Automatic Welding Interface And
Arc Welding Power Source
Operating Instructions and
Programming Instructions for
Auto Invision II
Visit our website at
www.MillerWelds.com
Page 2
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.
Page 3
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
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 FaceProtection, 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
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 :
1Garder les câbles ensembles en les torsadant ou en les
attachant avec du ruban adhésif.
2Mettre tous les câbles du côté opposé de l’opérateur.
3Ne pas courber pas et ne pas entourer pas les câbles autour de
votre corps.
4Garder le poste de soudage et les câbles le plus loin possible de
vous.
5Relier 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
11.11.21.3
22.1
33.13.23.3
44.1
56
+
2.2
+
2.3
+
+
S-179 310
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1Electric 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.
2Breathing 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.
3Welding 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.
4Arc 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.
5Become trained and read the
instructions before working on
the machine or welding.
6Do not remove or paint over
(cover) the label.
1/96
OM-196 188 Page 9
Page 16
1Warning! Watch Out! There
2Electric shock from wiring can
3Disconnect input plug or
123456
4Hazardous voltage remains
V
V
> 60 s
V
S-179 190-A
5Always wait 60 seconds after
6Check input capacitor voltage,
1Warning! Watch Out! There
2When power is applied failed
12345
3Flying pieces of parts can
4Always wear long sleeves and
S-179 304-A
5After 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
1Warning! Watch Out! There
1
are possible hazards as
shown by the symbols.
2Falling equipment can cause
injury and damage to unit.
3Always lift and support unit
using both handles. Keep
angle of lifting device less
than 60 degrees.
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.
4Circuit 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 Voltage400
Input Amperes At Rated Output31
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes45
Min Input Conductor Size In AWG/Kcmil10
Max Recommended Input Conductor LengthIn Feet (Meters)264 (80)
Min Grounding Conductor Size In AWG/Kcmil10
Reference: 1993 National Electrical Code (NEC).S-0092J
3-8.Connecting Input Power
Input Fi l t e r
Board
L1
Tools Needed:
5/16 in
Y Always connect
2
L1
L2
L3
L2
=GND/PE
grounding conductor
first.
L3
1
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.
1Input 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).
2Line 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
3-9.Rear Panel Connections
4
1
C
D
Example Receptacle
B
P
E
2
A
N
T
RS
G
F
M
L
K
J
H
1Receptacle
2Keyway
34-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.
4Peripheral Receptacle
Receptacle provides connection to
touch sensor, water flow switch, jog
+/–, and n/o relay contacts circuitry.
5
5Robot 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).
610-Socket Receptacle (Wire
Feed/Shielding Gas Control
Connection To Motor Drive
Assembly)
6
Ref. S-0003-A / 802 748
OM-196 188 Page 16
Page 23
3-10. Peripheral Receptacle Functions
Output Relay Con-
AK
Output Relay Con-
AK
M
E
F
Signal
Touch Sensor ON
l
Programmable
B
C
D
J
M
L
H
F
E
Coolant Flow
Switch Input
FunctionSocketSocket Information
AContact 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
BContact 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.
DContact closure to C completes 24 volts dc
solenoid circuit to purge shielding gas line.
EContact 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.
KContact 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
2
1Touch Sensor Board PC18
2Switch 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
1
. Disconnect the setup pendant from the welding
power source before welding.
3
Y Turn Off welding power
source and weld control.
1Welding Power Source
2Interconnecting Cord
3Setup Pendant
To make connections, align plug
with receptacle, insert plug, and
use thumb screws on receptacle to
secure plug.
2
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 WeldingWhen 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
InductanceIn 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
SynergicSynergic refers to the unit’s ability to use preprogrammed pulse parameters to determine the actual
TrimTerm 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 ModeIs used to select use of the optional data card storage and retrieval capabilities.
Process ModeIs used to select the type of process to be used, including Pulse, Adaptive Pulse, or Mig.
Sequence ModeIs used to select and program the weld sequences which include preflow, run-in, weld, crater,
Setup Screen Terms:
Access CodeNOTE: The optional Data Card is required to activate this feature. With code off, access to the setup
Arc StartNOTE: Do not use the Hot Start setting for .035 in (9 mm) or smaller wire. Use the Hot Start mode for
Arc TimeAllows 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 FeatureWhen using the optional Data Card and turning the name feature on, programs written to the card can
Program ResetBy selecting program reset in the memory reset mode, the unit defaults to original factory program
RangeThe interface requires that the voltage and amperage range of the welding power source be entered.
