Miller ARC DATA PRO PDM1 WELDING DATA MONITOR Owner's manual

Brand: Miller

Model: ARC DATA PRO PDM1 WELDING DATA MONITOR

Category: Welding System

Type: Owner's manual

This manual is also suitable for

MF424384D

Arc Data Pro PDM1

Welding Data Monitor

Processes

Description

OM-273 221A 2015−10

Portable Data Recorder

Induction Heating

Multiprocess Welding

Submerged Arc (SAW) Welding

Electroslag (ESW) Welding

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 4......................................................

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

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

SECTION 2 − DEFINITIONS 5..................................................................

2-1. Additional Safety Symbols And Definitions 5................................................

2-2. Miscellaneous Symbols And Definitions 5..................................................

SECTION 3 − SPECIFICATIONS 6..............................................................

3-1. General Description 6..................................................................

3-2. Serial Number And Rating Label Location 6................................................

3-3. Specifications 6........................................................................

3-4. Environmental Specifications 6...........................................................

SECTION 4 − INSTALLATION 7................................................................

4-1. Heat Input Calculation 7.................................................................

4-2. Installing PDM1 Shunt Filter For Amperage/Voltage Measurement 7............................

4-3. Amperage/Voltage 5-Pin Receptacle Information 8...........................................

4-4. Temperature Sensor Installation 8........................................................

4-5. Process Table 10.......................................................................

4-6. Connecting Input power 10...............................................................

SECTION 5 − OPEREATION 11.................................................................

5-1. Controls 11............................................................................

5-2. Arc Data Pro Starting Procedure 12........................................................

5-3. Create And Save Welding Acquisition Data 16...............................................

5-4. How To Get A Snapshot On Acquisition Data 18.............................................

5-5. How To Use Graphic Icons 20.............................................................

5-6. Review Test Procedure 20................................................................

SECTION 6 − TROUBLESHOOTING 29..........................................................

6-1. Troubleshooting 29......................................................................

SECTION 7 − BLOCK DIAGRAM 30.............................................................

7-1. Block Diagram 30.......................................................................

SECTION 8 − PARTS LIST 31...................................................................

WARRANTY

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

ITW Welding Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that the prod

uct(s) identified in this declaration conform to the essential requirements and provisions of the stat

ed Council Directive(s) and Standard(s).

Product/Apparatus Identification:

Product Stock Number

ARC DATA PRO PDM1 PORTABLE DATA MONITOR 029083096

Council Directives:

·2006/95/EC Low Voltage

·2004/108/EC Electromagnetic Compatibility

·2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment

Standards:

·IEC 61010-1:2010. Safety requirements for electrical equipment for measurement, control, and laboratory use- Part

1: General requirements

·IEC 61326-1:2012. Electrical equipment for measurement, control and laboratory use -EMC requirements-

Part 1: General requirements

EU Signatory:

October 9

, 2015

___________________________________________________________________________________

Massimigliano Lavarini Date of Declaration

ITW WELDING ITALY PRODUCTION MANAGER

956 172 205

OM-273 321 Page 1

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som 2015−09

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if

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

possible hazards are shown in the adjoining symbols

or explained in the text.

Indicates a hazardous situation which, if not avoided,

could result in death or serious injury. The possible

hazards are shown in the adjoining symbols or ex-

plained in the text.

NOTICE − Indicates statements not related to personal injury.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC

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

bols and related instructions below for necessary actions to avoid the

hazards.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual

to call attention to and identify possible hazards. When you

see the symbol, watch out, and follow the related instructions

to avoid the hazard. The safety information given below is

only a summary of the more complete safety information

found in the Safety Standards listed in Section 1-5. Read and

follow all Safety Standards.

Only qualified persons should install, operate, maintain, and

repair this unit.

During operation, keep everybody, especially children, away.

Touching live electrical parts can cause fatal shock

or severe burns. The electrode and work circuit i

electrically live whenever the output is on. The inpu

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automati

wire welding, the wire, wire reel, drive roll housing

and all metal parts touching the welding wire are

electrically live. Incorrectly installed or improperl

grounded equipment is a hazard.

