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OM-196 188K
July 2003
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding
Automatic Welding
Description
Automatic Welding Interface And
Arc Welding Power Source
Operating Instructions and
Programming Instructions for
Auto Invision II
Visit our website at
www.MillerWelds.com
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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 bu
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TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . .
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TABLE OF CONTENTS SECTION 8 – INTRODUCTION TO PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 8-1. Pulse MIG Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 8-2. Standard Pulse Welding Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 8-3. Program 1 – 1.2 mm Steel (.045”), 98-2 Argon-Oxy . . . . . . . . . . . . . . .
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TABLE OF CONTENTS SECTION 14 – SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 14-1. Setup Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 14-2. Using Setup Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 14-3. Selecting Or Changing Acces
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Declaration of Conformity For European Community (CE) Products Manufacturer’s Name: Miller Electric Mfg. Co. Manufacturer’s Address: 1635 W. Spencer Street Appleton, WI 54914 USA Declares that the product: Auto Invision II conforms to the following Directives and Standards: Directives Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC Low Voltage Directive: 73/23/EEC Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC Standards Electromagnetic compatibility (EMC) Pr
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. 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 li
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 3. Do not coil or drape cables around your body. years of resea
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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. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous au
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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SECTION 2 – DEFINITIONS 2-1. Manufacturer’s Warning Label Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric 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. 2 Breathing welding fumes can be hazardous t
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1 Warning! Watch Out! There are possible hazards as shown by the symbols. 2 Electric shock from wiring can kill. 3 Disconnect input plug or power before working on 12 3 4 5 6 machine. 4 Hazardous voltage remains on input capacitors after power is turned off. Do not V touch fully charged V capacitors. 5 Always wait 60 seconds after > 60 s V power is turned off before S-179 190-A working on unit, OR 6 Check input capacitor voltage, and be sure it is near 0 before touching any parts. 4/96 1 Warning
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2-2. Symbols And Definitions Amperage Positive Remote Voltage V A Output Circuit Breaker Negative On Protective Earth Off Inductance Voltage Input (Ground) 2-3. Manufacturer’s Rating Label S-184 765 2-4. Harmonic Data HARMONIC DATA per IEC 61000-3-12, draft 2000-9-29 PRIMARY; 400V/30.5A/60hz LOAD; 450A/38Vdc/390IPM/,MAXIMUM OUTPUT, GMAW. R sce = 227.28 THD 61 Amps PWHD 35 Amps Table 4, balanced three phase equipment. OM-196 188 Page 11
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SECTION 3 – INSTALLATION 3-1. Specifications Maximum Maximum Amperes Input Amperes Input Wire Wire Input Input Rated Rated W Welding elding V Voltage oltage Wire Feed Speed Wire Feed Speed Open- Open- At Rated Load At Rated Load KV KVA A KW KW Diameter Diameter Power Power Output Output Range Range Range* Range* Circuit Circuit Output 60 Hz, Output 60 Hz, Range Range Voltage DC Three-Phase 450 A @ 38 V 450 A @ 38 Vo ollt ts s D DC C, , Standard: Standard: Three Three 100% Duty Cycle; 100% Duty
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3-3. Selecting A Location 2 Do not move or operate Movement Tipping unit where it could tip. 3 OR 1 Location 1 Lifting Forks Special installation may be required where gasoline or volatile Use lifting forks to move unit. liquids are present – see NEC Article 511 or CEC Section 20. Extend forks beyond opposite side of unit. 5 2 Lifting Handles Use handles to lift unit. 3 Hand Cart Use cart or similar device to move 4 18 in unit. (460 mm) 4 Rating Label Use rating label to determine input powe
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3-5. Weld Output Terminals And Selecting Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding 45 m 60 m 70 m 90 m 105 m 120 m 30 m (100 ft) Or Less (150 ft) (200 ft) (250 ft) (300 ft) (350 ft) (400 ft) Welding 10 – 60% 60 – 100% 10 – 100% Duty Cycle Amperes Duty Cycle Duty Cycle 100 25 25 25 35 35 50 55 55 150 35 35 35 50 55 70 95 95 200 35 35 50 55 70 95 120 120 250 35 50 55 70 95 120 2-70 2-70 300 50 55 70 95 120 2-70 2-95 2-95 350 55 70 95 120 2-70 2-95 2-95 2-120 Positive Po