SecurityNOTE: The optional Data Card is required to activate this feature. Is used to limit what the operator
Software ScreenSelection 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 ResetBy 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 ShutdownWhen this feature is on, the system immediately shuts down if no arc voltage is sensed. An error
Wire Feed ModeAllows 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
CE
1Power Switch
. The fan motor is thermostatically
controlled and only runs when cooling is
needed.
23
2Voltmeter (see Section 4-3)3Ammeter (see Section 4-3)
4-3.Meter Functions
Note
ModeMeter Reading At IdleMeter Reading While Welding
MIG
Pulsed
MIG
The meters display the actual weld output values for approximately three seconds after the arc
is broken.
VA
24.5
Preset VoltsBlank
VA
PPPPPP
Pulse DisplayPulse Display
Ref. 186 067
VA
24.5250
Actual VoltsActual Amps
VA
24.5250
Actual VoltsActual Amps
OM-196 188 Page 21
Page 28
4-4.Upper Front Panel Controls
12345 67
8
1Setup Pendant Receptacle
Receptacle for connecting pendant
interconnecting cord.
2Jog Forward Push Button
Advances wire out of the gun.
3Wirefeed Indicator LED
LED lights when wire feed motor is
energized.
4Jog Reverse Push Button
Retracts wire up into the gun.
5Gas Indicator LED
LED lights when gas solenoid is energized.
6Purge Push Button
Momentarily energizes gas solenoid to
purge air from gun shielding gas line, or to
adjust shielding gas regulator.
7Contactor Indicator LED
LED lights when welding power source
contactor is energized.
8Main 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 Amperes60% 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
0
Minutes
6 Minutes Welding4 Minutes Resting
A/V
15
OR
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
8
1
2
3
4
7
6
5
802 815
1Increase Button
Works with security feature on welding
power source to allow increasing weld
parameter values within the allowable range.
2Decrease Button
Works with security feature on welding
power source to allow decreasing weld
parameter values within the allowable range.
3Parameter Select Button
Press button to move indicator in right
window display, and to make selections in
setup screens.
4Mode Select Button
Press button to move indicator in left window
display.
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
1
1
Turn Off welding power source, a n d
disconnect input power.
1Outside Handle Screws
To loosen top, remove two outside
handle screws from both handles
and all side bolts.
2Interconnect Board PC2
3Voltmeter
Measure the dc voltage across the
screw terminals on PC2 as shown
until voltage drops to near 0 (zero)
volts.
Proceed with job inside unit. Reinstall cover when finished.
2
+ lead to lower right
terminal, – lead to
upper right terminal
3
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.
1Help 1 Display
Indicates a malfunction in the
primary power circuit. If this display
is shown, contact a Factory
Authorized Service Agent.
2Help 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.
3Help 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.
4Help 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.
5Help 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.
6Help 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.
7Help 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.
8Help 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.
1
AV
HE.LP–1
AV
2
HE.LP–2
AV
3
HE.LP–3
AV
4
HE.LP–4
AV
5
HE.LP–5
AV
6
HE.LP–6
AV
7
HE.LP–7
AV
8
HE.LP–8
OM-196 188 Page 27
Page 34
5-5.Front Panel Error Displays
1
MemCRCE r r o r
2
Mem RangeEr r
3
NoVo l tSensedEr ror
4
NoTachSensedEr r or
5
ArcStopError
6
8
Er rorCardRead
9
NoF l owDet ec t ed
10
GrdCur rentDetect
11
Wi reSt i ckEr ror
12
ArcFai lTimeOutErr
13
ArcStar tError
7
Stop WeldCycleErr
1Memory 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.
2Memory 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.
3No 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.
4No 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.
5Arc 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.
6Arc 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.
7Stop 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.
8Error 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.
9No Flow Detected
No coolant is detected after preflow in the
weld cycle. Check coolant system and flow
switch for proper operation.
NoInputIPM
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
1
LED2
LED3
LED4
LED5
LED6
LED8
LED7
LED9
LED10
LED11
LED12
1Weld 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
LEDStatusDiagnosis
1OnIndicates auxiliary output relay is not energized.
OffIndicates auxiliary output relay is energized.
2OnIndicates gas valve is not energized.
