Page 2 - From Miller to You
Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributor to receive the latest fullline catalog or individual catalog sheets. To locate your nearestdistributor or service agency call 1-800-...
Page 3 - TABLE OF CONTENTS; WARNING
TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards ...
Page 6 - Declaration of Conformity For; Auto Invision II; Directives
dec_con1_11/02 Declaration of Conformity For European Community (CE) Products Manufacturer ’s Name: Miller Electric Mfg. Co. Manufacturer ’s Address: 1635 W. Spencer StreetAppleton, WI 54914 USA Declares that the product: Auto Invision II conforms to the following Directives and Standards: Directive...
Page 7 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.
OM-196 188 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. T...
Page 9 - Additional Symbols For Installation, Operation, And Maintenance; Principal Safety Standards
OM-196 188 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 nearcombustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system isproperly siz...
Page 10 - EMF Information
OM-196 188 Page 4 1-5. EMF Information Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining...
Page 11 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-196 188 Page 5 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 procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Y Identifie un mes...
Page 12 - LE BRUIT peut affecter l’ouïe.
OM-196 188 Page 6 Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS DE L’ARC peuvent pro-voquer ...
Page 15 - SECTION 2 – DEFINITIONS; Manufacturer ’s Warning Label Definitions
OM-196 188 Page 9 SECTION 2 – DEFINITIONS 2-1. Manufacturer ’s Warning Label Definitions Warning! Watch Out! There arepossible hazards as shown by thesymbols. 1 Electric shock from weldingelectrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode withbare hand. Do not wear ...
Page 18 - SECTION 3 – INSTALLATION; Specifications; Dimensions And Weight
OM-196 188 Page 12 SECTION 3 – INSTALLATION 3-1. Specifications Input Rated Welding Voltage Wire Feed Speed Wire Maximum Open- Amperes Input At Rated Load Input Power Rated Welding Output Voltage Range Wire Feed Speed Range* Wire Diameter Range Maximum Open- Circuit Amperes Input At Rated Load Outpu...
Page 19 - Selecting A Location; Connection Diagram
OM-196 188 Page 13 3-3. Selecting A Location loc_2 3/96 - 801 958 / 801 914-A 1 Lifting Forks Use lifting forks to move unit. Extend forks beyond opposite sideof unit. 2 Lifting Handles Use handles to lift unit. 3 Hand Cart Use cart or similar device to moveunit. 4 Rating Label Use rating label to d...
Page 20 - Weld Output Terminals And Selecting Cable Sizes; 15 Volts AC Duplex Receptacle And Circuit Breakers
OM-196 188 Page 14 3-5. Weld Output Terminals And Selecting Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding 30 m (100 ft) Or Less 45 m (150 ft) 60 m (200 ft) 70 m (250 ft) 90 m (300 ft) 105 m (350 ft) 120 m (400 ft) Welding Amperes 10 – 60% Duty Cycle 60 – 100% Duty Cycle 10 – ...
Page 21 - Electrical Service Guide; Connecting Input Power
OM-196 188 Page 15 3-7. Electrical Service Guide Three-Phase Input Voltage 400 Input Amperes At Rated Output 31 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 45 Min Input Conductor Size In AWG/Kcmil 10 Max Recommended Input Conductor Length In Feet (Meters) 264 (80) Min Groundin...
Page 22 - Rear Panel Connections
OM-196 188 Page 16 3 5 6 4 1 Receptacle 2 Keyway 3 4-Pin Receptacle (OptionalExternal Voltage SensingConnection) To connect interconnecting cord toreceptacle, align keyway, insertplug, and tighten threaded collar. Secure ring terminal on remainingend of cord to work. 4 Peripheral Receptacle Receptac...
Page 24 - -12. Touch Sensor Board PC18 Switch S1 Settings
OM-196 188 Page 18 3-11. Touch Sensor Operation The touch sensor feature allows the robot to locate a weldment using the wire feed system and welding power source.Voltage sense leads provide a path for touch sensor voltage when this feature is turned on at the peripheral receptacle.Turning on touch ...
Page 25 - -13. Connecting Setup Pendant To Welding Power Source
OM-196 188 Page 19 3-13. Connecting Setup Pendant To Welding Power Source 802 816 Y Turn Off welding powersource and weld control. 1 Welding Power Source 2 Interconnecting Cord 3 Setup Pendant To make connections, align plugwith receptacle, insert plug, anduse thumb screws on receptacle tosecure plu...
