Miller-electric Welder User Manual

Auto Invision IIVisit our website atwww.MillerWelds.comProcessesOM-196 188KJuly 2003DescriptionMIG (GMAW) WeldingPulsed MIG (GMAW-P)Flux Cored (FCAW)

OM-196 188 Page 41-5. EMF InformationConsiderations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it f

OM-196 188 Page 94Make copies of this chart for future use.NOTEProgram # Wire Size/Type GasProgram Name Card #Gun Model Flowrate CFHIPM Apk Ab

OM-196 188 Page 95> ProcessSequenceSharpArcCardPrg 1> Adapt Pulse035” SteelArgon – OxyWelding parameters are the samefor both a Pulse and an Ada

OM-196 188 Page 961 Setup Pendant DisplayDefault display when unit is firstturned On, at other times use modeselect button to select Process.Go to Sec

OM-196 188 Page 971 Start Parameters DisplayParameter ranges are as follows:Seconds, 0-2.5 Sec. If value set iszero (0), there is no Run-In se-quence.

OM-196 188 Page 981 Crater Parameters DisplayParameter ranges are as follows:Seconds, 0-2.50 Sec. If value set iszero (0), there is no Cratersequence.

OM-196 188 Page 991 Postflow Parameters DisplayPostflow can be adjusted from0-9.9 seconds. If value set is zero(0), there is no Postflow sequence.1>

OM-196 188 Page 100SECTION 12 – SETTING SharpArcE CONTROL12-1. Selecting And Adjusting SharpArcE Control1 SharpArcSharpArc is used to adjust arccone

OM-196 188 Page 101SECTION 13 – USING THE OPTIONAL DATA CARD1 LabelPeel backing from label and applyto data card with THIS SIDE UP bymetal pins.Write

OM-196 188 Page 102Use Mode Select button to selectCard.1 Card Display2 WriteUsed to transfer program data fromunit to card. The program card canhold

OM-196 188 Page 10313-3. Naming Programs And Writing To CardAll program types (Pulse, Adaptive Pulse, and MIG) can be stored on a data cardand retriev

OM-196 188 Page 5SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANTUTILISATIONsom _nd_fre 4/981-1. Signification des symbolesSignifie Mise en garde ! Soye

OM-196 188 Page 10413-4. Reading From CardPrograms developed on the Auto Invision will not run the same on Auto Invision II.NOTEUse Mode Select button

OM-196 188 Page 1051 Warning DisplayIf there are no programs on thecard, this series of displays appear.Write> ReadDeleteDoneWARNING:Card EmptyPres

OM-196 188 Page 10613-7. Selecting Security LockSecurity lock works only when a data card is inserted.NOTE1 Security DisplayUse this display to lock a

OM-196 188 Page 107SECTION 14 – SETUP14-1. Setup Flow Chart>Memory No Reset No Reset 14-12ProgramResetSystemResetTotalReset>Wiretype Wire Type H

OM-196 188 Page 1081 Front Panel Setup DisplayFront panel display during setup.2 Pulse Panel Mode AndParameter Select Buttons3 Power Switch On Rear Pa

OM-196 188 Page 10914-3. Selecting Or Changing Access CodeAccess code works only when a data card is inserted (see Section 13).NOTE1 Code DisplayWith

OM-196 188 Page 1101 Mig Type DisplayWith DVC Voltage Correction On,the unit uses closed-loop feedbackor voltage sensing leads tomaintain set voltage

OM-196 188 Page 11114-7. Selecting Arc Start MethodArc Start selection is not used when welding in non-pulsed MIG.Do not use the Hot Start setting for

OM-196 188 Page 1121 Wire Feed DisplayThe displayed unit of wire speed(IPM or MPM) can be changedalong with the wire feed motor type(Standard, Low Spe

OM-196 188 Page 11314-10. Selecting Wire TypeIf wire type is changed, perform a system reset (see Section 14-12) immediatelyafter selecting wire type

OM-196 188 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptib

OM-196 188 Page 1141 No ResetPress Parameter Select button toexit memory reset parameter with-out resetting any data.2 Program ResetPress Parameter Se

OM-196 188 Page 1151 Name DisplayWhen a data card is used, the pro-grams written from the unit to thecard can be named.MemoryShutdown> NameProgramC

