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Miller Electric Remote Operator Interface, Owner'S Manual

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ROI

(Remote Operator Interface)

Processes

Description

MIG (GMAW) Welding

Wire Feeder

OM-217 834G

2006

−

06

File: Advanced Manufacturing Systems

Visit our website at

www.MillerWelds.com/ams

Summary of Contents for Remote Operator Interface

Page 1: ...ROI Remote Operator Interface Processes Description MIG GMAW Welding Wire Feeder OM 217 834G 2006 06 File Advanced Manufacturing Systems Visit our website at www MillerWelds com ams ...

Page 2: ...ntinue 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 operatio...

Page 3: ...ION 4 INSTALLATION 9 4 1 Mounting Plate Hole Layout 9 4 2 Installing Insulator Kit 10 4 3 Remote Operator Interface And Wire Drive Installation 11 4 4 Connection Diagram 11 4 5 Rear Panel Connections 12 4 6 9 Pin Network Receptacle Information 12 4 7 Gun Recommendation Table 12 4 8 Power Source Display At Power Up 13 4 9 Dual Schedule Switch Option 13 SECTION 5 OPERATION 14 5 1 Operational Terms 1...

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Page 5: ...10 147 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 prop...

Page 6: ...ombustibles such as a butane lighter or matches from your person before doing any welding D Follow requirements in OSHA 1910 252 a 2 iv and NFPA 51B for hot work and have a fire watcher and extinguisher nearby 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 shield...

Page 7: ...es computers and communicationsequipment 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 installa tion D If notified by the FCC about interference stop using the equipmentat once D Have the installation regularly checked and maintaine...

Page 8: ...A Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Documents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov 1 6 EMF Information Considerations About Welding And The...

Page 9: ...ion selon la norme OSHA 29 CFR 1910 147 voir normes de sécurité D Installer le poste correctement et le mettre à la terre convenablement selon les consignes du manuel de l opérateur et les normes nationales provinciales et locales D Toujours vérifier la terre du cordon d alimentation Vérifier et s assurer que le fil de terre du cordon d alimentation est bien raccordé à la borne de terre du section...

Page 10: ...ble de ses poches telles qu un allumeur au butane ou des allumettes D Suivre les consignes de OSHA 1910 252 a 2 iv et de NFPA 51B pour travaux de soudage et prévoir un détecteur d incendie et un ex tincteur à proximité 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 des étincelles et des particules ...

Page 11: ...s interférences avec les équipe ments de radio navigation et de communica tion les services de sécurité et les ordinateurs D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l instal lation D L utilisateurest tenu de faire corriger rapidement par un électri cien qualifié les interférences résultant de l installation D Si le FCC sig...

Page 12: ... Part 1926 Subpart J de U S Government Printing Office Superinten dent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux régionaux le téléphone de la région 5 Chicago est 312 353 2220 site Internet www osha gov 2 6 Information EMF Considérations sur le soudage et les effets de basse fréquence et des champs magnétiques et électriques Le courant de soudage pendant son passage dans le...

Page 13: ...eight 40 Volts DC 10 Amperes Axcess Series Standard 40 To 1400 ipm 1 0 To 35 6 mpm 035 To 1 16 in 0 8 To 1 6 mm Max Spool Weight 60 lb 27 kg 100 Volts 750 Amperes 100 Duty Cycle Length 7 in 178 mm Width 7 in 178 mm Height 12 in 305 mm 11 lb 5 kg SECTION 4 INSTALLATION 4 1 Mounting Plate Hole Layout Ref 200 553 A 4 in 102 mm 1 3 4 in 44 mm 3 in 76 mm 1 3 4 in 44 mm 7 32 in 5 6 mm Dia 4 holes ...

Page 14: ...w 4 5 Nylon Shoulder Washer 4 6 3 8 in Flat Washer 4 Place insulator plate between ROI base and metal mounting surface Place nylon shoulder washer over screw Place flat washer over shoulder washer Insert hardware assembly through hole in metal mounting base insu lator and into ROI base 4 loca tions Tighten hardware to secure control 1 2 3 4 5 6 1 2 in Tools Needed ...