Page 26 - SECTION 4 – OPERATION; Operational Terms
OM-196 188 Page 20 SECTION 4 – OPERATION 4-1. Operational Terms The following is a list of terms and their definitions as they apply to this interface unit: General Terms: Adaptive Pulse Welding When the “adaptive pulse” welding process is selected, the unit will attempt to automatically regulatepul...
Page 27 - Lower Front Panel Controls; CE; Meter Functions; Note; PPP
OM-196 188 Page 21 System Reset By selecting system reset in the memory reset mode, the unit defaults to original factory settings forall programs and all set up excluding System, Arc Time, and Model Type. Voltage (Control Feedback) Allows voltage to be monitored at the output terminals by two metho...
Page 28 - Upper Front Panel Controls
OM-196 188 Page 22 4-4. Upper Front Panel Controls 1 Setup Pendant Receptacle Receptacle for connecting pendantinterconnecting cord. 2 Jog Forward Push Button Advances wire out of the gun. 3 Wirefeed Indicator LED LED lights when wire feed motor isenergized. 4 Jog Reverse Push Button Retracts wire u...
Page 29 - Duty Cycle And Overheating
OM-196 188 Page 23 4-5. Duty Cycle And Overheating Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating. If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Reduce amperage orduty cycle before welding....
Page 30 - Setup Pendant Controls
OM-196 188 Page 24 4-7. Setup Pendant Controls 1 Increase Button Works with security feature on weldingpower source to allow increasing weldparameter values within the allowable range.2 Decrease Button Works with security feature on weldingpower source to allow decreasing weldparameter values within...
Page 31 - SECTION 5 – MAINTENANCE & TROUBLESHOOTING; Routine Maintenance; Months; Blowing Out Inside Of Unit
OM-196 188 Page 25 SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. . Maintain more oftenduring severe conditions. 3 Months Replacedamaged orunreadablelabel. Repair orreplacecrackedcables. Replacecrackedtorch body. Repair orreplace cracked...
Page 32 - Removing Case and Measuring Input Capacitor Voltage
OM-196 188 Page 26 5-3. Removing Case and Measuring Input Capacitor Voltage Turn Off welding power source, anddisconnect input power. 1 Outside Handle Screws To loosen top, remove two outsidehandle screws from both handlesand all side bolts. 2 Interconnect Board PC2 3 Voltmeter Measure the dc voltag...
Page 33 - Voltmeter/Ammeter Help Displays
OM-196 188 Page 27 5-4. Voltmeter/Ammeter Help Displays . All directions are in reference tothe front of the unit. All circuitryreferred to is located inside theunit. 1 Help 1 Display Indicates a malfunction in theprimary power circuit. If this displayis shown, contact a FactoryAuthorized Service Ag...
Page 34 - Front Panel Error Displays
OM-196 188 Page 28 1 Memory CRC Error Display Corrupted program data has been detectedor loaded. The “X” value indicates the pro-gram number. May be caused by incompatible informationon the data card or bad memory.2 Memory Range Error Display Improper welding power source range isselected. The “X” v...
Page 35 - Weld Interface Board PC12 Diagnostic LED’s
OM-196 188 Page 29 1 Weld Interface Board PC12 Diagnostic LED’s are visible insideunit, located on PC12 (see illustrationfor board location). Refer to Section 5-7 for informationon diagnostic LED’s. Reinstall cover and left side panelafter checking diagnostic LED’s. 191 842 1 5-6. Weld Interface Boa...
Page 36 - Diagnostic LED’s On Weld Interface Board PC12
OM-196 188 Page 30 5-7. Diagnostic LED’s On Weld Interface Board PC12 LED Status Diagnosis 1 On Indicates auxiliary output relay is not energized. Off Indicates auxiliary output relay is energized. 2 On Indicates gas valve is not energized. Off Indicates gas valve is energized. 3 On Indicates +24 vo...
Page 37 - Customer Interface Board PC14 Diagnostic LED’s
OM-196 188 Page 31 1 Customer Interface Board PC14 Diagnostic LED’s are visible insideunit, located on PC14 (see illustrationfor board location). Refer to Section 5-9 for informationon diagnostic LED’s. Reinstall top cover after checkingdiagnostic LED’s. 1 5-8. Customer Interface Board PC14 Diagnost...