OffIndicates gas valve is energized.
3OnIndicates +24 volts dc is present for gas valve.
OffIndicates +24 volts dc is not present for gas valve.
4OnIndicates +15 volts dc is present on weld interface board PC12.
OffIndicates +15 volts dc is not present on weld interface board PC12.
5OnIndicates –15 volts dc is present on weld interface board PC12.
OffIndicates –15 volts dc is not present on weld interface board PC12.
6OnIndicates +15 volts dc power source supply is present on weld interface board PC12.
OffIndicates +15 volts dc power source supply is not present on weld interface board PC12.
7OnIndicates –15 volts dc power source supply is present on weld interface board PC12.
OffIndicates –15 volts dc power source supply is not present on weld interface board PC12.
8OnIndicates +5 volts dc is present on weld interface board PC12.
OffIndicates +5 volts dc is not present on weld interface board PC12.
9OnInput signal for no Jog retract.
OffInput signal for Jog retract.
10OnInput signal for no Jog advance.
OffInput signal for Jog advance.
11OnIndicates CV mode is selected.
OffIndicates CC mode is selected.
12OnInput signal for no welding power source contactor.
OffInput signal for welding power source contactor.
13OnIndicates an Emergency Stop condition is not present.
OffIndicates an Emergency Stop condition is present.
1Customer 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
1
2
3
4
8
9
10
11
14
15
16
17
18
19
LEDStatusDiagnosis
OnIndicates –15 volts dc RA supply is present on customer interface board PC14.
OffIndicates –15 volts dc RA supply is not present on customer interface board PC14.
OnIndicates +15 volts dc RA supply is present on customer interface board PC14.
OffIndicates +15 volts dc RA supply is not present on customer interface board PC14.
OnInput signal On from robot for no Emergency Stop.
OffInput signal Off from robot for Emergency Stop.
OnIndicates +24 volts dc RD supply is present on customer interface board PC14.
OffIndicates +24 volts dc RD supply is not present on customer interface board PC14.
5OnInput signal On from robot for shielding gas.
OffInput signal Off from robot for no shielding gas.
6OnInput signal On from robot to energize contactor.
OffInput signal Off from robot to not energize contactor.
7OnInput signal On from robot for jog retract.
OffInput signal Off from robot for no jog retract.
OnInput signal On from robot for jog advance.
OffInput signal Off from robot for no jog advance.
OnIndicates automatic configuration Bit D is set.
OffIndicates automatic configuration Bit D is not set.
OnInput signal On for RPS-C.
OffInput signal Off for RPS-C.
OnInput signal On for RPS-B.
OffInput signal Off for RPS-B.
12OnIndicates remote program A selected.
OffIndicates remote program A not selected.
13OnInput signal On from peripheral for touch sensor.
OffInput signal Off from peripheral for no touch sensor.
OnIndicates automatic configuration Bit B is set.
OffIndicates automatic configuration Bit B is not set.
OnIndicates automatic configuration Bit A is set.
OffIndicates automatic configuration Bit A is not set.
OnIndicates automatic configuration Bit C is set.
OffIndicates automatic configuration Bit C is not set.
OnInput signal On from relay CR4 for wire stuck in weld joint.
OffInput signal Off from relay CR4 for wire not stuck in weld joint.
OnInput signal On from relay CR6 for flow (shielding gas or coolant) present.
OffInput signal Off from relay CR6 for flow (shielding gas or coolant) not present.
OnInput signal On from relay CR5 for arc detect.
OffInput signal Off from relay CR5 for no arc detect.
20OnInput signal On from relay CR2.
OffInput signal Off from relay CR2.
OnInput signal On from relay CR1 for welding power source ready and no detected errors present.
21
22OnInput signal On from peripheral for flow switch.
OffInput signal Off from relay CR1 for welding power source not ready, detected errors are present, or unit
is in Setup or Control mode.
OffInput signal Off from peripheral for no flow switch.
OM-196 188 Page 32
Page 39
LEDDiagnosisStatus
25
26
23OnInput signal On from peripheral for jog advance.
OffInput signal Off from peripheral for no jog advance.
24OnInput signal On from peripheral for jog retract.
OffInput signal Off from peripheral for no jog retract.
OnInput signal On from peripheral for shielding gas purge.
OffInput signal Off from peripheral for no shielding gas purge.
OnInput signal On for touch sensor.
