Miller Electric Remote Operator Interface manual

ROI (Remo te Operato r Interface) Processes Description MIG (GMA W) W elding Wire Feeder OM-217 834G 2006 − 06 File: Advanced Manufacturing Systems V isit our website at www.MillerWelds.com/ams[...]

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 specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

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

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OM-217 834 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety me[...]

OM-217 834 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching[...]

OM-217 834 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.[...]

OM-217 834 Page 4 1-5. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Recommended Safe Practices for the Preparation for W elding and Cut- ting of Containers and Piping , American Welding Society Standard A W[...]

OM-217 834 Pa ge 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les ut ilisés Sy m bole graphique d’av ertis sement ! Attention ! Cette pro- cédur e c omporte des r is ques p o[...]

OM-217 834 Page 6 Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la pe[...]

OM-217 834 Pa ge 7 2-3 . Dangers s uppl émentaire s en r el ation avec l’install ation, le f onc t i onnement et l a mainte nance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharg[...]

OM-217 834 Page 8 2-5. Princi pales n ormes de sécurit é Safety in W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www .global.ihs.com). Recommended Safe Practices fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W el[...]

OM-217 834 Page 9 SECTION 3 − INTRODUCTION 3-1. Specifications T ype of Input Power W elding Power Source T ype Wire Feed Speed Range Wire Diameter Range W elding Circuit Rating Overall Dimensions W eight 40 V olts DC 10 Amperes Axcess Series Standard: 40 T o 1400 ipm (1.0 T o 35.6 mpm) .035 T o 1/16 in (0.8 T o 1.6 mm) Max Spool W eight: 60 lb ([...]

OM-217 834 Page 10 4-2. Installing Insulator Kit 804 165-A Y T urn Off and disconnect input power . 1 ROI Control 2 Insulator Plate 3 Mounting Plate 4 1/4-20x3/4 in Screw (4) 5 Nylon Shoulder Washer (4) 6 3/8 in Flat W asher (4) Place insulator plate between ROI base and metal mounting surface. Place nylon shoulder washer over screw . Place flat wa[...]

OM-217 834 Page 1 1 Ref. 803 697-E T y pical Swingarc installati on s hown; howev er , various inst allations ar e poss ible d epending on the applicat ion. 1 Remote Operator Interface 2 Swingarc Swivel Assembly 3 Boom 4 AA40G Wire Drive Assembly 5 Trigger Cable 4-3. Remote Operator Interface And Wire Drive Installation 1 2 3 4 5 5 803 698-E 1 W el[...]

OM-217 834 Page 12 4-5. Rear Panel Connections Ref. 803 503-A 1 9-Pin Network Receptacle 2 Motor Control/Shielding Gas V alve Receptacle 3 Rating Label Location 1 2 3 4-6. 9-Pin Network Receptacle Information 9 Pin Pin Information A Capacitor C1 to ground B Shield G F C V olt sense H G E F D Can low I H D E E Can high A B I C D F +24 volts dc commo[...]

OM-217 834 Page 13 4-8. Power Source Display At Power Up 1 Upper Display 2 Lower Display Program Process Wire T ype Gas T ype T rigger Control Adjust V olts Time WFS Amps Process Set Up Feeder Set Up T rigger Hold 2 1 Arc Adjust Arc Ctl Sequence Power Source Upper Display Lower Di splay Axcess Axcs 300/450/675 10 44 V oltage Range Net W ait DTEC OF[...]

OM-217 834 Page 14 SECTION 5 − OPERA TION 5-1. Operational T erms The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder: General T erms: Arc Adjust T erm used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases the actual arc length. Likewise, decreasing ar[...]

OM-217 834 Page 15 General T erms: Sequence Selecting Sequence will allow setting of preflow , start, crater , and postflow times and parameters. Preflow Setting a time value for gas flow prior to arc start. Start Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (which is only adjustable with the optional PDA with[...]

OM-217 834 Page 16 5-3. Front Panel Sections See Section 5-5 See Section 5-6 See Section 5-9 See Section 5-8 See Section 5-7 See Section 5-4 Program Process Wire T ype Gas T ype T rigger Control Adjust V olts T ime WFS Amps Process Set Up Feeder Set Up T rigger Hold Arc Adjust Arc Ctl Sequence[...]

OM-217 834 Page 17 5-4. Program Push Button 1 3 Program 2 1 Program Display The number of the active program is displayed. 2 Program Push Button 3 Program Push Button LED The LED lights to indicate that programs can be changed using the Adjust knob. Momentarily pres s button to illuminate LED. T o c hange the program number , rot ate Adjus t knob t[...]