Page 38 - Diagnostic LED’s On Customer Interface Board PC14
OM-196 188 Page 32 5-9. Diagnostic LED’s On Customer Interface Board PC14 LED Status Diagnosis 1 On Indicates –15 volts dc RA supply is present on customer interface board PC14. 1 Off Indicates –15 volts dc RA supply is not present on customer interface board PC14. 2 On Indicates +15 volts dc RA sup...
Page 40 - -11. Diagnostic LED’s On Motor Board PC13
OM-196 188 Page 34 5-11. Diagnostic LED’s On Motor Board PC13 LED Status Diagnosis 1 On Indicates motor reverse relay is energized. Red Off Indicates motor reverse relay is not energized. 2 On LED should be On. Indicates 115 volts ac input is sufficiently charging +170 volts dc bus for motor. Red Of...
Page 41 - Notes
Page 42 - SECTION 6 – ELECTRICAL DIAGRAMS; Figure 6-1. Circuit Diagram For Welding Power Source
OM-196 188 Page 36 SECTION 6 – ELECTRICAL DIAGRAMS Figure 6-1. Circuit Diagram For Welding Power Source
Page 54 - Figure 6-8. Circuit Diagram For Interface Module
OM-196 188 Page 48 Figure 6-8. Circuit Diagram For Interface Module
Page 56 - Figure 6-9. Circuit Diagram For Microprocessor Board PC11
OM-196 188 Page 50 Figure 6-9. Circuit Diagram For Microprocessor Board PC11
Page 58 - Figure 6-10. Circuit Diagram For Motor Board PC13
OM-196 188 Page 52 Figure 6-10. Circuit Diagram For Motor Board PC13
Page 60 - Figure 6-11. Circuit Diagram For Switch Board PC15
OM-196 188 Page 54 Figure 6-11. Circuit Diagram For Switch Board PC15 182 996
Page 61 - Figure 6-12. Circuit Diagram For Junction Board PC16
OM-196 188 Page 55 200 739 Figure 6-12. Circuit Diagram For Junction Board PC16
Page 72 - Figure 6-18. Circuit Diagram For Touch Sensor Board PC18
OM-196 188 Page 66 Figure 6-18. Circuit Diagram For Touch Sensor Board PC18 174 578-A
Page 73 - Figure 6-19. Circuit Diagram For Setup Pendant
OM-196 188 Page 67 200 739-A Figure 6-19. Circuit Diagram For Setup Pendant
Page 75 - Figure 6-21. Circuit Diagram For Power Distribution Board PC20
OM-196 188 Page 69 191 531 Figure 6-21. Circuit Diagram For Power Distribution Board PC20
Page 76 - SECTION 7 – PARTS LIST
OM-196 188 Page 70 SECTION 7 – PARTS LIST . Hardware is common andnot available unless listed. 802 872-D 1 2 5 6 7 8 9 10 44 45 46 55 59 60 62 63 64 65 66 67 68 70 75 71 72 73 74 76 77 78 79 80 81 82 83 84 85 81 86 87 13 15 11 9 48 47 58 57 56 12 14 49 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31...
Page 79 - Setup Pendant
OM-196 188 Page 73 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Complete Assembly (Continued) Quantity 144 844 STAND-OFF, No. 6-32 x .875 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 091 772 STAND-OFF, No. 6-32 x .6...
Page 81 - Programming Instructions for
Auto Invision II OM-196 188K July 2003 Programming Instructions for
Page 82 - SECTION 8 – INTRODUCTION TO PROGRAMMING; Pulse MIG Programs; Standard Pulse Welding Programs
OM-196 188 Page 76 SECTION 8 – INTRODUCTION TO PROGRAMMING The interface unit is designed foruse in pulse MIG welding (adaptiveor standard), or MIG welding. The unit is factory-equipped witheight programs for pulse MIGwelding. The unit also provides memory forthe creation of up to eight MIGprograms ...
