Miller AROI Owner's manual

Brand: Miller

Model: AROI

Category: Welding System

Type: Owner's manual

This manual is also suitable for

Visit our website at

www.MillerWelds.com

AROI

(Automatic Remote

Operator Interface)

Processes

Description

MIG (GMAW) Welding

Wire Feeder

OM-223 528A

February 2005

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 catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at

www.MillerWelds.com on the web.

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 build and sell Miller products continue 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 operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

there’s a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide the

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001:2000 Quality

System Standard.

Working as hard as you do

− every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Mil_Thank 7/03

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 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. California Proposition 65 Warnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. 7 . . . . . . . . . . .

2-4. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Information sur les champs électromagnétiques 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INTRODUCTION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − INSTALLATION 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Mounting Plate Hole Layout 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Remote Operator Interface And Wire Drive Installation 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Connection Diagram 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Rear Panel Connections 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. 9-Pin Network Receptacle Information 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Gun Recommendation Table 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Power Source Display At Power Up 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Input Connections To AROI Receptacle RC100 (Remote Program Number

Select And Remote Start/Stop Select) 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Output Connections To AROI Receptacle RC100 (Output A, Output B,

Arc Established Output, And Error Output 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATION 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Operational Terms 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Power Switch 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Front Panel Sections 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Program Push Button 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Upper Display 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Lower Display 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Feeder Set Up Push Button 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Setting Output Relay A And Outut Relay B 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-9. Adjust Knob 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-10. Process Set Up Push Button 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-11. Jog/Purge 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − SETTING SEQUENCE PARAMETERS 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Sequence Parameters In A Program 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − MAINTENANCE 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Diagnostics 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − ELECTRICAL DIAGRAM 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − PARTS LIST 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

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OM-223 528 Page 1

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som _8/03

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

Y Marks a special safety message.

. Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Arc Welding Hazards

Y 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.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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.

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 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 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 proper grounding conduc-

tor first − double-check connections.

D Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced 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 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.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes. Do not breathe the fumes.

D If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.

D Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings,

cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld

area, the area is well ventilated, and if necessary, while wearing an

air-supplied respirator. The coatings and any metals containing

these elements can give off toxic fumes if welded.

OM-223 528 Page 2

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Sparks fly off from the

weld.

ARC RAYS can burn eyes and skin.

D 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 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (leather and wool) and foot protection.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is

safe before doing any welding.

WELDING can cause fire or explosion.

D Protect yourself and others from flying sparks and hot metal.

D Do not weld where flying sparks can strike flammable material.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock and fire hazards.

D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

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

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.

D Wearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise level is

high.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding

process, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder − explosion will result.

D Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

OM-223 528 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.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

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

equipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings

Y Welding or cutting equipment produces fumes or gases which

contain chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California Health &

Safety Code Section 25249.5 et seq.)

Y Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of

California to cause cancer and birth defects or other

reproductive harm. Wash hands after handling.

For Gasoline Engines:

Y Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive

harm.

For Diesel Engines:

Y Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and

other reproductive harm.

OM-223 528 Page 4

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,

from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

(phone: 305-443-9353, website: www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers and Piping, American Welding Society Standard

AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Mi-

ami, FL 33126 (phone: 305-443-9353, website: www.aws.org).

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA

02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www.

sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1735 Jefferson Davis Highway,

Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web-

site: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:

800−463−6727 or in Toronto 416−747−4044, website: www.csa−in-

ternational.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11

West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,

website: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B, from National Fire Protection Association,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:

617−770−3000, website: www.nfpa.org and www. sparky.org).

OSHA, 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 Effects Of Low Frequency

Electric And Magnetic Fields

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

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,

then following the above procedures is recommended.

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OM-223 528 Page 8

2-4. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,

de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

(téléphone : (305) 443−9353, site Web : www.aws.org).

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers and Piping, norme American Welding Society AWS

F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL

33126 (téléphone : (305) 443−9353, site Web : www.aws.org).

National Electrical Code, norme NFPA 70, de la National Fire Protection

Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA

02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et

www.sparky.org).

Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,

de la Compressed Gas Association, 1735 Jefferson Davis Highway,

Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,

site Web : www.cganet.com).

Code for Safety in Welding and Cutting, norme CSA W117.2, de la Ca-

nadian Standards Association, Standards Sales, 178 boulevard

Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)

463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−interna-

tional.org).