OM-196 188 Page 1161 Jog IPM DisplayJog wire feed speed can be variedbetween 50 and 780 inches perminute, IPM.When not welding, a Robot Joglocal setti

OM-196 188 Page 1171 Monitor DisplayProvides a means to enable/dis-able the arc voltage error featureand to set an acceptable range ofdeviation from s

OM-196 188 Page 1181 Ramps DisplayThe ramps function allows outputpower to be tapered from start toweld and/or from weld to crater.2 Program NumberCho

OM-196 188 Page 119SECTION 15 – CONTROL MENUThe control menu allows the user access to rise time setting that controls rise and fall time of the pulse

OM-196 188 Page 12015-2. Setting Rise Time ParameterMaximum Rise Time setting will make the welding power source go to itsmaximum output in the maximu

OM-196 188 Page 12115-4. Setting Auto Configure Parameter1 Auto Configure DisplaySetting allows user to do manualconfiguration or automaticconfigurati

OM-196 188 Page 12215-5. Setting Retract On/Off1 Retract DisplaySettings allow user to turn the re-tract feature On or Off. The retractfeature allows

OM-196 188 Page 1231 Exit Control Menu DisplayAllows the user to leave the controlmenu.1AutoConfigRetractShrpStrt> ExitExit CntrlMenu NowPress15-7.

OM-196 188 Page 71-3. Dangers supplémentaires en relation avec l’installation, le fonctionnementet la maintenanceRisque D’INCENDIE OUD’EXPLOSION.D Ne

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/03Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2003 Miller Electric Mfg. Co. 1/03Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-196 188 Page 81-4. Principales normes de sécuritéSafety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-ding Society, 550 N.W. Lejeune

OM-196 188 Page 9SECTION 2 – DEFINITIONS2-1. Manufacturer’s Warning Label DefinitionsWarning! Watch Out! There arepossible hazards as shown by thesymb

OM-196 188 Page 10> 60 sVS-179 190-AVV1 Warning! Watch Out! Thereare possible hazards asshown by the symbols.2 Electric shock from wiring cankill.3

OM-196 188 Page 112-2. Symbols And DefinitionsAAmperage Positive RemoteVVoltageOutput Circuit Breaker Negative OnOff InductanceProtective Earth(Ground

OM-196 188 Page 12SECTION 3 – INSTALLATION3-1. SpecificationsInputRated WeldingVoltageWire Feed SpeedWireMaximumOpen-Amperes InputAt Rated LoadInputPo

OM-196 188 Page 133-3. Selecting A Locationloc_2 3/96 - 801 958 / 801 914-A1 Lifting ForksUse lifting forks to move unit.Extend forks beyond opposite

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-196 188 Page 143-5. Weld Output Terminals And Selecting Cable SizesTotal Cable (Copper) Length In Weld Circuit Not Exceeding30 m (100 ft) Or Less45

OM-196 188 Page 153-7. Electrical Service GuideThree-PhaseInput Voltage 400Input Amperes At Rated Output 31Max Recommended Standard Fuse Or Circuit Br

OM-196 188 Page 1635641 Receptacle2 Keyway3 4-Pin Receptacle (OptionalExternal Voltage SensingConnection)To connect interconnecting cord toreceptacle,

OM-196 188 Page 173-10. Peripheral Receptacle FunctionsFunction Socket Socket InformationProgrammableOutput Relay Con-A Contact closure to B dependent

OM-196 188 Page 183-11. Touch Sensor OperationThe touch sensor feature allows the robot to locate a weldment using the wire feed system and welding po

OM-196 188 Page 193-13. Connecting Setup Pendant To Welding Power Source802 816Y Turn Off welding powersource and weld control.1 Welding Power Source2

OM-196 188 Page 20SECTION 4 – OPERATION4-1. Operational Terms The following is a list of terms and their definitions as they apply to this interface u

OM-196 188 Page 21System Reset By selecting system reset in the memory reset mode, the unit defaults to original factory settings forall programs and

OM-196 188 Page 224-4. Upper Front Panel Controls1 Setup Pendant ReceptacleReceptacle for connecting pendantinterconnecting cord.2 Jog Forward Push Bu

OM-196 188 Page 234-5. Duty Cycle And OverheatingDuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.If unit o

TABLE OF CONTENTSSECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1. . .