Page 92 - -20. Setup Pendant Parameter Select Button
OM-196 188 Page 86 Ref. 154 109 1 Parameter Display 2 Moving Line Moving line is under value that canbe changed. 3 Pulse Panel Parameter SelectButton Press pulse panel parameter selectbutton to move indicator in right win-dow display. 1 > Process SequenceSharpArcCard > Prg 1 Pulse035” SteelArg...
Page 93 - -21. Setup Pendant Parameter Increase And Decrease Buttons
OM-196 188 Page 87 Ref. 154 109 Use mode select button to selectmode to be changed (see 8-19). Use pulse panel parameter selectbutton to select parameter to bechanged (see 8-20). 1 Increase Button Press button to increase value thatis underlined by the moving line. 2 Decrease Button Press button to ...
Page 94 - SECTION 9 – GETTING STARTED FOR PULSE WELDING; Weld Cycle For Pulse Welding
OM-196 188 Page 88 SECTION 9 – GETTING STARTED FOR PULSE WELDING Ref. S-0271 9-1. Weld Cycle For Pulse Welding Wire Speed Weld Start Start Power Start Speed Preflow Time Arc Strike Weld Speed Weld Time Weld Stop Crater Time Crater Speed Arc Out Retract Time Postflow Time Time Run-In Setting Robot Mo...
Page 96 - Setting Postflow Sequence Display; SECTION 10 – TEACHING A PULSE WELDING PROGRAM
OM-196 188 Page 90 9-5. Setting Postflow Sequence Display 1 Postflow Parameters Display Postflow can be adjusted from0-9.9 seconds. If value set is zero(0), there is no Postflow sequence. 1 > Poflw 0.0 Sec Poflw > 0.0 Sec > Poflw 1.2 Sec Parameter Select Parameter Select Set Desired Time In...
Page 99 - 0-4. Setting Teach Point Parameters For Pulse Welding Program
OM-196 188 Page 93 Pulse035” SteelArgon – Oxy > Teach Off When the Process Teach mode is On, andone of the following pulse parameters is se-lected: Apk, Abk, PPS, PWms, or Vpk, thepulse panel displays the selected pulse pa-rameter instead of Trim (arc length). Whenthe pulse parameter is selected,...
Page 100 - NOTE
OM-196 188 Page 94 Make copies of this chart for future use. NOTE Program # Wire Size/Type Gas Program Name Card # Gun Model Flowrate CFH IPM Apk Abk PPS PWms Vpk COMMENTS Preflow: Sec. Run-In Trim: IPM: Sec.: Crater Trim: IPM: Sec.: Postflow: Sec.
Page 101 - 0-5. Changing To Adaptive Pulse Welding; SECTION 11 – TEACHING A MIG WELDING PROGRAM
OM-196 188 Page 95 > Process SequenceSharpArcCard Prg 1 > Adapt Pulse 035” SteelArgon – Oxy Welding parameters are the samefor both a Pulse and an AdaptivePulse welding program. Whilewelding adaptively, the unit usesfeedback to attempt to maintain aconstant arc length. To change toAdaptive Pul...
Page 106 - Control
OM-196 188 Page 100 SECTION 12 – SETTING SharpArc E CONTROL 12-1. Selecting And Adjusting SharpArc E Control 1 SharpArc SharpArc is used to adjust arc cone width and arc characteristics. Use mode select button to move >to select SharpArc. Use DisplayControl to adjust Arc setting. SharpArc set...
Page 107 - SECTION 13 – USING THE OPTIONAL DATA CARD
OM-196 188 Page 101 SECTION 13 – USING THE OPTIONAL DATA CARD 1 Label Peel backing from label and applyto data card with THIS SIDE UP bymetal pins. Write the names of the programsstored on the card on the label.Write the name of the piece ofequipment the card is used with onthe label. 2 Data Card 3 ...
Page 109 - 3-3. Naming Programs And Writing To Card
OM-196 188 Page 103 13-3. Naming Programs And Writing To Card All program types (Pulse, Adaptive Pulse, and MIG) can be stored on a data cardand retrieved. Setup and Control menus do not save to the card. NOTE 1 Card Display Use Mode Select button to select Card.2 Moving Line Moving line is under va...
Page 131 - (Equipment with a serial number preface of “LC” or newer)
Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 6/03 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...
Page 132 - Please complete and retain with your personal records.; For Service
PRINTED IN USA 2003 Miller Electric Mfg. Co. 1/03 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters–USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...