Practice For Occupational And Educational Eye And Face Protection,

norme ANSI Z87.1, de l’American National Standards Institute, 11 West

42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,

site Web : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, norme NFPA 51B, de la National Fire Protection Association,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (télé-

phone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).

OSHA, 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, de l’U.S. Government Printing Office, Super-

intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a

10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)

353−2220, site Web : www.osha.gov).

2-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et les effets des champs magnéti-

ques basse fréquence sur l’organisme

En parcourant les câbles de soudage, le courant crée des champs élec-

tromagnétiques. Les effets potentiels de tels champs restent

préoccupants. Cependant, après avoir examiné plus de 500 études qui

ont été faites pendant une période de recherche de 17 ans, un comité

de spécialistes du National Research Council a conclu : « L’accumula-

tion de preuves n’a pas démontré que l’exposition aux champs

magnétiques et aux champs électriques à haute fréquence constitue un

risque pour la santé humaine ». Toutefois, les études et l’examen des

preuves se poursuivent. En attendant les conclusions finales de la re-

cherche, il serait souhaitable de réduire l’exposition aux champs

électromagnétiques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques en milieu de travail, res-

pecter les consignes suivantes :

1. Garder les câbles ensemble en les torsadant ou en les fixant avec du

ruban adhésif.

2. Mettre tous les câbles du côté opposé à l’opérateur.

3. Ne pas s’enrouler les câbles autour du corps.

4. Garder le poste de soudage et les câbles le plus loin possible de soi.

5. Placer la pince de masse le plus près possible de la zone de soudage.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout

consulter leur médecin. Si ce dernier les déclare aptes, il leur est recom-

mandé de respecter les consignes ci-dessus.

OM-223 528 Page 9

SECTION 3 − INTRODUCTION

3-1. Specifications

Type of Input

Power

Welding Power

Source Type

Wire Feed Speed Range

Wire Diameter

Range

Welding Circuit

Rating

Overall

Dimensions

Weight

40 Volts DC

10 Amperes

Axcess Series Standard: 40 To 1400 ipm (1.0

To 35.6 mpm)

.030 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: 7-1/2 in

(191 mm)

Width: 7 in

(178 mm)

Height: 12-1/2 in

(318 mm)

10 lb

(4.5 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)

804 116-A

Typical Swingarc installation shown;

however, various installations are

possible depending on the

application.

1 Remote Operator Interface

2 Swingarc Swivel Assembly

3 Boom

4 AA40G Wire Drive Assembly

5 Trigger Cable

6 Input/Output Cable

7 Network Cable

. Do not route weld cable inside

tube with control cables.

8 Weld Cable Tray

Route weld cable in tray.

4-2. Remote Operator Interface And Wire Drive Installation

OM-223 528 Page 10

804 117-A

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

12 Input/Output Cable

13 Customer-Supplied PLC

4-3. Connection Diagram

4-4. Rear Panel Connections

804 091-A

1 9-Pin Network Receptacle

2 Input/Output Receptacle

3 Motor Control/Shielding Gas

Valve Receptacle

4 Rating Label Location

OM-223 528 Page 11

4-5. 9-Pin Network Receptacle Information

Pin Pin Information

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

I Motor voltage +40 volts

4-6. Gun Recommendation Table

Process Gun

GMAW − Hard or Cored Wires 400, 500, And 600 Amp

Air-Cooled Guns

GMAW − Pulse Water-Cooled Guns

4-7. Power Source Display At Power Up

1 Upper Display

2 Lower Display

Program

Process

Wire Type

Gas Type

Output A

Adjust

Volts Time

WFS Amps

Process Set Up Feeder Set Up

Output B

Arc Adjust

Arc Ctl

Sequence

Power Source

Upper Display

Lower Display

Axcess AROI 300/450/675 10 44

Voltage Range

Net Wait

DTEC OFF

OM-223 528 Page 12

4-8. Input Connections To AROI Receptacle RC100 (Remote Program Number

Select And Remote Start/Stop Select)

Receptacle RC100 Prog.

Prog

Prog.

L Input Common

C Contactor On

B Program Select Input C X X X X

F Program Select Input B X X X X

M Program Select Input A X X X X

X = Input terminal activated (shorted to RC100 L. When inputs to RC100 M, F, and B are activated, Program 8 is

selected. If no program select input is activated, Program 1 is selected.

