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OM-220979 Page 1

SECTION 1 

 SAFETY PRECAUTIONS - READ BEFORE USING

som 2015

09

7

Protect yourself and others from injury —

 

read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

DANGER! 

 Indicates a hazardous situation which, if

not avoided, will result in death or serious injury. The

possible hazards are shown in the adjoining symbols

or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE

 

 Indicates statements not related to personal injury.

.

Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-

bols and related instructions below for necessary actions to avoid the

hazards.

1-2. Arc Welding Hazards

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 1-5. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

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

power circuit and machine internal circuits are also

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.

ELECTRIC SHOCK can kill.

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 ONLY if required for the welding process.

D

If AC output is required, use remote output control if present on

unit.

D

Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp

locations or while wearing wet clothing; on metal structures such

as floors, gratings, or scaffolds; when in cramped positions such

as sitting, kneeling, or lying; or when there is a high risk of unavoid-

able or accidental contact with the workpiece or ground. For these

conditions, use the following equipment in order presented: 1) a

semiautomatic DC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit volt-

age. In most situations, use of a DC, constant voltage wire welder

is recommended. And, do not work alone!

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, ground, and operate 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

Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D

Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare

wiring can kill.

D

Turn off all equipment when not in use.

D

Do not use worn, damaged, undersized, or repaired cables.

D

Do not drape cables over your body.

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

Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be

present.

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. Disconnect cable for process not in

use.

D

Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter weld-

ing power sources AFTER removal of input power.

D

Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

HOT PARTS can burn.

D

Do not touch hot parts bare handed.

D

Allow cooling period before working on

equipment.

D

To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

Содержание ROI BOX CE

Страница 1: ...ROI Remote Operator Interface CE Processes Description MIG GMAW Welding Wire Feeder OM 220979S 2016 02 File Advanced Manufacturing Systems Visit our website at www MillerWelds com ams...

Страница 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...

Страница 3: ...Label Location 12 4 2 Unit Specifications 12 4 3 Environmental Specifications 12 SECTION 5 INSTALLATION 13 5 1 Mounting Plate Hole Layout 13 5 2 Installing Insulator Kit 13 5 3 Remote Operator Interf...

Страница 4: ...I BOX CE 195383 Council Directives 2014 35 EU Low Voltage 2014 30 EU Electromagnetic Compatibility 2011 65 EU Restriction of the use of certain hazardous substances in electrical and electronic equipm...

Страница 5: ...neeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC...

Страница 6: ...ared according to AWS F4 1 and AWS A6 0 see Safety Standards D Do not weld where the atmosphere can contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as clo...

Страница 7: ...S can injure D Keep away from moving parts such as fans D Keep all doors panels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for ma...

Страница 8: ...PA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of...

Страница 9: ...s dans un environnement humideou si l on porte des v tements mouill s sur des structures m talliquestelles que sols grilles ou chafaudages en position coinc e comme assise genoux ou couch e ou s il y...

Страница 10: ...br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un sur chauffement ou un incendie Avant de commencer le soudage v rifier et s assur...

Страница 11: ...areil D Tenir l quipement c bles et cordons distance des v hicules mobiles lors de toute op ration en hauteur D Suivre les consignes du Manuel des applications pour l quation de levage NIOSH r vis e P...

Страница 12: ...ational Electrical Code NFPA Standard 70 from National Fire Protec tion Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cy...

Страница 13: ...tion Safe37 2012 05 Wear dry insulating gloves Do not touch electrode with bare hand Do not wear wet or damaged gloves Safe2 2012 05 Protect yourself from electric shock by insulating yourself from wo...

Страница 14: ...welding voltage during operation keep hands and metal objects away Safe33 2012 05 Wear hat and safety glasses Use ear protection and button shirt collar Use welding helmet with correct shade of filte...

Страница 15: ...urge By Gas Fast Constant Current Circuit Breaker Constant Voltage Slow Trigger Hold Off Trigger Hold On I2 Rated Welding Current Increase Read Instructions U1 Primary Voltage U2 Conventional Load Vol...

Страница 16: ...d by the general public as the EMF limits for the general public might be exceeded during welding This equipment is built in accordance with EN 60974 1 and is intended to be used only in an occupation...

Страница 17: ...er 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 Washer 4 Place insulator plate between ROI base and metal mounting surface Place nyl...