Page 15: ... Assembly 5 Trigger Cable 4 3 Remote Operator Interface And Wire Drive Installation 1 2 3 4 5 5 803 698 E 1 Welding Power Source 2 Wire Feeder 3 Gas Cylinder 4 Gas Hose 5 Network Feeder Cable 6 Negative Weld Cable 7 Workpiece 8 Voltage Sensing Lead Optional Positive voltage sensing lead is contained in the motor cable 9 Positive Weld Cable 10 Motor Cable 11 Trigger Cable 4 4 Connection Diagram 1 2...

Page 16: ...ork Receptacle Information 9 Pin Pin Information A Capacitor C1 to ground B Shield G F C Volt sense H G E F D Can low I H D E E Can high A B I C D F 24 volts dc common B C G 24 volts dc H Motor voltage 40 volts dc common I Motor voltage 40 volts dc 4 7 Gun Recommendation Table Process Gun GMAW Hard or Cored Wires 400 500 And 600 Amp Air Cooled Guns GMAW Pulse Water Cooled Guns ...

Page 17: ...Control Adjust Volts Time WFS Amps Process Set Up Feeder Set Up Trigger Hold 2 1 Arc Adjust Arc Ctl Sequence Power Source Upper Display Lower Display Axcess Axcs 300 450 675 10 44 Voltage Range Net Wait DTEC OFF 4 9 Dual Schedule Switch Option 1 Maint 2P Maintained Contact 2 Pole Switch DSS 9M Part 041 793 1 1 1 2 2 3 A 4 B DSS 9M ...

Page 18: ...d by peak and minimum current levels Benefits are shorter arc lengths better puddle control more tolerant of tip to work variation less audible noise no arc wandering allows weld to fill in at toes increasing travel speed and deposition and more tolerant to poor fit up and gaps Accuspeed CV Pulse process designed for high travel speeds Typically used in Robotic applications Arc is de signed to be ...

Page 19: ... setting of voltage arc adjust wire feed rate and time value for arc ends Postflow Setting a time value for gas flow after arc end Feeder Set Up Allow selection of Sequence and trigger functions Auto Thread Method of jogging wire without holding jog or trigger switch Pressing Jog and Retract simultaneously will automatically feed wire Default setting is 192 at a feed rate of 700 ipm these values c...

Page 20: ... 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 Type Gas Type Trigger Control Adjust Volts Time WFS Amps Process Set Up Feeder Set Up Trigger Hold Arc Adjust Arc Ctl Sequence ...

Page 21: ...oltage The display will show actual voltage for approximately 3 seconds after welding stops before returning to preset value 2 Upper Display Push Button Press the button to illuminate the LED and allow changing information in the display 3 Upper Display Push Button LED The upper display push button LED illuminates to indicate that information displayed can be changed by the Adjust knob 4 Volts LED...

Page 22: ... and can be adjusted using the Adjust knob 6 Lower Display Push Button 7 Lower Display Push Button LED Pressing the button illuminates the LED and selects either WFS or Arc Ctl value for changing using the Adjust knob To select Arc Ctl press and hold lower display button for 2 seconds The top display will show either INDU for a MIG program or ARC for Pulse Accu pulse or RMD optional To exit Arc Ct...

Page 23: ...either STRT or CRTR and the WFS LED will begin flash ing Use the Adjust knob to change the WFS value Pressing the Feeder Set Up button two more times will exit the Sequence menu and return the system to standby mode 4 Trigger Control LED Press the Feeder Set Up button twice and the Trigger Control LED will illuminate and the upper display will show the different trig ger control selections Use the...

Page 24: ...Up push button a sixth time will show PROG in the upper display and LOAD in the lower display The new program would be loaded for that particular program in slot 1 thru 8 If no changes were made to any setup items no program will be loaded and unit will return to standby mode If a custom program is loaded using an optional PDA with File Management Wa veWriter software the Program Display will have...