OffInput signal Off for no touch sensor.
5-10. Motor Board PC13 Diagnostic LED’s
1Motor 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
1
LED4
LED3LED11
212 353-A
OM-196 188 Page 33
Page 40
5-11. Diagnostic LED’s On Motor Board PC13
LEDStatusDiagnosis
1On Indicates motor reverse relay is energized.
RedOffIndicates motor reverse relay is not energized.
2OnLED should be On. Indicates 115 volts ac input is sufficiently charging +170 volts dc bus for motor.
RedOffIf LED is Of f, check 115 volts ac input.
9OnLED should be On. Indicates +15 volts dc regulated bus is on.
RedOffIf LED is Of f, check for a short at board traces between bus and ground or at RC1-6 for 24 volts ac input
11OnLED should be On. Indicates +5 volts dc regulated bus is on.
Red
4OnIndicates encoder input from motor to microprocessor is greater than 3 ipm.
GreenOffIndicates motor is off or encoder input from motor to microprocessor is less than 3 ipm.
3OnIndicates microprocessor is operating without sensing any faults.
GreenBlinkingIf microprocessor senses a fault, LED blinks to indicate type of fault.
OffIf LED is Off, check for a short at board traces between bus and ground or at RC1-6 for 24 volts ac input
3 BlinksPC13 sensed an overcurrent condition in wire drive. Check motor cables and connections for short cir-
4 BlinksPC13 PWM (pulse width modulation) output was on, but no encoder pulses were sensed for more than
5 BlinksMotor 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.
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
TroubleRemedy
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
♦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.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-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
73/64” 5356, Argon
8.035” SIB, Argon
Hardwire Selected
.035” Steel, Argon – Oxy
.045” Steel, Argon – Oxy
.035” Steel, Argon – CO2
.045” Steel, Argon – CO2
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.
8-3.Program 1 – 1.2 mm Steel (.045”), 98-2 Argon-Oxy
Wire Size/Type: 1.2 mm (.045”) SteelGas: Ar - Oxy / 19 L/min (40 CFH)
MPM / IPMApkAbkPPSPWmsVpkCOMMENTS
19.1 / 7505401592633.134.5
17.8 / 7005301502503.033.9
16.5 / 6505201412372.933.3
15.2 / 6005101332252.932.7
14.0 / 5505001242122.832.0
12.7 / 5004901152002.831.4
11.4 / 4504801101872.731.0
10.2 / 4004701051752.730.6
8.9 / 3504601001622.630.2
7.6 / 300450951502.629.8
6.4 / 250422821322.428.7
5.1 / 200395691142.327.6
3.8 / 15036756962.126.4
2.5 / 10034043782.025.3
1.3 / 5031230601.824.2
8-4.Program 2 – 1.0 mm Steel (.040”), 80-20 Argon-CO
Wire Size/Type: 1.0 mm (.040”) SteelGas: Ar - CO2/ 19 L/min (40 CFH)
MPM / IPMApkAbkPPSPWmsVpkCOMMENTS
17.9 / 705471902062.338.4
17.8 / 700470902052.338.4
16.5 / 650460871962.338.2
15.2 / 600450851882.338.0
14.0 / 550440821792.237.7
12.7 / 500430801702.237.5
11.4 / 450410771602.136.1
10.2 / 400390751502.134.8
8.9 / 350370721402.033.4
7.6 / 300350701302.032.1
6.4 / 250355621111.832.3
5.1 / 20036055921.632.5
3.8 / 15036547731.432.6
2.5 / 10037039531.232.8
2
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”) SteelGas: Ar - CO2 / 19 L/min (40 CFH)
MPM / IPMApkAbkPPSPWmsVpkCOMMENTS
19.1 / 7505701342462.941.2
17.8 / 7005601302352.940.6
16.5 / 6505501262242.940.0
15.2 / 6005401232132.939.5
14.0 / 5505301192012.838.9
12.7 / 5005201151902.838.3
11.4 / 4505021071772.737.4
10.2 / 4004851001652.736.6
8.9 / 350467921522.635.7