4-9. Output Connections To AROI Receptacle RC100 (Output A, Output B,

Arc Established Output, And Error Output

Terminal Strip 200T Input Terminals Outputs

J Error Output normally-open

K Relay common

A Output A normally-open

D Output B normally-open

N Arc Established Output normally-open

OM-223 528 Page 13

SECTION 5 − OPERATION

5-1. Operational Terms

The following is a list of terms and their definitions as they apply to the interface unit in the wire feeder:

General Terms:

Adaptive Pulse Welding When the “adaptive pulse” welding process is selected, the unit will attempt to automatically regulate

pulse frequency in order to maintain a constant arc length, regardless of change in welding wire

stickout.

Abk (Background Amperage) Abk is the low weld current. Background current preheats welding wire and maintains the arc. When

background current is too low, the arc is unstable and hard to maintain.

Apk (Peak Amperage) Apk is the high pulse of welding current. Peak current melts the welding wire and forms a droplet. The

droplet is forced into the weld puddle.

Vpk (Peak Voltage) Arc voltage during peak current phase of the pulse waveform. This determines arc length during

adaptive pulse welding.

Inductance In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit

metal transfers per second (provided no other changes are made) and increase the arc-on time. The

increased arc-on time makes the pool more fluid.

PPS (Pulses Per Second) PPS, pulse rate, and frequency (Hz) are used interchangeably. A PPS or pulse rate of 60 Hz means

60 pulses of current are produced each second.

PWms (Pulse Width in Milliseconds) PWms is the time spent at peak current (1.2 ms is .0012 seconds). This time must be long enough to

form a droplet of welding wire. The stiffness or fluidity of the molten weld puddle is controlled by

PWms.

Synergic Synergic refers to the unit’s ability to use preprogrammed pulse parameters to determine the actual

pulse settings of Peak Amperage, Background Amperage, Pulse Frequency and Pulse Width at any

specific wire feed speed setting.

Arc Adjust Term used to represent arc length adjustments in pulse programs. Increasing Arc Adjust increases

the actual arc length. Likewise, decreasing arc adjust shortens arc length. Arc Adjust is replaced by

volts in MIG programs.

Program Eight active slots for selection of various processes, wire type, and parameters.

Process A selection made for MIG, Pulse, Accu-pulse, and RMD (optional).

MIG CV weld process with individual settings of voltage and wire speed.

Pulse Conventional pulse program using peak, background, pulse width, frequency, and peak voltage as

factory taught data. Adaptive method is controlled by frequency adjustment.

Accu-pulse Pulse process utilizing constant current ramps with constant voltage control of peaks and back-

grounds. Adaptive response is controlled 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.

RMD (optional) RMD refers to Regulated Metal Deposition. A precisely controlled short-circuit transfer. Benefits of

RMD are well suited to thin materials, improves gap filling and spatter reduction. Provides less heat

input into workpiece, minimizes distortion and allows use of larger diameter wire on thin gauge

materials.

Wire Type Selection of wire type by alloys and classification.

Gase Type Selection of shielding gas being used in application.

Process Set Up Selection procedure for entering program.

Program Load Enters selected program information into program slot.

Volts Preset voltage in MIG mode at idle, actual voltage while welding, and 3 seconds hold value at end of

weld.

Time Indicates time values being set for timed functions (e.g. Preflow, Postflow which are only available in

the Arc On and Analog input or the Arc On and No Analog input modes).

Arc Length Distance from end of wire electrode to workpiece.

WFS Term used to represent wire feed speed. In MIG mode, wire feed setting is independent of voltage

setting. In pulse, Accu-pulse, and RMD (optional) adjusting wire feed speed also increases power

level on wire electrode (one knob control).

Amps Indicates average amperage while welding and 3 seconds hold value at end of weld.

Arc Control Pressing this button will allow setting of inductance in MIG mode and sharp arc in pulse, Accu-pulse,

and RMD (optional).

Inductance In short circuit GMAW welding, an increase in inductance will decrease the number of short circuit

transfers per second (provided no other changes are made) and increase the arc-on time. The

increased arc-on time makes the welding puddle more fluid.

OM-223 528 Page 14

Sharp Arc In pulse and Accu-pulse mode this adjustment changes the arc cone by adjusting the preprogrammed

factory pulse data. In RMD (optional) this control will affect the arc in much the same way as

inductance.

Adjust Control knob used to change or set parameters and functions.

