Adaptive Pulse, or Mig. Sequence Mode Is used to select and program the weld sequences which include preflow, run-in, weld, crater,

Setup Screen Terms: Access Code NOTE: The optional Data Card is required to activate this feature. With code off, access to the setup

Arc Start NOTE: Do not use the Hot Start setting for .035 in (9 mm) or smaller wire. Use the Hot Start mode for

Arc Time Allows actual arc time up to 9,999.99 hours and weld cycles up to 999,999 to be accumulated and

Mig Type (Voltage Correction)

Name Feature When using the optional Data Card and turning the name feature on, programs written to the card can

Program Reset By selecting program reset in the memory reset mode, the unit defaults to original factory program

Range The interface requires that the voltage and amperage range of the welding power source be entered.

Security NOTE: The optional Data Card is required to activate this feature. Is used to limit what the operator

Software Screen Selection of this function will display the software version of the unit. When talking with factory service

OM-196 188 Page 20

burnback, and postflow.

displays is not restricted. With code on, the operator must know and enter the access code to access or change any of the setup displays. To use code, press Parameter Select button to enter access code. When the correct letter is entered, the indicator automatically moves to the next character. When the final access code letter is entered, the display automatically changes to the initial setup display.

pulse welding with 450 Ampere Inverter Model when high initial weld current is necessary to start large diameter welding wires. When in Hot Start, the 450 Ampere Inverter Model starts the arc in the CV mode and switches to CC once the arc is started. Do not use Hot Start unless using 450 Ampere Inverter Model.

displayed on the digital display, and can be reset to zero as required. With DVC Voltage Correction On, the unit uses closed-loop control based on voltage feedback to

maintain set voltage parameters. With DVC Voltage Correction Of f, feedback from the arc is not used for closed-loop feedback to maintain voltage parameters. Feedback from the arc is still used for other functions.

be identified by name, number, job number, etc.

settings for the program last active. All other program and setup information remains the same.

Obtain this information from the welding power source Owner’s Manual.

can control. This includes accessing the number of the program, 1 through 8, and the range of welding parameters within the program.

personnel, this number may be required.

Page 27

System Reset By selecting system reset in the memory reset mode, the unit defaults to original factory settings for

Voltage (Control Feedback) Allows voltage to be monitored at the output terminals by two methods. This can be selected through

Arc Start/Volt Sense Shutdown When this feature is on, the system immediately shuts down if no arc voltage is sensed. An error

Wire Feed Mode Allows the selection of inches per minute or meters per minute for wire feed speed. This mode is also

all programs and all set up excluding System, Arc Time, and Model T ype.

the internal connections of the unit, or through the unit’s external voltage sense lead. When using the V . Sense setting, arc voltage feedback is through the voltage sense leads connected to the feeder. Use this setting when there is more than 50 ft (15 m) of weld cable used.

message is displayed. When this feature is off, wire feeds even when there is no arc voltage sensed.

used to select motor type; standard speed, low speed, or high speed.

4-2. Lower Front Panel Controls

1 Power Switch

. The fan motor is thermostatically

controlled and only runs when cooling is needed.

2 Voltmeter (see Section 4-3) 3 Ammeter (see Section 4-3)

4-3. Meter Functions

Note

Mode Meter Reading At Idle Meter Reading While Welding

MIG

Pulsed

MIG

The meters display the actual weld output values for approximately three seconds after the arc is broken.

24.5

Preset Volts Blank

PPP PPP

Pulse Display Pulse Display

Ref. 186 067

24.5 250

Actual Volts Actual Amps

24.5 250

Actual Volts Actual Amps

OM-196 188 Page 21

Page 28

4-4. Upper Front Panel Controls

1 2 345 67

1 Setup Pendant Receptacle Receptacle for connecting pendant

interconnecting cord. 2 Jog Forward Push Button Advances wire out of the gun. 3 Wirefeed Indicator LED LED lights when wire feed motor is

energized.

4 Jog Reverse Push Button Retracts wire up into the gun. 5 Gas Indicator LED LED lights when gas solenoid is energized. 6 Purge Push Button Momentarily energizes gas solenoid to

purge air from gun shielding gas line, or to adjust shielding gas regulator.

7 Contactor Indicator LED LED lights when welding power source

contactor is energized. 8 Main Display Shows system state, active program, error

messages, weld parameters at idle and during welding.

184 197

OM-196 188 Page 22

Page 29

4-5. Duty Cycle And Overheating

4-6. Volt-Ampere Curves

100% Duty Cycle At 450 Amperes 60% Duty Cycle At 565 Amperes

Duty Cycle is percentage of 10 mi n utes that unit can weld at rated load without overheating.

If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.

Y Exceeding duty cycle can

damage unit and void warranty.

Continuous Welding

Overheating

Minutes

6 Minutes Welding 4 Minutes Resting

A/V

Reduce Duty Cycle

duty1 4/95 – 181 560

Volt-ampere curves show minimum and maximum voltage and amperage output capabilities of unit. Curves of other settings fall between curves shown.

va_curve1 4/95 – 181 562

OM-196 188 Page 23

Page 30

4-7. Setup Pendant Controls

802 815

1 Increase Button Works with security feature on welding

power source to allow increasing weld parameter values within the allowable range.

2 Decrease Button Works with security feature on welding

power source to allow decreasing weld parameter values within the allowable range.

3 Parameter Select Button Press button to move indicator in right

window display, and to make selections in setup screens.

4 Mode Select Button

Press button to move indicator in left window display.

5 Interconnecting Cable Receptacle 6 Parameter Display 7 Mode Display 8 Card Slot

OM-196 188 Page 24

Page 31

SECTION 5 – MAINTENANCE & TROUBLESHOOTING

5-2. Blowing Out Inside Of Unit

5-1. Routine Maintenance

3 Months

Replace damaged or unreadable label.

Repair or replace cracked cables and cords.

Clean an d tighten weld terminals.

Repair or replace cracked cables.

Y Disconnect power

before maintaining.

6 Months

Blow out inside.

. Maintain more often

during severe conditions.

Replace cracked torch body.

Y Do not remove case when

blowing out inside of unit.

To blow out unit, direct airflow through front and back louvers as shown.

801 914

OM-196 188 Page 25

Page 32

5-3. Removing Case and Measuring Input Capacitor Voltage

Y Significant DC voltage can remain on capacitors af-

ter unit is Off. Always check the voltage as shown to be sure the input capacitors have discharged before working on unit.

Tools Needed:

5/16 in

Turn Off welding power source, a n d disconnect input power.

1 Outside Handle Screws To loosen top, remove two outside

handle screws from both handles and all side bolts.

2 Interconnect Board PC2 3 Voltmeter Measure the dc voltage across the

screw terminals on PC2 as shown until voltage drops to near 0 (zero) volts.

Proceed with job inside unit. Reinstall cover when finished.

+ lead to lower right

terminal, – lead to

upper right terminal

OM-196 188 Page 26

Ref. 801 914 / Ref. 801 917

Page 33

5-4. Voltmeter/Ammeter Help Displays

. All directions are in reference to

the front of the unit. All circuitry referred to is located inside the unit.

1 Help 1 Display Indicates a malfunction in the

primary power circuit. If this display is shown, contact a Factory Authorized Service Agent.

2 Help 2 Display Indicates a malfunction in the

thermal protection circuitry located on the left side of the unit. If this display is shown, contact a Factory Authorized Service Agent.

3 Help 3 Display Indicates the left side of the unit has

overheated. The unit has shut down to allow the fan to cool it (see Section 4-5). Operation will continue when the unit has cooled.

4 Help 4 Display Indicates a malfunction in the

thermal protection circuitry located on the right side of the unit. If this display is shown, contact a Factory Authorized Service Agent.

5 Help 5 Display Indicates the right side of the unit

has overheated. The unit has shut down to allow the fan to cool it (see Section 4-5). Operation will continue when the unit has cooled.