7.6 / 300450851402.634.9
6.4 / 250435741202.434.1
5.1 / 200420641002.333.4
3.8 / 15040553802.132.6
2.5 / 10039043601.931.8
1.3 / 5037532401.731.0
2
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 / IPMApkAbkPPSPWmsVpkCOMMENTS
15.6 / 615301661172.033.1
15.2 / 600300651152.033.1
14.0 / 550295611091.933.0
12.7 / 500290581031.933.0
11.4 / 45028554961.832.9
10.2 / 40028050901.832.9
9.2 / 36027147841.832.1
8.3 / 32526345781.831.3
7.3 / 29025442711.730.5
6.4 / 25024540651.729.7
5.6 / 22024638561.629.7
4.8 / 19024837471.629.8
4.0 / 16024935371.529.8
3.2 / 12525034281.429.9
3.0 / 12025034261.429.9
2
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”) 316Gas: Ar - CO2 / 19 L/min (40 CFH)
MPM / IPMApkAbkPPSPWmsVpkCOMMENTS
19.1 / 7504431441832.634.0
17.8 / 7004251301752.533.8
16.5 / 6504071161672.433.6
15.2 / 6003901031602.333.4
14.0 / 550372891522.233.1
12.7 / 500355751452.132.9
11.4 / 450351711362.032.7
10.2 / 400348681282.032.5
8.9 / 350344641191.932.3
7.6 / 300340601101.932.1
6.7 / 26533054991.831.1
5.7 / 22532048891.830.1
4.7 / 18531041781.729.0
3.8 / 15030035671.728.0
2.8 / 11029029561.627.0
2
8-8.Program 6 – 1.2 mm 316 (.045”), 98-2 Argon-CO
Wire Size/Type: 1.2 mm (.045”) 316Gas: Ar - CO2 / 19 L/min (40 CFH)
MPM / IPMApkAbkPPSPWmsVpkCOMMENTS
18.6 / 7354911802153.335.2
17.1 / 6754801752053.234.4
15.7 / 6204691641953.133.6
14.3 / 5654581531853.132.8
12.9 / 5104461411753.032.0
11.4 / 4504351301652.931.2
10.0 / 3954211171512.730.7
8.6 / 3404081051382.630.3
7.1 / 285394921242.429.8
5.7 / 225380801102.329.3
5.1 / 200375751002.229.1
4.4 / 17537070902.128.9
3.8 / 15036565801.928.6
3.2 / 12536060701.828.4
2.5 / 10035555601.728.2
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”) 308LGas: Ar - CO2 / 19 L/min (40 CFH)
MPM / IPMApkAbkPPSPWmsVpkCOMMENTS
19.1 / 7504361201832.534.2
17.8 / 7004251151752.433.7
16.5 / 6504141101672.333.2
15.2 / 6004031051602.332.7
14.0 / 5503911001522.232.1
12.7 / 500380951452.131.6
11.4 / 450370861362.031.1
10.2 / 400360781282.030.6
8.9 / 350350691191.930.3
7.6 / 300340601101.929.5
6.7 / 265330541001.829.0
5.7 / 22532048901.828.6
4.7 / 18531041801.728.1
3.8 / 15030035701.727.7
2.8 / 11029029601.627.2
2
8-10. Program 8 – 1.2 mm 308L (.045”), 98-2 Argon-CO
Wire Size/Type: 1.2 mm (.045”) 308LGas: Ar - CO2 / 19 L/min (40 CFH)
MPM / IPMApkAbkPPSPWmsVpkCOMMENTS
18.6 / 7354911862743.536.0
17.1 / 6754801752103.434.8
15.7 / 6204641641963.333.6
14.3 / 5654581531833.232.5
12.9 / 5104461411693.131.3
11.4 / 4504351301553.030.1
10.0 / 3954221191412.929.9
8.6 / 3404101081282.829.7
7.1 / 285397961142.629.4
5.7 / 225385851002.529.2
5.1 / 20037979922.329.1
4.4 / 17537373852.229.1
3.8 / 15036666712.029.0
3.2 / 12536060701.829.0
2.5 / 10035454621.628.9
2
OM-196 188 Page 80
Page 87
8-11. Program 1 – 1.2 mm Metal Core (.045”), 95-5 Argon-CO
2
Note
Wire Size/Type: 1.2 mm (.045”) Metal CoreGas: Ar - CO2 / 19 L/min (40 CFH)
MPM / IPMApkAbkPPSPWmsVpkCOMMENTS
19.1 / 7505251602112.931.6
17.8 / 7005151552052.931.3
16.5 / 6505051501992.931.0
15.2 / 6004951451932.930.8
14.0 / 5504851401862.830.5
12.7 / 5004751351802.830.3
11.4 / 4504621241722.730.3
10.2 / 4004501131652.730.4
8.9 / 3504371011572.630.4
7.6 / 300425901492.530.5
6.4 / 250381811382.228.8
5.1 / 200338721272.027.2
3.8 / 150294621161.725.5
2.5 / 100250531051.523.9
1.3 / 5020644941.222.2
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 / IPMApkAbkPPSPWmsVpkCOMMENTS
18.1 / 7155621942063.834.0