Sequence Selecting Sequence will allow setting of preflow, start, crater, and postflow times and parameters

(which are only available in the Arc On and Analog input or the Arc On and No Analog input modes).

Preflow Setting a time value for gas flow prior to arc start (which is only available in the Arc On and Analog

input or the Arc On and No Analog input modes).

Start Provides voltage/arc adjust, wire feed rate, and time value for modified arc starts (which is only

adjustable with the optional PDA with File Management software).

Crater Allows setting of voltage/arc adjust, wire feed rate, and time value for arc ends (which is only

available in the Arc On and Analog input or the Arc On and No Analog input modes).

Postflow Setting a time value for gas flow after arc end (which is only available in the Arc On and Analog input

or the Arc On and No Analog input modes).

Feeder Set Up Allow selection of Sequence 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 can be

changed using a PDA with File Management software). Pressing jog, purge, or trigger switch will

terminate the auto-threading feature.

Output A Relay and

Output B Relay

Normally open, programmable output relays that allow the user to select when these relays turn on or

off during a weld sequence.

Arc Established Relay Normally open relay that energizes when an arc is established.

Error Output Relay Normally open relay that energizes when an error condition occurs.

Contactor Input When this is input is shorted to input common, machine output turns on. When this input is open,

machine output is off.

Remote Program Select A,

Remote Program Select B, and

Remote Program Select C

These inputs provide remote control of weld program selection when these inputs are shorted to input

common. The remote program selection feature is on by default, to turn this feature off see Section

5-5.

5-2. Power Switch

1 Power Switch

803 694-A

OM-223 528 Page 15

5-3. Front Panel Sections

See

Section

5-5

See

Section

5-6

See

Section

5-10

See

Section

5-9

See

Section

5-7

See

Section

5-4

Program

Process

Wire Type

Gas Type

Output A

Adjust

Volts Time

WFS Amps

Process Set Up Feeder Set Up

Output B

Arc Adjust

Arc Ctl

Sequence

OM-223 528 Page 16

5-4. Program Push Button

Program

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 press button to

illuminate LED. To change the

program number, rotate Adjust knob

to select one of eight programs.

Pressing and holding the push

button will display current wire size,

wire type and process.

To reset feeder to factory settings,

turn power source off for 10

seconds. Press and hold button in

on power up, wait until top display

shows RST and bottom display

shows NO before releasing button.

Feeder Set Up button LED will

begin flashing. Turn Adjust knob to

change bottom display to show

YES, then press Feeder Set Up

button to confirm selection. The top

display will show CYCL and the

lower display will show PWR. Turn

welding power source power off for

10 seconds, then turn power back

on again.

5-5. Upper Display

1 Upper Display

The upper display at idle (not welding) shows

preset volts with process selection MIG or Arc

Adjust for all other processes. When welding,

the display shows actual voltage. 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

. Holding the Upper Display Push Button in

during power up allows enabling and

disabling remote program select. Use the

Adjust knob to change the remote

program select setting. Press the Feeder

Set Up push button to allow the unit to

continue its power up procedure.

The upper display push button LED

illuminates to indicate that information

displayed can be changed by the Adjust knob.

4 Volts LED

Indicates a voltage value is being displayed,

preset voltage in MIG when not welding and

actual voltage while welding.

5 Arc Adjust LED

Indicates that displayed value is an arc length

value when the process is Pulse, Accu-pulse,

or RMD (optional).

. At any time while welding, the display

allows adjustment of the weld voltage or

arc adjust preset values by turning the

Adjust knob. The preset values will be

displayed while the knob is being rotated

and return to displaying actual values

when adjustment is completed.

Volts Arc Adjust

OM-223 528 Page 17

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 Time LED is illuminated.

2 WFS (Wire Feed Speed) LED

LED illuminates to indicate the preset wire feed

value is being displayed and can be adjusted

using the Adjust knob.

3 Amps LED

LED illuminates to indicate the average

amperage is being displayed while welding

and for 3 seconds after welding is terminated.

The amperage must be above a minimum

value of 25 amps for this function to operate.

4 Arc Ctl (Arc Control) LED

LED illuminates to indicate that inductance

(MIG) or sharp arc [Pulse, Accu-pulse, or

RMD (optional)] is being displayed and can be

adjusted using the Adjust knob.

5 Time LED

LED illuminates to indicate that a time value is

being displayed for a sequence function 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 Ctl or INDU, either press the upper display

push button or press and hold the lower display

push button for 2 seconds.