6 Help 6 Display Indicates that the input voltage is

too low and the unit has automatically shut down. Operation will continue when the voltage is within ±15% of the operating range. If this display is shown, have an electrician check the input voltage.

7 Help 7 Display Indicates that the input voltage is

too high and the unit has automatically shut down. Operation will continue when the voltage is within ±15% of the operating range. If this display is shown, have an electrician check the input voltage.

8 Help 8 Display Indicates a malfunction in the sec-

ondary power circuit of the unit. If this display is shown, contact a Factory Authorized Service Agent. In addition, when the optional ground current sensor is installed, this display indicates weld current in the ground conductor. When this occurs, have an electrician check the primary and secondary connections.

HE.L P–1

HE.L P–2

HE.L P–3

HE.L P–4

HE.L P–5

HE.L P–6

HE.L P–7

HE.L P–8

OM-196 188 Page 27

Page 34

5-5. Front Panel Error Displays

Mem CRC E r r o r

Mem Range Er r

No Vo l t Sensed Er ror

No Tach Sensed Er r or

Arc Stop Error

Er ror Card Read

No F l ow Det ec t ed

Grd Cur rent Detect

Wi re St i ck Er ror

Arc Fai l TimeOut Err

Arc Star t Error

Stop Weld Cycle Err

1 Memory CRC Error Display Corrupted program data has been detected

or loaded. The “X” value indicates the program number.

May be caused by incompatible information on the data card or bad memory.

2 Memory Range Error Display Improper welding power source range is

selected. The “X” value indicates the program number.

May be caused by improper range settings or improper data loaded into the interface unit.

3 No Volt Sensed Error Display The arc voltage sense circuit did not receive

feedback within the required time after an arc was established.

May be caused by an inability to establish an arc in the pulse schedule, or a lack of voltage feedback.

4 No Tach Sensed Error Display The motor tachometer feedback is not

reaching the control. May be caused by obstructions in the wire

feed system or a faulty wire drive system. 5 Arc Stop Error Display Trouble is occurring at arc end. May be caused by obstructions in the wire

feed sys t e m o r a f a u l t y w i r e d r i v e s y s t e m o r torch is touching part at end of weld.

6 Arc Start Error Display Trouble is occurring at arc start. May be caused by obstructions in the wire

feed system or a faulty wire drive system. 7 Stop Weld Cycle Error Display An error has been detected and the robot

hasn’t stopped the weld cycle, causing the interface unit to stop the weld cycle and wait for the robot to stop.

8 Error Card Read Display The card reader is not working properly. May be caused by a bad data card, a bad

data card reader, a faulty microprocessor circuit board, or a wiring problem.

9 No Flow Detected No coolant is detected after preflow in the

weld cycle. Check coolant system and flow switch for proper operation.

No Input IPM

10 Ground Current Detect Error Display Weld current has been detected in the earth

ground connection. May be caused by a conductor making

connection to the unit chassis. 11 Wire Stick Error Display The welding wire has stuck to the workpiece

at the end of the weld. May be caused by poor weld conditions. 12 Arc Fail Time Out Error Display An arc was not established within the allotted

time. May be caused by an inoperable wire drive,

absence of shield gas, or improperly operating welding power source.

13 No Input IPM Display Analog IPM (inches per minute) from robot is

not being received. May be caused by having no wire feed speed

programmed at the robot.

OM-196 188 Page 28

Page 35

5-6. Weld Interface Board PC12 Diagnostic LED’s

LED1

LED2

LED3

LED4

LED5

LED6

LED8

LED7

LED9

LED10

LED11

LED12

1 Weld Interface Board PC12 Diagnostic LED’s are visible inside

unit, located on PC12 (see illustration for board location).

Refer to Section 5-7 for information on diagnostic LED’s.

Reinstall cover and left side panel after checking diagnostic LED’s.

LED13

Top View

191 842

OM-196 188 Page 29

Page 36

5-7. Diagnostic LED’s On Weld Interface Board PC12

LED Status Diagnosis

1 On Indicates auxiliary output relay is not energized.

Off Indicates auxiliary output relay is energized.

2 On Indicates gas valve is not energized.

Off Indicates gas valve is energized.

3 On Indicates +24 volts dc is present for gas valve.

Off Indicates +24 volts dc is not present for gas valve.

4 On Indicates +15 volts dc is present on weld interface board PC12.

Off Indicates +15 volts dc is not present on weld interface board PC12.

5 On Indicates –15 volts dc is present on weld interface board PC12.

Off Indicates –15 volts dc is not present on weld interface board PC12.

6 On Indicates +15 volts dc power source supply is present on weld interface board PC12.

Off Indicates +15 volts dc power source supply is not present on weld interface board PC12.

7 On Indicates –15 volts dc power source supply is present on weld interface board PC12.

Off Indicates –15 volts dc power source supply is not present on weld interface board PC12.

8 On Indicates +5 volts dc is present on weld interface board PC12.

Off Indicates +5 volts dc is not present on weld interface board PC12.

9 On Input signal for no Jog retract.

Off Input signal for Jog retract.

10 On Input signal for no Jog advance.

Off Input signal for Jog advance.

11 On Indicates CV mode is selected.

Off Indicates CC mode is selected.

12 On Input signal for no welding power source contactor.

Off Input signal for welding power source contactor.

13 On Indicates an Emergency Stop condition is not present.

Off Indicates an Emergency Stop condition is present.

OM-196 188 Page 30

Page 37

5-8. Customer Interface Board PC14 Diagnostic LED’s

LED8

LED11

LED12

LED13

LED6

LED5

LED7

LED10

LED9

LED14

LED15

1 Customer Interface Board PC14 Diagnostic LED’s are visible inside

unit, located on PC14 (see illustration for board location).

Refer to Section 5-9 for information on diagnostic LED’s.

Reinstall top cover after checking diagnostic LED’s.

LED16

LED22

LED23

LED24

LED25

LED4

LED3

LED2

LED1

LED21

LED20

LED19

LED18

LED17

Top View

OM-196 188 Page 31

Page 38

5-9. Diagnostic LED’s On Customer Interface Board PC14

LED Status Diagnosis

On Indicates –15 volts dc RA supply is present on customer interface board PC14. Off Indicates –15 volts dc RA supply is not present on customer interface board PC14. On Indicates +15 volts dc RA supply is present on customer interface board PC14. Off Indicates +15 volts dc RA supply is not present on customer interface board PC14. On Input signal On from robot for no Emergency Stop. Off Input signal Off from robot for Emergency Stop. On Indicates +24 volts dc RD supply is present on customer interface board PC14. Off Indicates +24 volts dc RD supply is not present on customer interface board PC14.

5 On Input signal On from robot for shielding gas.

Off Input signal Off from robot for no shielding gas.

6 On Input signal On from robot to energize contactor.

Off Input signal Off from robot to not energize contactor.

7 On Input signal On from robot for jog retract.

Off Input signal Off from robot for no jog retract. On Input signal On from robot for jog advance. Off Input signal Off from robot for no jog advance. On Indicates automatic configuration Bit D is set. Off Indicates automatic configuration Bit D is not set. On Input signal On for RPS-C. Off Input signal Off for RPS-C. On Input signal On for RPS-B. Off Input signal Off for RPS-B.

12 On Indicates remote program A selected.

Off Indicates remote program A not selected.

13 On Input signal On from peripheral for touch sensor.

Off Input signal Off from peripheral for no touch sensor. On Indicates automatic configuration Bit B is set. Off Indicates automatic configuration Bit B is not set. On Indicates automatic configuration Bit A is set. Off Indicates automatic configuration Bit A is not set. On Indicates automatic configuration Bit C is set. Off Indicates automatic configuration Bit C is not set. On Input signal On from relay CR4 for wire stuck in weld joint. Off Input signal Off from relay CR4 for wire not stuck in weld joint. On Input signal On from relay CR6 for flow (shielding gas or coolant) present. Off Input signal Off from relay CR6 for flow (shielding gas or coolant) not present. On Input signal On from relay CR5 for arc detect. Off Input signal Off from relay CR5 for no arc detect.