17.8 / 7005601902063.733.9
16.5 / 6505511752083.533.7
15.2 / 6005431602103.333.5
14.0 / 5505341452113.033.2
12.7 / 5005251302132.833.0
11.4 / 4505121211992.732.2
10.2 / 4005001131852.731.5
8.9 / 3504871041712.630.7
7.6 / 300475951572.529.9
6.4 / 250427821422.428.2
5.1 / 200380701272.326.6
3.8 / 150332571112.224.9
2.5 / 10028445962.123.3
2.2 / 9027242922.122.9
2
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 4043Gas: Ar / 19 L/min (40 CFH)
MPM / IPMApkAbkPPSPWmsVpkCOMMENTS
17.9 / 7054921601902.931.6
17.8 / 7004901601902.931.5
16.5 / 6504511671952.830.1
15.2 / 6004121742002.828.8
14.0 / 5503731802052.727.4
12.7 / 5003341872102.726.1
11.4 / 4503161691962.626.1
10.2 / 4002981511832.526.1
8.9 / 3502791331692.326.1
7.6 / 3002611151552.226.1
6.4 / 250259911352.025.5
5.1 / 200258681151.824.9
3.8 / 15025644951.524.2
2.5 / 10025520741.323.6
8-14. Program 4 – 1.0 mm ER 4043 (.040”), Argon
Wire Size/Type: 1.0 mm (.040”) ER 4043Gas: Ar / 19 L/min (40 CFH)
MPM / IPMApkAbkPPSPWmsVpkCOMMENTS
19.4 / 7604761361761.833.2
18.5 / 7254701301701.732.5
17.7 / 6954641241641.631.8
16.9 / 6654591181581.631.2
16.1 / 6304531111521.530.5
15.2 / 5954481051461.429.9
13.8 / 540421951361.429.4
12.4 / 485394851271.429.0
11.0 / 430367751171.328.5
9.7 / 380340651081.328.1
8.3 / 32531854931.327.4
6.9 / 27029744791.426.7
5.5 / 21527533641.426.0
4.1 / 16025422501.425.3
2.7 / 10523211351.424.6
OM-196 188 Page 82
Page 89
8-15. Program 5 – 1.0 mm 5356 (.040”), Argon
Wire Size/Type: 1.0 mm (.040”) 4043Gas: Ar / 19 L/min (40 CFH)
MPM / IPMApkAbkPPSPWmsVpkCOMMENTS
18.6 / 735410751561.327.0
18.5 / 730410751561.327.0
17.7 / 695407691521.326.9
16.9 / 665405641481.326.8
16.1 / 630402581441.326.6
15.2 / 600400521401.326.5
13.8 / 540369511341.326.2
12.4 / 485338511281.326.0
11.0 / 430306501221.225.7
9.7 / 380275501161.225.5
8.3 / 32528144941.125.4
6.9 / 27028838721.125.3
5.5 / 21529431501.025.2
4.1 / 16030025281.025.1
4.0 / 15530025271.025.1
8-16. Program 6 – 1.2 mm ER 5356 (.045”), Argon
Wire Size/Type: 1.2 mm (.045”) ER 5356Gas: Ar / 19 L/min (40 CFH)
MPM / IPMApkAbkPPSPWmsVpkCOMMENTS
19.4 / 7603781492542.825.3
18.5 / 7253741442452.725.3
17.7 / 6953701392362.625.3
16.9 / 6653661352782.525.3
16.1 / 6303621302192.425.3
15.2 / 5953581262102.325.3
13.8 / 5403461152002.224.6
12.4 / 4853341041902.123.9
11.0 / 430322921802.023.2
9.7 / 380310811701.927.5
8.3 / 325302721421.722.4
6.9 / 270295631141.622.4
5.5 / 21528754851.422.3
4.1 / 16028045571.222.2
2.7 / 10527236291.022.1
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”) SteelGas: Ar - Oxy / 19 L/min (40 CFH)
MPM / IPMApkAbkPPSPWmsVpkCOMMENTS
19.7 / 7753841211432.033.9
17.8 / 7003751101351.933.6
15.9 / 625366991271.833.3
14.0 / 550358881201.733.0
12.1 / 475349761121.632.6
10.2 / 400340651041.532.3
8.9 / 35033456941.531.8
7.6 / 30032848851.531.3
6.4 / 25032139751.430.7
5.1 / 20031530651.430.2
4.4 / 17030629581.329.5
3.8 / 15029828511.328.9
3.2 / 12528926441.228.2
2.5 / 10028025371.127.6
1.9 / 7527124301.026.9
8-18. Program 8 – 1.0 mm Steel (.040”), 98-2 Argon-Oxy
Wire Size/Type: 1.0 mm (.040”) SteelGas: Ar - Oxy/ 19 L/min (40 CFH)
MPM / IPMApkAbkPPSPWmsVpkCOMMENTS
17.9 / 705451902012.433.7
17.8 / 700450902002.433.6
16.5 / 650440901922.432.8
15.2 / 600430901852.432.0
14.0 / 550420901772.331.1
12.7 / 500410901702.330.3
11.4 / 450392821622.329.4
10.2 / 400375751552.328.5
8.9 / 350357671472.227.5
7.6 / 300340601402.226.6
6.4 / 250320551202.126.9
5.1 / 200300501002.027.3