OM-196 188 Page 244-7. Setup Pendant Controls1 Increase ButtonWorks with security feature on weldingpower source to allow increasing weldparameter val

OM-196 188 Page 25SECTION 5 – MAINTENANCE & TROUBLESHOOTING5-1. Routine MaintenanceY Disconnect power before maintaining.. Maintain more oftenduri

OM-196 188 Page 265-3. Removing Case and Measuring Input Capacitor VoltageTurn Off welding power source, anddisconnect input power.1 Outside Handle Sc

OM-196 188 Page 275-4. Voltmeter/Ammeter Help Displays. All directions are in reference tothe front of the unit. All circuitryreferred to is located i

OM-196 188 Page 281 Memory CRC Error DisplayCorrupted program data has been detectedor loaded. The “X” value indicates the pro-gram number.May be caus

OM-196 188 Page 291 Weld Interface Board PC12Diagnostic LED’s are visible insideunit, located on PC12 (see illustrationfor board location).Refer to Se

OM-196 188 Page 305-7. Diagnostic LED’s On Weld Interface Board PC12LED Status Diagnosis1 On Indicates auxiliary output relay is not energized.Off Ind

OM-196 188 Page 311 Customer Interface Board PC14Diagnostic LED’s are visible insideunit, located on PC14 (see illustrationfor board location).Refer t

OM-196 188 Page 325-9. Diagnostic LED’s On Customer Interface Board PC14LED Status Diagnosis1On Indicates –15 volts dc RA supply is present on custome

OM-196 188 Page 33LED DiagnosisStatus23 On Input signal On from peripheral for jog advance.Off Input signal Off from peripheral for no jog advance.24

TABLE OF CONTENTSSECTION 8 – INTRODUCTION TO PROGRAMMING 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Pulse MI

OM-196 188 Page 345-11. Diagnostic LED’s On Motor Board PC13LED Status Diagnosis1 On Indicates motor reverse relay is energized.Red Off Indicates mot

OM-196 188 Page 35Notes

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

OM-196 188 Page 37203 505-A

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

OM-196 188 Page 39203 311 (1 of 3)

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

OM-196 188 Page 41203 311 (2 of 3)

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

OM-196 188 Page 43203 311 (3 of 3)

TABLE OF CONTENTSSECTION 14 – SETUP 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OM-196 188 Page 45190 696

OM-196 188 Page 46184 183Figure 6-6. Circuit Diagram For Interconnect Board PC2188 015Figure 6-7. Circuit Diagram For Gate Boards PC4 And PC5

OM-196 188 Page 47Notes

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

OM-196 188 Page 49193 709-A

OM-196 188 Page 50Figure 6-9. Circuit Diagram For Microprocessor Board PC11

OM-196 188 Page 51191 838

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

OM-196 188 Page 53212 354-A

dec_con1_11/02Declaration of Conformity ForEuropean Community (CE) ProductsManufacturer’s Name: Miller Electric Mfg. Co.Manufacturer’s Address: 1635 W

OM-196 188 Page 54Figure 6-11. Circuit Diagram For Switch Board PC15182 996

OM-196 188 Page 55200 739Figure 6-12. Circuit Diagram For Junction Board PC16

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

OM-196 188 Page 57191 843-A (Part 1 of 2)

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

OM-196 188 Page 59191 843-A (Part 2 of 2)

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

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

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

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

OM-196 188 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_4/981-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswi

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

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

OM-196 188 Page 66Figure 6-18. Circuit Diagram For Touch Sensor Board PC18174 578-A

OM-196 188 Page 67200 739-AFigure 6-19. Circuit Diagram For Setup Pendant

OM-196 188 Page 68Figure 6-20. Circuit Diagram For Setup Pendant Centronix Junction Board PC3200 739

OM-196 188 Page 69191 531Figure 6-21. Circuit Diagram For Power Distribution Board PC20

OM-196 188 Page 70SECTION 7 – PARTS LIST. Hardware is common andnot available unless listed.802 872-D1256789104445465559606263646566676870757172737476

OM-196 188 Page 71DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-1. Complete AssemblyQuantity1 185 970 COVER, top 1. . . . . . . . . . . . . . . . . . .