20 On Input signal On from relay CR2.

Off Input signal Off from relay CR2. On Input signal On from relay CR1 for welding power source ready and no detected errors present.

22 On Input signal On from peripheral for flow switch.

Off Input signal Off from relay CR1 for welding power source not ready, detected errors are present, or unit

is in Setup or Control mode.

Off Input signal Off from peripheral for no flow switch.

OM-196 188 Page 32

Page 39

LED DiagnosisStatus

23 On Input signal On from peripheral for jog advance.

Off Input signal Off from peripheral for no jog advance.

24 On Input signal On from peripheral for jog retract.

Off Input signal Off from peripheral for no jog retract. On Input signal On from peripheral for shielding gas purge. Off Input signal Off from peripheral for no shielding gas purge. On Input signal On for touch sensor. Off Input signal Off for no touch sensor.

5-10. Motor Board PC13 Diagnostic LED’s

1 Motor Board PC13 Diagnostic LED’s are visible inside

unit, located on PC13 (see illustration for board location).

Refer to Section 5-11 for information on diagnostic LED’s.

Reinstall cover after checking diagnostic LED’s.

LED1

Top View

LED2

LED9

LED4

LED3 LED11

212 353-A

OM-196 188 Page 33

Page 40

5-11. Diagnostic LED’s On Motor Board PC13

LED Status Diagnosis

1 On Indicates motor reverse relay is energized.

Red Off Indicates motor reverse relay is not energized.

2 On LED should be On. Indicates 115 volts ac input is sufficiently charging +170 volts dc bus for motor.

Red Off If LED is Of f, check 115 volts ac input.

9 On LED should be On. Indicates +15 volts dc regulated bus is on.

Red Off If LED is Of f, check for a short at board traces between bus and ground or at RC1-6 for 24 volts ac input

11 On LED should be On. Indicates +5 volts dc regulated bus is on.

Red

4 On Indicates encoder input from motor to microprocessor is greater than 3 ipm.

Green Off Indicates motor is off or encoder input from motor to microprocessor is less than 3 ipm.

3 On Indicates microprocessor is operating without sensing any faults.

Green Blinking If microprocessor senses a fault, LED blinks to indicate type of fault.

Off If LED is Off, check for a short at board traces between bus and ground or at RC1-6 for 24 volts ac input

3 Blinks PC13 sensed an overcurrent condition in wire drive. Check motor cables and connections for short cir-

4 Blinks PC13 PWM (pulse width modulation) output was on, but no encoder pulses were sensed for more than

5 Blinks Motor was not operating at proper speed for over 2 seconds. This fault results from monitoring amount of

6 Blinks +170 volts dc motor bus has dropped below +90 volts dc. Check 115 volts ac input to PC13.

to regulator.

cuits or bad connections. Check motor armature resistance, typical range is 10 to 20 ohms.

1 second. Check motor cables and connections for short circuits or bad connections. Electronic resetable fuses called PTCs protect encoder power supply . If motor cable has a short circuit, PTCs will g o t o high resistance to protect PC13. Do a pin-to-pin check for shorted conductors inside cable jacket, and replace cable if necessary. Check motor encoder, and replace encoder if necessary.

velocity error (command speed – actual speed) to make sure that motor is running within a calculated percentage o f command speed. For example, if motor is at a high speed and PWM is at maximum voltage, a dirty liner or other load drags down motor speed will result in this fault condition. Clean liner, correct other load conditions, such as spool hub tension too tight, or reduce wire feed speed.

5-12. Troubleshooting

Trouble Remedy

No weld output; unit completely inoperative.

No weld output; meter display On. Check, repair, or replace remote control.

Erratic or improper weld output. Use proper size and type of weld cable (see Section 3-5).

No 115 volts ac output at duplex receptacle, Remote 14 receptacle.

No 24 volts ac output at Remote 14 receptacle.

Place line disconnect switch in On position (see Section 3-8).

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-8). Check for proper input power connections (see Section 3-8).

Unit overheated. Allow unit to cool with fan On (see Section 4-5). Check voltmeter/ammeter Help displays.

Clean and tighten all weld connections. Reset circuit breaker CB1 (see Section 3-6).

Reset circuit breaker CB2 (see Section 3-6).

OM-196 188 Page 34

Page 41

Notes

OM-196 188 Page 35

Page 42

SECTION 6 – ELECTRICAL DIAGRAMS

OM-196 188 Page 36

Figure 6-1. Circuit Diagram For Welding Power Source

Page 43

203 505-A

OM-196 188 Page 37

Page 44

OM-196 188 Page 38

Figure 6-2. Circuit Diagram For Control Board PC1 (Part 1 of 3)

Page 45

203 311 (1 of 3)

OM-196 188 Page 39

Page 46

OM-196 188 Page 40

Figure 6-3. Circuit Diagram For Control Board PC1 (Part 2 of 3)

Page 47

203 311 (2 of 3)

OM-196 188 Page 41

Page 48

OM-196 188 Page 42

Figure 6-4. Circuit Diagram For Control Board PC1 (Part 3 of 3)

Page 49

203 311 (3 of 3)

OM-196 188 Page 43

Page 50

OM-196 188 Page 44

Figure 6-5. Circuit Diagram For Function/Meter Board PC3

Page 51

190 696

OM-196 188 Page 45

Page 52

Figure 6-6. Circuit Diagram For Interconnect Board PC2

184 183

OM-196 188 Page 46

188 015

Figure 6-7. Circuit Diagram For Gate Boards PC4 And PC5

Page 53

Notes

OM-196 188 Page 47

Page 54

OM-196 188 Page 48

Figure 6-8. Circuit Diagram For Interface Module

Page 55

193 709-A

OM-196 188 Page 49

Page 56

OM-196 188 Page 50

Figure 6-9. Circuit Diagram For Microprocessor Board PC11

Page 57

191 838

OM-196 188 Page 51

Page 58

OM-196 188 Page 52

Figure 6-10. Circuit Diagram For Motor Board PC13

Page 59

OM-196 188 Page 53

212 354-A

Page 60

OM-196 188 Page 54

182 996

Figure 6-11. Circuit Diagram For Switch Board PC15

Page 61

Figure 6-12. Circuit Diagram For Junction Board PC16

200 739

OM-196 188 Page 55

Page 62

OM-196 188 Page 56

Figure 6-13. Circuit Diagram For Interface Board PC12 (Part 1 of 2)

Page 63

191 843-A (Part 1 of 2)

OM-196 188 Page 57

Page 64

OM-196 188 Page 58

Figure 6-14. Circuit Diagram For Interface Board PC12 (Part 2 of 2)

Page 65

191 843-A (Part 2 of 2)

OM-196 188 Page 59

Page 66

Figure 6-15. Circuit Diagram For Customer Interface Board PC14 (Part 1 of 3)

OM-196 188 Page 60

Page 67

Pensar 86147s03 (Part 1 of 3)

OM-196 188 Page 61

Page 68

Figure 6-16. Circuit Diagram For Customer Interface Board PC14 (Part 2 of 3)

OM-196 188 Page 62

Page 69

Pensar 86147s03 (Part 2 of 3)

OM-196 188 Page 63

Page 70

Figure 6-17. Circuit Diagram For Customer Interface Board PC14 (Part 3 of 3)

OM-196 188 Page 64

Page 71

Pensar 86147s03 (Part 3 of 3)

OM-196 188 Page 65

Page 72

Figure 6-18. Circuit Diagram For Touch Sensor Board PC18

174 578-A

OM-196 188 Page 66

Page 73

Figure 6-19. Circuit Diagram For Setup Pendant

200 739-A

OM-196 188 Page 67

Page 74

Figure 6-20. Circuit Diagram For Setup Pendant Centronix Junction Board PC3

OM-196 188 Page 68

200 739

Page 75

Figure 6-21. Circuit Diagram For Power Distribution Board PC20

191 531

OM-196 188 Page 69

Page 76

SECTION 7 – PARTS LIST

. Hardware is common and

not available unless listed.