OM-217 834 Page 18 5-6. Lower Display 1 Lower Display The lower display shows WFS (wire feed speed), AMPS (amperage), ARC CTL (arc control), or Time. The feeder displays only preset wire speed at idle (not welding). While welding, the average amperage is displayed. The lower display shows welding sequence time when the T ime LED is illuminated. 2 W[...]

OM-217 834 Page 19 5-7. Feeder Set Up Push Button 1 Feeder Set Up Push Button LED 2 Feeder Set Up Push Button • Press button to choose Sequence. Feeder Set Up push-button LED will illuminate. 3 Sequence LED • When the Feeder Set Up button is pressed once, the Sequence LED will illuminate and the upper display will show sequence options. Use the[...]

OM-217 834 Page 20 5-9. Process Set Up Push Button • Press the Process Set Up push button the first time will illuminate the button LED and the Process LED. The upper and lower displays will be used for Accu-pulse and only the lower display for MIG, Pulse and RM D (optional) to show the current process installed in this program. T o change proces[...]

OM-217 834 Page 21 5-10. Jog/Purge 803 693-A 1 Jog/Purge Push Button 2 Adjust Control 3 Gun Trigger Receptacle 1 2 3 The Jog/Purge switch provides the following functions: • Pressing left side of the Jog/Purge switch allows the operator to feed wire without energizing the weld power or gas valve circuit. The wire will feed at a 60 ipm rate for 3 [...]

OM-217 834 Page 22 5-1 1. Reset Mode 198 993 / 803 246-B . Reset mode is not active when Program Lock is enabled. Th e reset mode allows the operator to reload factory program settings for all eight active programs in the unit. . System configuration data will be lost during the Reset operation. Enter reset mode by turning power On and pressing the[...]

OM-217 834 Page 23 SECTION 6 − SETTING SEQUENCE P ARAMETERS 6-1. Sequence Parameters In A Program . For more information on Sequence mode, see Feeder Set Up Push Button in Section 5-7 . We ld Time can only be set by us ing an o ptional PDA with File Management/WaveWriter softwar e. If time is set to zero in any tim ed sequenc e, t he sequenc e is[...]

OM-217 834 Page 24 SECTION 7 − MAINTENANCE 7-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more often during severe conditions. n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference Every 3 Months Months l Unreadable Labels nl Cracked Parts nl Cords Every 6 Months OR ~ In[...]

OM-217 834 Page 25 7-2. Diagnostics ERR T ACH • The tach error occurs 2 seconds after the loss of tachometer feedback. The motor speed is re gul a ted through the monitoring of voltage and current. Press Jog/Purge button to clear error . ERR MOTR • The motor error indicates that the motor has been drawing too much current for too long. T o reme[...]

OM-217 834 Page 26 7-2. Diagnostics (Continued) WELD W AIT • The weld wait erro r indicates unit was not ready for a weld sequence. Press Jog/ Purge button to clear error . MOTR COM • The motor communication erro r indi- cates motor board lost data communica- tions. Press Jog/Purge button to clear error . PLS W AIT • The uim communication err[...]

OM-217 834 Page 27 Notes[...]

OM-217 834 Page 28 SECTION 8 − ELECTRICAL DIAGRAM Figure 8-1. Circuit Diagram[...]

OM-217 834 Page 29 214 842-E[...]

OM-217 834 Page 30 SECTION 9 − P ARTS LIST 803 696-B . Hardware is common and not available unless listed. 1 2 3 4 5 7 10 13 14 15 16 17 18 19 20 6 8 9 11 12 Figure 9-1. Remote Operator Interface Description Part No. Dia. Mkgs. Item No. Figure 9-1. Remote Operator Interface Quantity 1 214 839 WRAPPER, feeder 1 . . . . . . . . . . . . . . . . . . [...]

OM-217 834 Page 31 Description Part No. Dia. Mkgs. Item No. Figure 9-1. Remote Operator Interface (Continued) Quantity 14 PC1 212 459 CIRCUIT CARD ASSY , trigger filter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 RC4 048 282 RCPT W/SKTS, (service kit) 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

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Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 2006 − 01 Y our distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expe[...]

PRINTED IN USA © 2006 Miller Electric Mfg. Co. 2006 − 01 Miller Elect ric Mfg. Co. An Illinois T ool Wor k s Comp any 1635 W es t Spencer St reet Applet on, WI 5 4914 USA International He adquarters − US A USA Phone: 920-735-4505 Aut o-Att ended USA & Canada F AX : 920-735-4134 Int ernational F A X: 920-735-4125 European Headqua rters − [...]