OM-196 188 Page 72DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-1. Complete Assembly (Continued)Quantity47 T2 185 231 TRANSFORMER, control 200/400 VAC 1.

OM-196 188 Page 73DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-1. Complete Assembly (Continued)Quantity144 844 STAND-OFF, No. 6-32 x .875 5. . . . . . .

OM-196 188 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Sp

OM-196 188 Page 74Notes

Auto Invision IIOM-196 188KJuly 2003Programming Instructions for

OM-196 188 Page 76SECTION 8 – INTRODUCTION TO PROGRAMMINGThe interface unit is designed foruse in pulse MIG welding (adaptiveor standard), or MIG weld

OM-196 188 Page 778-3. Program 1 – 1.2 mm Steel (.045”), 98-2 Argon-Oxy Wire Size/Type: 1.2 mm (.045”) Steel Gas: Ar - Oxy / 19 L/min (40 CFH)MPM / IP

OM-196 188 Page 788-5. Program 3 – 1.2 mm Steel (.045”), 80-20 Argon-CO2Wire Size/Type: 1.2 mm (.045”) Steel Gas: Ar - CO2 / 19 L/min (40 CFH)MPM / IP

OM-196 188 Page 798-7. Program 5 – 1.0 mm 316 (.040”), 98-2 Argon-CO2 Wire Size/Type: 1.0 mm (.040”) 316 Gas: Ar - CO2 / 19 L/min (40 CFH)MPM / IPM Ap

OM-196 188 Page 808-9. Program 7 – 1.0 mm 308L (.040”), 98-2 Argon-CO2 Wire Size/Type: 1.0 mm (.040”) 308L Gas: Ar - CO2 / 19 L/min (40 CFH)MPM / IPM

OM-196 188 Page 818-11. Program 1 – 1.2 mm Metal Core (.045”), 95-5 Argon-CO2The next 8 programs are available after changing software wiretype (see S

OM-196 188 Page 828-13. Program 3 – 1.2 mm ER 4043 (.045”), ArgonWire Size/Type: 1.2 mm (.045”) ER 4043 Gas: Ar / 19 L/min (40 CFH)MPM / IPM Apk Abk P

OM-196 188 Page 838-15. Program 5 – 1.0 mm 5356 (.040”), ArgonWire Size/Type: 1.0 mm (.040”) 4043 Gas: Ar / 19 L/min (40 CFH)MPM / IPM Apk Abk PPS PWm

OM-196 188 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over,

OM-196 188 Page 848-17. Program 7 – .8 mm Steel (.030”), 98-2 Argon-OxyWire Size/Type: .8 mm (.30”) Steel Gas: Ar - Oxy / 19 L/min (40 CFH)MPM / IPM A

OM-196 188 Page 858-19. Setup Pendant Mode Select Button1 Mode Display2 Mode Select ButtonPress Mode Select button to moveindicator in left window dis

OM-196 188 Page 86Ref. 154 1091 Parameter Display2 Moving LineMoving line is under value that canbe changed.3 Pulse Panel Parameter SelectButtonPress

OM-196 188 Page 87Ref. 154 109Use mode select button to selectmode to be changed (see 8-19).Use pulse panel parameter selectbutton to select parameter

OM-196 188 Page 88SECTION 9 – GETTING STARTED FOR PULSE WELDINGRef. S-02719-1. Weld Cycle For Pulse WeldingWireSpeedWeldStartStartPowerStartSpeedPrefl

OM-196 188 Page 899-3. Setting Weld Sequence Display1 Weld Parameters DisplayParameter ranges are as follows:Trim (Arc Length), 0-99Wire Feed Speed, 5

OM-196 188 Page 909-5. Setting Postflow Sequence Display1 Postflow Parameters DisplayPostflow can be adjusted from0-9.9 seconds. If value set is zero(

OM-196 188 Page 91The teach mode allows the user to createcustom pulse MIG welding programs. Theteach mode has 15 teach points. At eachteach point, th

OM-196 188 Page 9210-3. Selecting Teach Point Wire Feed Speed For Pulse Welding Program1 Process DisplayWhen unit is first turned On,Process is the de

OM-196 188 Page 93Pulse035” SteelArgon – Oxy> Teach OffWhen the Process Teach mode is On, andone of the following pulse parameters is se-lected: Ap