802 872-D

Figure 7-1. Complete Assembly

OM-196 188 Page 70

Page 77

Part

Dia.

Item

No.

Mkgs.

No.

Description

Quanti

Figure 7-1. Complete Assembly

1 185 970 COVER, top 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 195 585 HANDLE, carrying rubber 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 179 310 LABEL, warning general precautionary 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 183 827 BUS BAR, output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 HD1 168 829 TRANSDUCER, current 600A 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG19 115 094 HOUSING PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 +179 902 WINDTUNNEL, LH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 185 836 LABEL, warning electric shock 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 T1 185 524 TRANSFORMER, HF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 FM2 183 918 MOTOR, fan 24VDC 3000RPM 43CFM w/10 ohm resistor 1. . . . . . . . . . . . . . . . . . . . . . . . . .

12 194 450 BRACKET, mtg capacitor/PC board/fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 PC1 203 309 CIRCUIT CARD ASSEMBLY, control (400 volt model) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG2 115 092 HOUSING PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG3 130 203 HOUSING PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG5 113 752 HOUSING PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG7 115 094 HOUSING PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG21 211 138 PLUG, w/leads 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 194 371 SPACER, al 3.500 log 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 C3-6 192 935 CAPACITOR, elctlt 2700uf 420 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 144 842 ACTUATOR, switch 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 209 310 NAMEPLATE, front upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 201 387 CIRCUIT CARD ASSY, connector 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 208 824 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 PC17 203 663 DISPLAY, vfd dotmatrix 1x20 alphanumeric 20 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 PC15 182 998 CIRCUIT CARD ASSY, switch board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 193 716 PANEL, center 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 PC20 191 533 CIRCUIT CARD ASSY, power distribution 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 T11 193 706 TRANSFORMER, control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 PC16 201 387 CIRCUIT CARD ASSY, junction board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 PC12 191 841 CIRCUIT CARD ASSY, interface board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 097 132 STAND-OFF, No. 6-32 x .375 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 PC11 202 005 CIRCUIT CARD ASSY, micro board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 PC14 203 665 CIRCUIT CARD ASSY, customer interface 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 PC18 212 320 CIRCUIT CARD ASSY, touch sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 PC13 213 193 CIRCUIT CARD ASSY, motor board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 PC21 200 077 CIRCUIT CARD ASSY, filter board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 195 994 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 RC70 201 058 CONNECTOR, receptacle 72-pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 RC8 200 591 CONNECTOR, circ ms/met 11 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 RC21 200 589 CONNECTOR, circ ms/met 10 pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 RC25 200 082 CONNECTOR, circ ms/met 4 pin size 14s 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 PC19 134 560 CIRCUIT CARD ASSY, filter board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 CB11 011 991 CIRCUIT BREAKER, man reset 1P 1.5A 250 VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 PC22 200 073 CIRCUIT CARD 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 CR12 187 252 SWITCH, reed 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 RC9 134 734 CONNECTOR, circ ms/cpc 14 pin size 20 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

079 739 CONNECTOR, clamp 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 RC1 134 735 CONNECTOR, circ ms/cpc 14 skt size 20 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 L1 180 026 INDUCTOR, input 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 Z1 180 029 STABILIZER, output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 181 925 INSULATOR, stabilizer lead 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-196 188 Page 71

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Figure 7-1. Complete Assembly (Continued)

47 T2 185 231 TRANSFORMER, control 200/400 VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RC10 166 679 HOUSING RECEPTACLE PINS & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 180 105 BRACKET, mtg transformer aux 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 +194 449 WINDTUNNEL, RH 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 RC2 604 176 RECEPTACLE, str dx grd 2P3W 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

175 282 COVER, receptacle weatherproof 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 CB1 161 078 CIRCUIT BREAKER, man reset 1P 7A 250 VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 CB2 093 995 CIRCUIT BREAKER, man reset 1P 15A 250 VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 179 847 PLATE, identification (order by model & serial number) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 195 847 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 W1 180 270 CONTACTOR, def prp 40A 3P 24VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 025 248 STAND-OFF, insul .250-20 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 C1,2 188 446 CAPACITOR, polyp .5uf 900VAC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 185 992 BUS BAR, capacitor 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 CT1 181 271 TRANSFORMER, current 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 177 547 BUSHING, snap-in nyl ct 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 T4 185 208 CHOKE, common mode 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 PC2 206 778 CIRCUIT CARD, interconnecting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG4 131 056 HOUSING RECEPTACLE & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG9 115 091 HOUSING PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG12 115 093 HOUSING PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 176 844 CORE, ferrite 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64 180 103 COIL, DI/DT 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 182 654 GASKET, DI/DT rubber 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 180 271 BRACKET, mtg choke 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182 738 HOLDER, DI/DT coils 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

67 SR1 184 260 KIT, diode power module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

68 PM1,2 186 656 KIT, transistor IGBT module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

69 RT1,2 173 632 THERMISTOR, NTC 30K ohm 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 179 930 HEAT SINK, power module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71 204 165 HEAT SINK, rect dual diode 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 R1,2,C9-12 175 194 RESISTOR/CAPACITOR 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 D1-4 201 531 KIT, diode ultra-fast recovery 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

74 179 826 INSULATOR, rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181 853 INSULATOR, screw 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75 179 900 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76 FM1 175 084 MOTOR, fan 24VDC 3000 RPM 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 179 928 SHROUD, fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

78 PC3 190 694 CIRCUIT CARD, front panel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLG11 115 091 HOUSING PLUG & SOCKETS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

185 959 CABLE, ribbon 34 posn 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 200 324 NAMEPLATE, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80 182 707 TERMINAL, pwr output black 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

81 186 543 CAPACITOR ASSEMBLY 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82 187 139 PANEL, front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

83 180 732 BOOT, negative output stud 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84 179 848 BOOT, positive output stud 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181 169 SPACER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180 735 WASHER, output stud 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85 181 245 TERMINAL, pwr output red 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

86 S1 128 756 SWITCH, tgl 3PST 40A 600VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

176 226 INSULATOR, switch power 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

87 +185 968 PANEL, side 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

178 551 INSULATOR, side 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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No.

Part

Dia.

Item

Mkgs.

No.

Description

Quanti

Figure 7-1. Complete Assembly (Continued)

144 844 STAND-OFF, No. 6-32 x .875 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

091 772 STAND-OFF, No. 6-32 x .625 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88 208 478 CAPACITOR MODULE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 179 276 BUSHING, snap-in nyl 1.000 x 1.375mtg hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 199 840 BUS BAR, diode 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

91 196 261 NAMEPLATE, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 PC7 206 776 CIRCUIT CARD, input filter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

♦OPTIONAL +When ordering a component originally displaying a precautionary label, the label should also be ordered.

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

No.

Mkgs.

No.