Page 25: ...nds and then ramps up to 700 ipm until trig ger is released or 30 seconds elapses If the gun trigger is still activated after 30 seconds the jog operation is terminated to prevent complete unspooling of the wire and an ERR STRT message is displayed on the upper and lower displays Releasing and pressing the trigger again will clear the error If Start Error is enabled using an optional PDA with File...

Page 26: ...utton to confirm the reset The reset message is displayed for 2 seconds while factory program settings are being reloaded During the reset mode the following factory default programs are loaded into the unit Cycl Pwr message appears on the display when programs complete loading Turn power off wait 10 seconds and turn power back on again to complete the reset operation After Reset is complete be su...

Page 27: ...software If time is set to zero in any timed sequence the sequence is skipped Maximum IPM may actually be lower depending on the process and wire type selection Trigger Pressed Trigger Released Start Time Preflow Weld Crater Time Postflow Start Time Time Postflow Crater Weld Preflow Sequence End Volts Arc Adjust IPM Seconds 2 Postflow Off 5 0 1 Preflow Off 5 0 Sequence Parameters 3 Start 4 Crater ...

Page 28: ...Disconnect power before maintaining Maintain more often during severe conditions n Check Z Change Clean l Replace To be done by Factory Authorized Service Agent Reference Every 3 Months Months l Unreadable Labels nl Cracked Parts nl Cords Every 6 Months OR Inside Unit ...

Page 29: ...og Purge button ERR GND The ground current error occurs if weld current is detected in the earth ground connection May be caused by a conductor making contact with unit chassis Check and repair feeder weld connections Press Jog Purge button to clear error ERR STUK The stuck error occurs if the welding wire sticks to the workpiece at the end of a weld May be caused by poor weld conditions The error...

Page 30: ...n emergency stop button Reset the emergency stop button and press Jog Purge button to clear error RMD DONE The RMD done error indicates the RMD demo is completed Press Jog Purge button to clear error OVER AVER The over average error indicates that cur rent is outside the average range for the set program parameters Check and correct program parameters Press Jog Purge but ton to clear error REL TRI...

Page 31: ...OM 217 834 Page 27 Notes ...

Page 32: ...OM 217 834 Page 28 SECTION 8 ELECTRICAL DIAGRAM Figure 8 1 Circuit Diagram ...

Page 33: ...OM 217 834 Page 29 214 842 E ...

Page 34: ... 210 655 NAMEPLATE overlay 1 3 PC5 227 879 CIRCUIT CARD ASSY switches 1 4 PC7 221 278 USER INTERFACE MODULE 1 5 212 808 BAFFLE pc mounting 1 6 207 676 STAND OFF no 6 32 x 250 lg 250 hex 4 7 PC6 221 280 WIRE FEED MODULE 1 8 097 132 STAND OFF SUPPORT pc card 4 9 RC1 211 018 CONNECTOR circ 97 met 9 pin size 20 rcpt 1 PLG40 43 48 115 093 HOUSING PLUG SKTS service kit 1 10 211 002 ENCLOSURE control 1 1...

Page 35: ...ice kit 1 PLG4 136 810 HOUSING PLUG SKTS service kit 1 PLG81 115 092 HOUSING PLUG SKTS service kit 1 PLG10 130 203 HOUSING PLUG SKTS service kit 1 PLG50 136 810 HOUSING PLUG SKTS service kit 1 PLG44 131 058 HOUSING PLUG SKTS service kit 1 PLG45 188 352 HOUSING RCPT SKTS service kit 1 PLG42 131 054 HOUSING RCPT SKTS service kit 1 PLG40 201 665 HOUSING RCPT PLUG SKTS service kit 1 149 251 CABLE trig...

Page 36: ...Notes ...

Page 37: ...Notes ...

Page 38: ...Notes ...

Page 39: ...n Heating Coils and Blankets Cables and Non Electronic Controls APT SAF Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate Spoolguns Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear Exception brushe...

Page 40: ...d retain with your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering...

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