Страница 18: ...ace 2 Swingarc Swivel Assembly 3 Boom 4 AA40G Wire Drive Assembly 5 Trigger Cable 1 2 3 4 5 5 803 698 E 5 4 Connection Diagram 1 Welding Power Source 2 Wire Feeder 3 Gas Cylinder 4 Gas Hose 5 Network...

Страница 19: ...ceptacle Information 9 Pin Pin Information A B I C H D G E F A Capacitor C1 to ground B Shield C Volt sense D Can low E Can high F 24 volts DC common G 24 volts DC H Motor voltage 40 volts DC common I...

Страница 20: ...play 2 1 Power Source Upper Display Lower Display Axcess Axcs 300 450 675 10 44 Voltage Range Net Wait DTEC OFF Process Setup Adjust Feeder Setup V t A 219 711 A 5 9 Dual Schedule Switch Option 1 Main...

Страница 21: ...ing of voltage arc adjust wire feed rate and time value for arc ends DS Dual Schedule Dual Schedule allows selecting a pair of programs that can be used together Feeder Set Up Allow selection of Seque...

Страница 22: ...le actual voltage while welding and 3 seconds hold value at end of weld Wire Type Selection of wire type by alloys and classification WFS Term used to represent wire feed speed In MIG mode wire feed s...

Страница 23: ...OM 220979 Page 19 6 3 Front Panel Sections See Section 6 5 See Section 6 6 See Section 6 9 See Section 6 8 See Section 6 7 See Section 6 4 Process Setup Adjust Feeder Setup V t A...

Страница 24: ...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 chan...

Страница 25: ...unction 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 changi...

Страница 26: ...s 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 sh...

Страница 27: ...n pressing the Process Set 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...

Страница 28: ...s 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...

Страница 29: ...Steel 90 Argon 10 CO2 Program 5 MIG 045 Mild Steel 75 Argon 25 CO2 Program 6 Accu pulse 045 Mild Steel 90 Argon 10 CO2 Program 7 Pulse 052 Mild Steel 90 Argon 10 CO2 Program 8 MIG 052 Mild Steel 75 Ar...

Страница 30: ...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...

Страница 31: ...tenance 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 l Unre...

Страница 32: ...R MOTR Section 8 2 F Arc Start Error ERR STRT Section 8 2 G No Tach Error ERR TACH Section 8 2 H Thermal Over Temperature ERR TEMP Section 8 2 I Unknown Error ERR UNKN Section 8 2 J Motor Communicatio...

Страница 33: ...software C No Coolant Flow Error ERR COOL Indicates no coolant flow in water flow switch option The error may be reset by reestablishing coolant flow to the gun and then pressing the Jog Purge button...

Страница 34: ...r Up Cnt that generated by the boost section of the inverter control board When either of these signals is active RC6 12 is pulled low this is the not ready line out of the inverter control board Shut...

Страница 35: ...chassis lifting eye bolts or weld secondary common Measure impedance between chassis and both weld secondary commons Measure the impedance across motor isolation barrier on motor housing All measureme...

Страница 36: ...lem is no longer an issue S A shorted output diode will cause an over current error and no weld output will be available N Release Trigger Error REL TRIG Indicates a timed weld has expired but the tri...

Страница 37: ...is message appears when RMD and Accuspeed demos are completed Pressing the Jog Purge button will change the screen to CYCL PWR on the display Turn unit power off and back on again RMD and Accuspeed sh...

Страница 38: ...OM 220979 Page 34 SECTION 9 ELECTRICAL DIAGRAM Figure 9 1 Circuit Diagram...

Страница 39: ...OM 220979 Page 35 214 842 F...

Страница 40: ...feeder 1 2 233582 PANEL pc card switch overlay 1 3 212808 BAFFLE pc mounting 1 4 097132 STAND OFF SUPPORT pc card 6 5 PC6 239601 WIRE FEED MODULE 1 6 098691 STAND OFF no 6 32 x 500 lg 250 hex stl m f...

Страница 41: ...SKTS service kit 1 PLG4 136810 HOUSING PLUG SKTS service kit 1 PLG81 115092 HOUSING PLUG SKTS service kit 1 PLG10 130203 HOUSING PLUG SKTS service kit 1 PLG50 136810 HOUSING PLUG SKTS service kit 1 PL...

Страница 42: ...Notes...

Страница 43: ...ns and Subarc SAW Torches Remote Controls and RFCS RJ45 Replacement Parts No labor Roughneck Guns Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable components suc...

Страница 44: ...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 Equip...

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