194 850

Setup Pendant

Description

Quanti

201 990 CASE, front/bottom 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

186 529 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173 111 PANEL, rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

185 963 NAMEPLATE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC1 158 160 CIRCUIT CARD ASSY, side display 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC2 156 623 CIRCUIT CARD ASSY, data card 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC3 200 738 CIRCUIT CARD ASSY, connector 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

186 530 CABLE, ribbon 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PB1-4 144 842 ACTUATOR, switch 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 425 CABLE, 6ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

604 804 SCREW, 8-15 x .375 hexwhd-pln stl pld sht met 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

072 785 SCREW, 6-32 x .375 hexwhd-slt stl pld slffmg 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181 157 STAND-OFF, No. 6-32 x .843 lg 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

098 691 STAND-OFF, No. 6-32 x .500 lg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

133 528 RIVET, al .125 dia x .188-.250 grip blk blind dome 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

602 062 SCREW, 4-40 x .375 pa hd-phl stl pld cone 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

019 663 MOUNT, NPRN 15/16OD x 3/8REC 3/16 x 3/8 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 892 RIVET, al .125 dia x .188-.250 grip blind domed hd 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 316 CONNECTOR, rect univ 039 6p/s 3 row 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

155 024 LENS, clear anti-glare .030 x 2.000 x 4.250 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-196 188 Page 73

Page 80

Notes

OM-196 188 Page 74

Page 81

OM-196 188K

July 2003

Programming Instructions for

Auto Invision II

Page 82

SECTION 8 – INTRODUCTION TO PROGRAMMING

8-1. Pulse MIG Programs

. Selecting hardwire or softwire is

done during setup (see Section 14)

Program

1 2 3 4 5 6 7 3/64” 5356, Argon 8 .035” SIB, Argon

Hardwire Selected

.035” Steel, Argon – Oxy

.045” Steel, Argon – Oxy .035” Steel, Argon – CO2 .045” Steel, Argon – CO2

.035” 309, Argon – CO2

.045” Steel, 309, Argon – CO2

Softwire Selected

.045” 4043, Argon .045” 5356, Argon .035” 4043, Argon .035” 5356, Argon 1/16” 4043, Argon 1/16” 5356, Argon

.045” Steel, Argon – CO2

.045” Steel, Argon – Oxy

The interface unit is designed for use in pulse MIG welding (adaptive or standard), or MIG welding.

The unit is factory-equipped with eight programs for pulse MIG welding.

The unit also provides memory for the creation of up to eight MIG programs (see Section 11).

The weld programs require the user to enter information specific to the welding application. This information is entered as a part of program development (see Section 9 for pulsed MIG information), and during setup (see Section 14).

The eight pulse programs are shown in the table. Each program can be used in standard pulse MIG or adaptive pulse MIG.

In an adaptive pulse MIG program, the unit manipulates certain weld variables to hold arc voltage constant. This feature is described in Section 10-5.

The factory-set parameters for each program can be changed to customize them for an application (see Section 10).

8-2. Standard Pulse Welding Programs

The following sixteen (16) pulse welding programs are in the control memory. Use this information if it is necessary to change a standard program, or as a basis to build your own custom program. If at any time while changing a standard program, or while building your own custom program, you want to go back to the standard program in the control memory, see Section 14-12 for System memory Reset instructions. See Section 10 for explanation of Pulse welding settings.

Apk = Peak Amperage, Abk = Background Amperage, PPS = Pulses Per Second, PWms = Pulse Width (milliseconds), Vpk = Peak Voltage

OM-196 188 Page 76

Page 83

8-3. Program 1 – 1.2 mm Steel (.045”), 98-2 Argon-Oxy

Wire Size/Type: 1.2 mm (.045”) Steel Gas: Ar - Oxy / 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

19.1 / 750 540 159 263 3.1 34.5

17.8 / 700 530 150 250 3.0 33.9

16.5 / 650 520 141 237 2.9 33.3

15.2 / 600 510 133 225 2.9 32.7

14.0 / 550 500 124 212 2.8 32.0

12.7 / 500 490 115 200 2.8 31.4

11.4 / 450 480 110 187 2.7 31.0

10.2 / 400 470 105 175 2.7 30.6

8.9 / 350 460 100 162 2.6 30.2

7.6 / 300 450 95 150 2.6 29.8

6.4 / 250 422 82 132 2.4 28.7

5.1 / 200 395 69 114 2.3 27.6

3.8 / 150 367 56 96 2.1 26.4

2.5 / 100 340 43 78 2.0 25.3

1.3 / 50 312 30 60 1.8 24.2

8-4. Program 2 – 1.0 mm Steel (.040”), 80-20 Argon-CO

Wire Size/Type: 1.0 mm (.040”) Steel Gas: Ar - CO2/ 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

17.9 / 705 471 90 206 2.3 38.4

17.8 / 700 470 90 205 2.3 38.4

16.5 / 650 460 87 196 2.3 38.2

15.2 / 600 450 85 188 2.3 38.0

14.0 / 550 440 82 179 2.2 37.7

12.7 / 500 430 80 170 2.2 37.5

11.4 / 450 410 77 160 2.1 36.1

10.2 / 400 390 75 150 2.1 34.8

8.9 / 350 370 72 140 2.0 33.4

7.6 / 300 350 70 130 2.0 32.1

6.4 / 250 355 62 111 1.8 32.3

5.1 / 200 360 55 92 1.6 32.5

3.8 / 150 365 47 73 1.4 32.6

2.5 / 100 370 39 53 1.2 32.8

OM-196 188 Page 77

Page 84

8-5. Program 3 – 1.2 mm Steel (.045”), 80-20 Argon-CO

Wire Size/Type: 1.2 mm (.045”) Steel Gas: Ar - CO2 / 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

19.1 / 750 570 134 246 2.9 41.2

17.8 / 700 560 130 235 2.9 40.6

16.5 / 650 550 126 224 2.9 40.0

15.2 / 600 540 123 213 2.9 39.5

14.0 / 550 530 119 201 2.8 38.9

12.7 / 500 520 115 190 2.8 38.3

11.4 / 450 502 107 177 2.7 37.4

10.2 / 400 485 100 165 2.7 36.6

8.9 / 350 467 92 152 2.6 35.7

7.6 / 300 450 85 140 2.6 34.9

6.4 / 250 435 74 120 2.4 34.1

5.1 / 200 420 64 100 2.3 33.4

3.8 / 150 405 53 80 2.1 32.6

2.5 / 100 390 43 60 1.9 31.8

1.3 / 50 375 32 40 1.7 31.0

8-6. Program 4 – .8 mm 316 (.030”), 98-2 Argon-CO

Wire Size/Type: .8 mm (.030”) 316 Gas: Ar - CO2 / 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

15.6 / 615 301 66 117 2.0 33.1

15.2 / 600 300 65 115 2.0 33.1

14.0 / 550 295 61 109 1.9 33.0

12.7 / 500 290 58 103 1.9 33.0

11.4 / 450 285 54 96 1.8 32.9

10.2 / 400 280 50 90 1.8 32.9

9.2 / 360 271 47 84 1.8 32.1

8.3 / 325 263 45 78 1.8 31.3

7.3 / 290 254 42 71 1.7 30.5

6.4 / 250 245 40 65 1.7 29.7

5.6 / 220 246 38 56 1.6 29.7

4.8 / 190 248 37 47 1.6 29.8

4.0 / 160 249 35 37 1.5 29.8

3.2 / 125 250 34 28 1.4 29.9

3.0 / 120 250 34 26 1.4 29.9

OM-196 188 Page 78

Page 85

8-7. Program 5 – 1.0 mm 316 (.040”), 98-2 Argon-CO

Wire Size/Type: 1.0 mm (.040”) 316 Gas: Ar - CO2 / 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

19.1 / 750 443 144 183 2.6 34.0

17.8 / 700 425 130 175 2.5 33.8

16.5 / 650 407 116 167 2.4 33.6

15.2 / 600 390 103 160 2.3 33.4

14.0 / 550 372 89 152 2.2 33.1

12.7 / 500 355 75 145 2.1 32.9

11.4 / 450 351 71 136 2.0 32.7

10.2 / 400 348 68 128 2.0 32.5

8.9 / 350 344 64 119 1.9 32.3

7.6 / 300 340 60 110 1.9 32.1

6.7 / 265 330 54 99 1.8 31.1

5.7 / 225 320 48 89 1.8 30.1

4.7 / 185 310 41 78 1.7 29.0

3.8 / 150 300 35 67 1.7 28.0

2.8 / 110 290 29 56 1.6 27.0

8-8. Program 6 – 1.2 mm 316 (.045”), 98-2 Argon-CO

Wire Size/Type: 1.2 mm (.045”) 316 Gas: Ar - CO2 / 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