When the lower display push-button LED and

the WFS LED are both illuminated, it is

possible to to change WFS while welding by

using the Adjust knob. The value in the display

will switch momentarily to show preset wire

feed speed while turning the Adjust knob and

revert back to actual value when adjustment is

completed.

When the Arc Ctl LED is illuminated, it is pos-

sible to change values while welding by using

the Adjust knob. To return to actual values on

the display, exit the Arc Ctl display.

. The lower display push button has addi-

tional functions when entering the se-

quence functions (see Section 5-7).

WFS Amps Arc Ctl

Time

OM-223 528 Page 18

5-7. Feeder Set Up Push Button

1 Feeder Set Up Push Button LED

. Holding the Feeder Set Up push button in

on power up allows changing the power

source set up to either semi-automatic or

auto ROI. Turn the Adjust knob to change

power source set up selection. Press the

Process Set Up push button and displays

will show a cycle power message to enter

selection. Turn unit power off and back on

again toreconfigure power source set up.

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 Adjust knob to select PRE

(preflow), STRT (start), CRTR (crater), or

POST (postflow).

• Press the lower display push button and the

Lower Display push-button LED will

illuminate as well as the lower display. The

Time LED will automatically begin flashing

indicating that a time value can be entered

by turning the Adjust knob. By entering a

time value the sequence state will become

active. To turn off a sequence state, change

the time value to OFF. To step back for

selecting another sequence option, press

the Upper Display push button.

• The Sequence option STRT and CRTR will

have additional parameter settings. By

pushing the Lower Display push button a

second time, while STRT or CRTR appear

in the upper display, allows entering voltage

(MIG) or Arc Adjust [Pulse, Accu-pulse, or

RMD (optional)]. Use the Adjust knob to

change the values indicated by the flashing

LED for either Volts or Arc Adjust. Pressing

the Lower Display push button a third time

will activate the WFS setting for 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 Output A

• When Output A is selected, this LED will

illuminate.

5 Output B

• When Output B is selected, this LED will

illuminate.

Output A

Feeder Set Up

Output B

Sequence

Sequence Diagram

Preflow

Time

Start

Time

Crater

Time

Postflow

Time

OM-223 528 Page 19

5-8. Setting Output Relay A And Outut Relay B

• When the Feeder Set Up button is pressed

once, the Sequence LED will illuminate and

the upper display will show sequence

options. See Section 5-7 for set up

procedures.

• Pressing the Feeder Set Up button a

second time will display Output A option,

and the Lower Display push-button LED will

illuminate. Rotate the Adjust knob to turn

Output A option on or off. When Output A is

on the Output A LED will illuminate.

• If Output A option is turned on, the upper dis-

play LED will begin flashing. Pressing the

Upper Display button allows selecting on/off

sequences in the weld program. Rotate the

Adjust knob to cycle through the se-

quences. The sequences are set up in a

weld program as follows:

Arcstrike (ARC), weld (WELD), and Se-

quence End are not time dependent and are

always present in a weld program.

Preflow (PRE), startpower (STRT), crater

(CRTR), and postflow (POST) are time de-

pendent and may or may not be present in

a weld program.

If a sequence was not enabled by setting a

time value while in the sequence option (see

Section 5-7), the sequence will appear as

DISA (disabled). When a sequence is dis-

abled, the output relay cannot be set.

• Pressing the Lower Display push button al-

lows setting a sequence on of off. if no

change is desired, dashes (−−−−) must be

selected. Pressing the Upper Display push

button or the Feeder Set Up button confirms

choices.

Pressing the Feeder Set Up button again

will display Output B option. To set Output B,

follow the same procedure listed previously

for Output A.

• Pressing the Feeder Set Up button again

will exit the Sequence menu and return the

system to standby mode.

Wire Speed

Time

Start

Time

Preflow

Weld WFS

Weld Time

Crater WFS

Crater

Time

Postflow

Time

PostflowCrater

Weld

Preflow

Sequence

End

Arc

Strike

Sequence Diagram

OM-223 528 Page 20

5-9. Adjust Knob

Adjust

1 Adjust Knob

The Adjust knob is used to change

functions and parameters. Refer to

the front panel sections for

information regarding use of this

control.

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Brand: Miller

Model: AROI

Category: Welding System

Type: Owner's manual

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