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
1
2
3
4
5
5
6
6
7
8
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
1
2
3
4
5
7
8
9
6
10
11
11
12
13
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
3
1
4
2
OM-223 528 Page 11
4-5. 9-Pin Network Receptacle Information
9
Pin Pin Information
A Capacitor C1 to ground
B Shield
G
F
C Volt sense
H
G
E
F
D Can low
I
H
D
E
E Can high
A
B
I
C
D
F +24 volts dc common
B
C
G + 24 volts dc
H Motor voltage −40 volts
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
2
1
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.
1
Prog
2
Prog.
3
Prog.
4
Prog.
5
Prog.
6
Prog.
7
Prog.
8
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
1
OM-223 528 Page 16
5-4. Program Push Button
1
3
Program
2
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
2
1
4
3
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
5
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).
6
1
3
2
7
WFS Amps Arc Ctl
4
Time
5
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.
1
3
4
Output A
Feeder Set Up
Output B
Sequence
Sequence Diagram
Preflow
Time
Start
Time
Crater
Time
Postflow
Time
2
5
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
Time
PostflowCrater
Weld
Preflow
Sequence
End
Arc
Strike
Sequence Diagram
OM-223 528 Page 20
5-9. Adjust Knob
Adjust
1
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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