18.6 / 735 491 180 215 3.3 35.2

17.1 / 675 480 175 205 3.2 34.4

15.7 / 620 469 164 195 3.1 33.6

14.3 / 565 458 153 185 3.1 32.8

12.9 / 510 446 141 175 3.0 32.0

11.4 / 450 435 130 165 2.9 31.2

10.0 / 395 421 117 151 2.7 30.7

8.6 / 340 408 105 138 2.6 30.3

7.1 / 285 394 92 124 2.4 29.8

5.7 / 225 380 80 110 2.3 29.3

5.1 / 200 375 75 100 2.2 29.1

4.4 / 175 370 70 90 2.1 28.9

3.8 / 150 365 65 80 1.9 28.6

3.2 / 125 360 60 70 1.8 28.4

2.5 / 100 355 55 60 1.7 28.2

OM-196 188 Page 79

Page 86

8-9. Program 7 – 1.0 mm 308L (.040”), 98-2 Argon-CO

Wire Size/Type: 1.0 mm (.040”) 308L Gas: Ar - CO2 / 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

19.1 / 750 436 120 183 2.5 34.2

17.8 / 700 425 115 175 2.4 33.7

16.5 / 650 414 110 167 2.3 33.2

15.2 / 600 403 105 160 2.3 32.7

14.0 / 550 391 100 152 2.2 32.1

12.7 / 500 380 95 145 2.1 31.6

11.4 / 450 370 86 136 2.0 31.1

10.2 / 400 360 78 128 2.0 30.6

8.9 / 350 350 69 119 1.9 30.3

7.6 / 300 340 60 110 1.9 29.5

6.7 / 265 330 54 100 1.8 29.0

5.7 / 225 320 48 90 1.8 28.6

4.7 / 185 310 41 80 1.7 28.1

3.8 / 150 300 35 70 1.7 27.7

2.8 / 110 290 29 60 1.6 27.2

8-10. Program 8 – 1.2 mm 308L (.045”), 98-2 Argon-CO

Wire Size/Type: 1.2 mm (.045”) 308L Gas: Ar - CO2 / 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

18.6 / 735 491 186 274 3.5 36.0

17.1 / 675 480 175 210 3.4 34.8

15.7 / 620 464 164 196 3.3 33.6

14.3 / 565 458 153 183 3.2 32.5

12.9 / 510 446 141 169 3.1 31.3

11.4 / 450 435 130 155 3.0 30.1

10.0 / 395 422 119 141 2.9 29.9

8.6 / 340 410 108 128 2.8 29.7

7.1 / 285 397 96 114 2.6 29.4

5.7 / 225 385 85 100 2.5 29.2

5.1 / 200 379 79 92 2.3 29.1

4.4 / 175 373 73 85 2.2 29.1

3.8 / 150 366 66 71 2.0 29.0

3.2 / 125 360 60 70 1.8 29.0

2.5 / 100 354 54 62 1.6 28.9

OM-196 188 Page 80

Page 87

8-11. Program 1 – 1.2 mm Metal Core (.045”), 95-5 Argon-CO

Note

Wire Size/Type: 1.2 mm (.045”) Metal Core Gas: Ar - CO2 / 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

19.1 / 750 525 160 211 2.9 31.6

17.8 / 700 515 155 205 2.9 31.3

16.5 / 650 505 150 199 2.9 31.0

15.2 / 600 495 145 193 2.9 30.8

14.0 / 550 485 140 186 2.8 30.5

12.7 / 500 475 135 180 2.8 30.3

11.4 / 450 462 124 172 2.7 30.3

10.2 / 400 450 113 165 2.7 30.4

8.9 / 350 437 101 157 2.6 30.4

7.6 / 300 425 90 149 2.5 30.5

6.4 / 250 381 81 138 2.2 28.8

5.1 / 200 338 72 127 2.0 27.2

3.8 / 150 294 62 116 1.7 25.5

2.5 / 100 250 53 105 1.5 23.9

1.3 / 50 206 44 94 1.2 22.2

The next 8 programs are available after changing software wiretype (see Section 14-10).

8-12. Program 2 – 1.4 mm Metal Core (.052”), 95-5 Argon-CO

Wire Size/Type: 1.4 mm (.052”) Metal Core Gas: Ar - CO2 / 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

18.1 / 715 562 194 206 3.8 34.0

17.8 / 700 560 190 206 3.7 33.9

16.5 / 650 551 175 208 3.5 33.7

15.2 / 600 543 160 210 3.3 33.5

14.0 / 550 534 145 211 3.0 33.2

12.7 / 500 525 130 213 2.8 33.0

11.4 / 450 512 121 199 2.7 32.2

10.2 / 400 500 113 185 2.7 31.5

8.9 / 350 487 104 171 2.6 30.7

7.6 / 300 475 95 157 2.5 29.9

6.4 / 250 427 82 142 2.4 28.2

5.1 / 200 380 70 127 2.3 26.6

3.8 / 150 332 57 111 2.2 24.9

2.5 / 100 284 45 96 2.1 23.3

2.2 / 90 272 42 92 2.1 22.9

OM-196 188 Page 81

Page 88

8-13. Program 3 – 1.2 mm ER 4043 (.045”), Argon

Wire Size/Type: 1.2 mm (.045”) ER 4043 Gas: Ar / 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

17.9 / 705 492 160 190 2.9 31.6

17.8 / 700 490 160 190 2.9 31.5

16.5 / 650 451 167 195 2.8 30.1

15.2 / 600 412 174 200 2.8 28.8

14.0 / 550 373 180 205 2.7 27.4

12.7 / 500 334 187 210 2.7 26.1

11.4 / 450 316 169 196 2.6 26.1

10.2 / 400 298 151 183 2.5 26.1

8.9 / 350 279 133 169 2.3 26.1

7.6 / 300 261 115 155 2.2 26.1

6.4 / 250 259 91 135 2.0 25.5

5.1 / 200 258 68 115 1.8 24.9

3.8 / 150 256 44 95 1.5 24.2

2.5 / 100 255 20 74 1.3 23.6

8-14. Program 4 – 1.0 mm ER 4043 (.040”), Argon

Wire Size/Type: 1.0 mm (.040”) ER 4043 Gas: Ar / 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

19.4 / 760 476 136 176 1.8 33.2

18.5 / 725 470 130 170 1.7 32.5

17.7 / 695 464 124 164 1.6 31.8

16.9 / 665 459 118 158 1.6 31.2

16.1 / 630 453 111 152 1.5 30.5

15.2 / 595 448 105 146 1.4 29.9

13.8 / 540 421 95 136 1.4 29.4

12.4 / 485 394 85 127 1.4 29.0

11.0 / 430 367 75 117 1.3 28.5

9.7 / 380 340 65 108 1.3 28.1

8.3 / 325 318 54 93 1.3 27.4

6.9 / 270 297 44 79 1.4 26.7

5.5 / 215 275 33 64 1.4 26.0

4.1 / 160 254 22 50 1.4 25.3

2.7 / 105 232 11 35 1.4 24.6

OM-196 188 Page 82

Page 89

8-15. Program 5 – 1.0 mm 5356 (.040”), Argon

Wire Size/Type: 1.0 mm (.040”) 4043 Gas: Ar / 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