3.8 / 15028045801.927.6
2.5 / 10026040601.827.9
2.4 / 9525739571.827.9
OM-196 188 Page 84
Page 91
8-19. Setup Pendant Mode Select Button
1
1Mode D i s p l a y
2Mode 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
2
> Prg 1
Pulse
035” Steel
Argon – Oxy
Ref. 154 109
OM-196 188 Page 85
Page 92
8-20. Setup Pendant Parameter Select Button
1Parameter Display
2Moving Line
Moving line is under value that can
be changed.
3Pulse Panel Parameter Select
Button
Press pulse panel parameter select
button to move indicator in right window display.
1
> Process
Sequence
SharpArc
Card
2
> Prg 1
Pulse
035” Steel
Argon – Oxy
3
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
1
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).
1Increase Button
Press button to increase value that
is underlined by the moving line.
2Decrease 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
Increase
> Prg 3
2
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
1
> Prflw
0.0 Sec
Weld Time
Crater Time
Weld
Stop
2
Crater
Speed
Retract Time
Arc
Out
Postflow
Time
TimeRun-In
Ref. S-0271
1Mode Select Button
When unit is turned On, Process is
the default mode, at other times,
use mode select button to select
Sequence.
2Parameter Select Button
Use parameter select button to
select parameters.
3Preflow 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.
3
> Prflw
0.0 Sec
OM-196 188 Page 88
Mode SelectParameter
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
1
Increase
Proceed to next Section.
1Weld 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
1
> 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
1Crater 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
1
> Poflw
0.0 Sec
Poflw
> 0.0 Sec
> Poflw
1.2 Sec
1Postflow 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.
1Apk – 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.
2Abk – Background Current Of
3
241
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.
3PPS – 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.
4PWms – 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.
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.
OM-196 188 Page 91
Page 98
10-3. Selecting Teach Point Wire Feed Speed For Pulse Welding Program
1Process Display
When unit is first turned On,
Process is the default screen, at
other times use mode select button
to select Process.
2Teach Display
Use parameter select button to
select Teach.
Use increase/decrease buttons to
select On.
3IPM (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
3
Teach On
> 400 IPM
28.1 Vpk
340 Apk
1
Parameter
Select
Parameter
Select
2
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
Select
Teach On
450 IPM
> 28.1 Vpk
340 Apk
1
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
Or
Increase/
Decrease
Increase/
Decrease
5
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
2
Wait for 5
seconds
Parameter
Select
Teach On
> 450 IPM
28.1 Vpk
340 Apk
Parameter
Select
Increase/
Decrease
Increase/
Decrease
4
6
31.2 Vpk
343 Apk
>70 Abk
160 PPS
Parameter
Select
3
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:
1Vpk Display
2Apk Display
3Abk Display
4PPS Display
5PWms 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.
6Custom 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 FlowrateCFH
IPMApkAbkPPSPWmsVpkCOMMENTS
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
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