18.6 / 735 410 75 156 1.3 27.0

18.5 / 730 410 75 156 1.3 27.0

17.7 / 695 407 69 152 1.3 26.9

16.9 / 665 405 64 148 1.3 26.8

16.1 / 630 402 58 144 1.3 26.6

15.2 / 600 400 52 140 1.3 26.5

13.8 / 540 369 51 134 1.3 26.2

12.4 / 485 338 51 128 1.3 26.0

11.0 / 430 306 50 122 1.2 25.7

9.7 / 380 275 50 116 1.2 25.5

8.3 / 325 281 44 94 1.1 25.4

6.9 / 270 288 38 72 1.1 25.3

5.5 / 215 294 31 50 1.0 25.2

4.1 / 160 300 25 28 1.0 25.1

4.0 / 155 300 25 27 1.0 25.1

8-16. Program 6 – 1.2 mm ER 5356 (.045”), Argon

Wire Size/Type: 1.2 mm (.045”) ER 5356 Gas: Ar / 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

19.4 / 760 378 149 254 2.8 25.3

18.5 / 725 374 144 245 2.7 25.3

17.7 / 695 370 139 236 2.6 25.3

16.9 / 665 366 135 278 2.5 25.3

16.1 / 630 362 130 219 2.4 25.3

15.2 / 595 358 126 210 2.3 25.3

13.8 / 540 346 115 200 2.2 24.6

12.4 / 485 334 104 190 2.1 23.9

11.0 / 430 322 92 180 2.0 23.2

9.7 / 380 310 81 170 1.9 27.5

8.3 / 325 302 72 142 1.7 22.4

6.9 / 270 295 63 114 1.6 22.4

5.5 / 215 287 54 85 1.4 22.3

4.1 / 160 280 45 57 1.2 22.2

2.7 / 105 272 36 29 1.0 22.1

OM-196 188 Page 83

Page 90

8-17. Program 7 – .8 mm Steel (.030”), 98-2 Argon-Oxy

Wire Size/Type: .8 mm (.30”) Steel Gas: Ar - Oxy / 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

19.7 / 775 384 121 143 2.0 33.9

17.8 / 700 375 110 135 1.9 33.6

15.9 / 625 366 99 127 1.8 33.3

14.0 / 550 358 88 120 1.7 33.0

12.1 / 475 349 76 112 1.6 32.6

10.2 / 400 340 65 104 1.5 32.3

8.9 / 350 334 56 94 1.5 31.8

7.6 / 300 328 48 85 1.5 31.3

6.4 / 250 321 39 75 1.4 30.7

5.1 / 200 315 30 65 1.4 30.2

4.4 / 170 306 29 58 1.3 29.5

3.8 / 150 298 28 51 1.3 28.9

3.2 / 125 289 26 44 1.2 28.2

2.5 / 100 280 25 37 1.1 27.6

1.9 / 75 271 24 30 1.0 26.9

8-18. Program 8 – 1.0 mm Steel (.040”), 98-2 Argon-Oxy

Wire Size/Type: 1.0 mm (.040”) Steel Gas: Ar - Oxy/ 19 L/min (40 CFH)

MPM / IPM Apk Abk PPS PWms Vpk COMMENTS

17.9 / 705 451 90 201 2.4 33.7

17.8 / 700 450 90 200 2.4 33.6

16.5 / 650 440 90 192 2.4 32.8

15.2 / 600 430 90 185 2.4 32.0

14.0 / 550 420 90 177 2.3 31.1

12.7 / 500 410 90 170 2.3 30.3

11.4 / 450 392 82 162 2.3 29.4

10.2 / 400 375 75 155 2.3 28.5

8.9 / 350 357 67 147 2.2 27.5

7.6 / 300 340 60 140 2.2 26.6

6.4 / 250 320 55 120 2.1 26.9

5.1 / 200 300 50 100 2.0 27.3

3.8 / 150 280 45 80 1.9 27.6

2.5 / 100 260 40 60 1.8 27.9

2.4 / 95 257 39 57 1.8 27.9

OM-196 188 Page 84

Page 91

8-19. Setup Pendant Mode Select Button

1 Mode D i s p l a y 2 Mode Select Button Press Mode Select button to move

indicator in left window display. Go to Section 8-20.

Process

> Sequence

SharpArc Card

> Process

Sequence SharpArc Card

> Prg 1

Pulse 035” Steel Argon – Oxy

Ref. 154 109

OM-196 188 Page 85

Page 92

8-20. Setup Pendant Parameter Select Button

1 Parameter Display 2 Moving Line Moving line is under value that can

be changed. 3 Pulse Panel Parameter Select

Button

Press pulse panel parameter select button to move indicator in right window display.

> Process

Sequence SharpArc Card

> Prg 1

Pulse 035” Steel Argon – Oxy

Prg 1

> Pulse

035” Steel Argon – Oxy

Pulse 035” Steel Argon – Oxy

> Teach Off

OM-196 188 Page 86

Ref. 154 109

Page 93

8-21. Setup Pendant Parameter Increase And Decrease Buttons

Use mode select button to select mode to b e changed (see 8-19).

Use pulse panel parameter select button to select parameter to be changed (see 8-20).

1 Increase Button Press button to increase value that

is underlined by the moving line. 2 Decrease Button

Press button to decrease value that is underlined by the moving line.

> Prg 1

Pulse 035” Steel Argon – Oxy

> Prg 2

Pulse 045” Steel Argon – Oxy

Increase

> Prg 3

Pulse 052” Steel Argon – Oxy

Decrease

> Prg 2

Pulse 045” Steel Argon – Oxy

Ref. 154 109

OM-196 188 Page 87

Page 94

SECTION 9 – GETTING STARTED FOR PULSE WELDING

9-1. Weld Cycle For Pulse Welding

. The type of robot connected determines what

combination of parameters are available.

Wire

Speed

Weld

Start

Preflow

Time

Start

Power

Start

Speed

Run-In

WFS

Setting

Robot

Motion

Weld

Speed

Arc

Strike

9-2. Setting Preflow Sequence Display

Process

> Sequence

SharpArc Card

> Prflw

0.0 Sec

Weld Time

Crater Time

Weld

Stop

Crater Speed

Retract Time

Arc Out

Postflow

Time

TimeRun-In

Ref. S-0271

1 Mode Select Button When unit is turned On, Process is

the default mode, at other times, use mode select button to select Sequence.

2 Parameter Select Button Use parameter select button to

select parameters. 3 Preflow Parameters Display Preflow can be adjusted from 0-9.9

seconds. If value set is zero (0), there is no Preflow sequence.

Go to Section 9-3.

> Prflw

0.0 Sec

OM-196 188 Page 88

Mode Select Parameter

Prflw

> 0.0 Sec

Parameter

Select

Set Desired Time

Increase/

Decrease

Select

Parameter

> Prflw

1.2 Sec

Select

Increase

Proceed to next Section.

Page 95

9-3. Setting Weld Sequence Display

Set Desired Weld

Sequence Trim

Increase/

Decrease

Set Desired Weld Sequence

Wire Feed Speed

Increase/

Decrease

Weld

>50 Trim

200 IPM

Weld

60 Trim

> 200 IPM

> Weld

60 Trim 300 IPM

Parameter

Select

Parameter

Select

Increase

Proceed to next Section.

1 Weld Parameters Display Parameter ranges are as follows: Trim (Arc Length), 0-99 Wire Feed Speed, 50-780 Inches

Per Minute, IPM Go to Section 9-4.

9-4. Setting Crater Sequence Display

> Cratr

0.20 Sec 60 Trim 150 IPM

Proceed to next Section.

Increase

>Cratr

0.00 Sec 50 Trim 200 IPM

Parameter

Select

Parameter

Select

Cratr

0.20 Sec 60 Trim

> 150 IPM

Set Desired Wire

Feed Speed

Increase/

Decrease

Cratr

> 0.00 Sec

50 Trim 200 IPM

Set Desired

Time

Increase/

Decrease

Parameter

Select

Cratr

0.20 Sec

>50 Trim

200 IPM

Set Desired

Trim

Increase/

Decrease

Parameter

Select

1 Crater Parameters Display Parameter ranges are as follows: Seconds, 0-2.50 Sec. If value set is

zero (0), there is no Crater sequence.

Trim (Arc Length), 0-99 Wire Feed Speed, 50-780 Inches

Per Minute, IPM Go to Section 9-5.

OM-196 188 Page 89

Page 96

9-5. Setting Postflow Sequence Display

> Poflw

0.0 Sec

Poflw

> 0.0 Sec

> Poflw

1.2 Sec

1 Postflow Parameters Display Postflow can be adjusted from

0-9.9 seconds. If value set is zero (0), there is no Postflow sequence.

Parameter

Select

Set Desired Time

Increase/

Decrease

Parameter

Select

Increase

Proceed to next Section.

SECTION 10 – TEACHING A PULSE WELDING PROGRAM

NOTE

10-1. Pulse Waveform Explained

Amps

(Current)

See GMAW-P (Pulsed MIG) Process Guide supplied with unit for more information.

This unit controls weld output for pulsed welds.

1 Apk – Peak Current Of

100-600 Amperes

Apk is the high pulse of welding current. Peak current melts the welding wire and forms a droplet. The droplet is forced into the weld puddle.

2 Abk – Background Current Of

2 41

Time

10-255 Amperes

Abk is the low weld current. Background current preheats welding wire and maintains the arc. When background current is too low, the arc is unstable and hard to maintain.

3 PPS – Pulses Per Second Of

20-400

PPS, pulse rate, and frequency (Hz) are used interchangeably. A PPS or pulse rate of 60 Hz means 60 pulses of current are produced each second.

4 PWms – Pulse Width Of

1.0-5.0 Milliseconds

PWms is the time spent at peak current (1.2 ms is .0012 seconds). This time must be long enough to form a droplet of welding wire. The stiffness or fluidity of the molten weld puddle is controlled by PWms.

Vpk = Peak Voltage

Arc Voltage during peak current phase of the pulse waveform. This determines arc length during adaptive pulse welding.

OM-196 188 Page 90

Ref. S-0259

Page 97

10-2. Teach Points Explained

IPM

780

750

700

650

600

550

500

450

400

350

300

250

200

150

100

150 180 210 240 270 300 330 360 370 420 450 480 510 540 565 Apk

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Abk 30 55 80 105 130 160 185 210 235 260 290 315 340 365 400 PPS

1 3 5 PWms24

2.5 5 7.5 10 12.5 15 17.5 20 22.5 25 27.5 30 32.5 35 37.5 Vpk

The teach mode allows the user to create custom pulse MIG welding programs. The teach mode has 15 teach points. At each teach point, the user can adjust five parameters: peak amperage (Apk), background amperage (Abk), pulses per second (PPS), pulse width in milliseconds (PWms), and peak voltage (Vpk) to shape the pulse waveform o f the weld output.

Wire feed speed teach points can range from the minimum to the maximum wire feed speed of the feeder. When using a standard speed motor, wire feed speed teach points typically range from 50 to 750 ipm. The feeder uses pulse parameters at teach points to establish the pulse parameters at any wire feed speed setting.

Below the wire feed speed of the lowest teach point, and above the wire feed speed

of the highest teach point, the unit may limit wire feed speed settings in pulse MIG to maintain all pulse parameters within the capability o f the unit.

Pulse MIG programs made by the manufacturer have pulse waveform information entered for all 15 teach points. The operator can relocate and modify the setting o f one, or any number of the 15 teach points if the factory set information is not appropriate for a specific application.

After the parameters for each teach point are established, an arc must be struck and maintained for at least 5 seconds in teach mode. This allows the wire feeder to learn the arc voltage length associated with the taught pulse parameters. To ensure a proper arc length reading, electrode stick-out must be

Example Of A Synergic

Setting For 425 IPM With

All Teach Points Set At

50 IPM Increments

Apk Abk PPS PWms

Vpk

carefully maintained. An alternate method is to adjust the Vpk value, then turn off Teach Mode and weld. If welding is performed with Teach Mode on, Vpk will be updated for other parameter settings.

The taught arc length represents a Trim (arc length) setting of 50. Increasing the value of Trim, increases the actual arc length. Likewise, decreasing the value of Trim will decrease actual arc length.

In the Pulse mode, the unit does not maintain a constant arc length with variations in electrode stick-out. In the Adaptive Pulse mode, the unit adjusts pulse frequency to maintain a constant arc length regardless of variations in electrode stick-out.

Proceed t o next section t o teach a pulse MIG program.

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Page 98

10-3. Selecting Teach Point Wire Feed Speed For Pulse Welding Program

1 Process Display When unit is first turned On,

Process is the default screen, at other times use mode select button to select Process.

2 Teach Display Use parameter select button to

select Teach. Use increase/decrease buttons to

select On. 3 IPM (Teach Point) The parameters associated with

this wire feed speed teach point can be modified. The wire feed speed value itself cannot be changed from the set point.

T o set or adjust teach point parameters, go to Section 10-4.

Mode

Select

> Process

Sequence SharpArc Card

> Prg 1

Pulse 035” Steel Argon – Oxy

Teach On

> 400 IPM

28.1 Vpk 340 Apk

Parameter

Select

Parameter

Select

Pulse 035” Steel

> Teach Off

Increase/

Decrease

> Teach On

400 IPM

28.1 Vpk 340 Apk

OM-196 188 Page 92

Page 99

10-4. Setting Teach Point Parameters For Pulse Welding Program

Increase/ Decrease

> Process

Sequence SharpArc Card

31.2 Vpk 343 Apk

>92 Abk

160 PPS

Parameter

Select

31.2 Vpk 343 Apk 92 Abk

> 160 PPS

Select

Teach On 450 IPM

> 28.1 Vpk

340 Apk

450 IPM

31.2 Vpk

> 343 Apk

70 Abk

343 Apk 92 Abk 280 PPS

> 1.9 PWms

Pulse 035” Steel Argon – Oxy

> Teach Off

Teach On

Increase/

Decrease

Increase/ Decrease

Increase/

Decrease

450 IPM

> 31.2 Vpk

340 Apk

450 IPM

31.2 Vpk

> 340 Apk

70 Abk

343 Apk 92 Abk 280 PPS

> 3.6 PWms

> Teach On

450 IPM

31.2 Vpk 343 Apk

Parameter

Select

Wait for 5

seconds

Parameter

Select

Teach On

> 450 IPM

28.1 Vpk 340 Apk

Parameter

Select

Increase/

Decrease

Increase/

Decrease

31.2 Vpk 343 Apk

>70 Abk

160 PPS

Parameter

Select

31.2 Vpk 343 Apk 92 Abk

> 280 PPS

Parameter

Prg 1 C Pulse 035” Steel Argon – Oxy

Parameter

When the Process Teach mode is On, and one of the following pulse parameters is selected: Apk, Abk, PPS, PWms, or Vpk, the pulse panel displays the selected pulse parameter instead of Trim (arc length). When the pulse parameter is selected, the value can be changed with the pulse panel controls as follows:

1 Vpk Display

2 Apk Display 3 Abk Display 4 PPS Display 5 PWms Display When values have been set for a teach point,

strike and maintain an arc for five seconds. Repeat procedure at each teach point until custom program is complete (see Section 10-2).

Turn Teach mode Off. 6 Custom Pulse Screen The letter C will appear in the upper right

corner of all customized programs.

Customized programs can be reverted back to factory-set values through memory reset (see Section 14-12).

OM-196 188 Page 93

Page 100

NOTE

Program # Wire Size/Type Gas

Program Name Card #

Gun Model Flowrate CFH

IPM Apk Abk PPS PWms Vpk COMMENTS

Make copies of this chart for future use.

Preflow: Sec.

Run-In Trim: IPM: Sec.:

Crater Trim: IPM: Sec.:

Postflow: Sec.

OM-196 188 Page 94