D Do not touch live electrical parts.

ELECTRIC SHOCK can kill.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.

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

unit.

D Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp

locations or while wearing wet clothing; on metal structures such

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

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

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

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

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

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

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

is recommended. And, do not work alone!

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

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

and sparks.

D Frequently inspect input power cord and ground conductor for

damage or bare wiring – replace immediately if damaged – bare

wiring can kill.

D Turn off all equipment when not in use.

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

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

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

present.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in

use.

D Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter weld-

ing power sources AFTER removal of input power.

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

capacitors according to instructions in Maintenance Section

before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed.

D Allow cooling period before working on

equipment.

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

lated welding gloves and clothing to prevent burns.

OM-273 321 Page 2

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 local forced ventilation at the

arc to remove welding fumes and gases. The recommended way

to determine adequate ventilation is to sample for the composition

and quantity of fumes and gases to which personnel are exposed.

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

D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,

consumables, coolants, degreasers, fluxes, and metals.

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 while wearing an air-supplied

respirator. The coatings and any metals containing these elements

can give off toxic fumes if welded.

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.

D Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and

sparks 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,

glare and sparks; warn others not to watch the arc.

D Wear body protection made from durable, flame−resistant mate-

rial (leather, heavy cotton, wool). Body protection includes

oil-free clothing such as leather gloves, heavy shirt, cuffless

trousers, high shoes, and a cap.

ARC RAYS can burn eyes and skin.

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 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 Do not weld where flying sparks can strike flammable material.

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

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 containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are

properly prepared according to AWS F4.1 and AWS A6.0 (see

Safety Standards).

D Do not weld where the atmosphere can contain flammable dust,

gas, or liquid vapors (such as gasoline).

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

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock, sparks, 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 body protection made from durable, flame−resistant material

(leather, heavy cotton, wool). Body protection includes oil-free

clothing 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.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,

consumables, coolants, degreasers, fluxes, and metals.

FLYING METAL or DIRT 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 compressed gas supply when not in use.

D Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EM

can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implante

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their docto

and the device manufacturer before going near arc welding, spo

welding, gouging, plasma arc cutting, or induction heating

operations.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise lev-

el is high.

NOISE can damage hearing.

Compressed 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, physical damage, 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 compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them

and associated parts in good condition.

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

not stand in front of or behind the regulator when opening the valve.

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

use or connected for use.

D Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)

publication P-1 listed in Safety Standards.

OM-273 321 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 EQUIPMENT can injure.

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.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94−110) when manu-

ally lifting heavy parts or equipment.

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.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper

face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

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 injure.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

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.

BATTERY EXPLOSION can injure.

D Do not use welder to charge batteries or jum

start vehicles unless it has a battery chargin

feature designed for this purpose.

MOVING PARTS can injure.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or

servicing unit. Read the safety information at

the beginning of the manual and in each

section.

D Use only genuine replacement parts from the manufacturer.

D Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and

local codes.

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.

OM-273 321 Page 4

1-4. California Proposition 65 Warnings

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.)

This product contains chemicals, including lead, known to

the state of California to cause cancer, birth defects, or other

reproductive harm. Wash hands after use.

1-5. Principal Safety Standards

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

is available as a free download from the American Welding Society at

http://www.aws.org or purchased from Global Engineering Documents

(phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding

and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: 1-877-413-5184, website:

www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com-

bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: 1-877-413-5184,

website: www.global.ihs.com).

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

tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:

www.nfpa.org and www. sparky.org).

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

from Compressed Gas Association, 14501 George Carter Way, Suite

103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga-

net.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2, from Canadian Standards Association, Standards Sales, 5060

Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS

(phone: 800-463-6727, website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec-

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

25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-

site: www.ansi.org).

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

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

Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).

OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of 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 15250-7954

(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—

phone for Region 5, Chicago, is 312-353-2220, website:

www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na-

tional Institute for Occupational Safety and Health (NIOSH), 1600

Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:

www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric

and magnetic fields (EMF). The current from arc welding (and allied pro-

cesses including spot welding, gouging, plasma arc cutting, and

induction heating operations) creates an EMF field around the welding

circuit. EMF fields can interfere with some medical implants, e.g. pace-

makers. Protective measures for persons wearing medical implants

have to be taken. For example, restrict access for passers−by or con-

duct individual risk assessment for welders. All welders should use the

following procedures in order to minimize exposure to EMF fields from

the welding circuit:

1. Keep cables close together by twisting or taping them, or using a

cable cover.

2. Do not place your body between welding cables. Arrange cables

to one side and away from the operator.

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

4. Keep head and trunk as far away from the equipment in the

welding circuit as possible.

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

possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire

feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the

device manufacturer before performing or going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating operations.

If cleared by your doctor, then following the above procedures is recom-

mended.

OM-273 221 Page 5

SECTION 2 − DEFINITIONS

2-1. Additional Safety Symbols And Definitions

Warning! Watch Out! There are possible hazards as shown by the symbols.

Safe1 2012−05

Do not remove or paint over (cover) the label.

Safe20 2012−05

Do not discard product (where applicable) with general waste.

Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection

facility.

Contact your local recycling office or your local distributor for further information.

Safe37 2012−05

Disconnect input plug or power before working on machine.

Safe5 2012−05

Consult rating label for input power requirements.

Safe34 2012−05

Become trained and read the instructions before working on the

machine or welding.

Safe40 2012−05

2-2. Miscellaneous Symbols And Definitions

Primary Voltage

Amperage

Hertz

Input

Input Voltage

Read Operator’s

Manual

Temperature

Voltage

Primary Current

Single Phase

Alternating

Current (AC)

Line Connection

USB

Ethernet

OM-273 221 Page 6

SECTION 3 − SPECIFICATIONS

3-1. General Description

Arc Data Pro PDM1 is a portable welding data collecting system which can be used to monitor all arc welding processes. Arc Data Pro PDM1 monitors

welding parameters like weld time, arc voltage, arc current, temperature, and heat input.

The data acquisition system converts analog waveforms in digital signals with a sampling frequency of 5 KHz (5000 points per second) allowing for

high signal resolution.

A wireless mini-keyboard allows the operator to configure operational programming (advanced user) and system data entry.

The system has USB ports for back-up files and an Ethernet port to communicate remotely.

The real time parameter process software is available in two formats with parameter values, graphic and table.

The basic software functions can be selected using the main display and Review Test button. Basic software functions include the following:

• Entering plant data and job order information.

• Weld time control.

• The ability to save all parameters into a log file where all data coming from probes are stored.

• The ability to export all data into a txt file in order to be available for USB key.

• Ethernet connection allows the operator to remotely have access to all parameters.

• Optional WI-FI connection for advanced remote control (tablet or smartphone).

• 60GB data storage with the option to increase capability with an external HD.

3-2. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the bottom of the suitcase. For future reference, write serial number in space

provided on back cover of this manual.

3-3. Specifications

Model Input Voltage

Input

Amperes

At Rated

Voltage

Auxiliary

Voltage

Dimensions

(mm)

Weight

(Kg)

Parameter Range Resolution Accuracy

PDM1 115 or 230 VAC

;

1-phase

50/60 Hz

2 A 12 VDC L: 470

H: 180

W: 360

10 Arc Voltage* 0-80 V 4.8 mV 15 mV

Arc Current* 0-1000 A 4.8 mA 15 mA

Temperature* 0-1100 °C 0.1% VFS +/- 1°C

(*) Optional Shunt Filter and Sensor Required

3-4. Environmental Specifications

A. IP Rating

IP Rating

IP44

This equipment is designed for outdoor use. It may be stored, but is not intended to be used for welding outside during precipitation unless

sheltered.

OM-273 221 Page 7

SECTION 4 − INSTALLATION

4-1. Heat Input Calculation

Where:

AVG

= Average Welding Voltage

AVG

= Average Welding Amperage

T= Total Arc Weld Time in seconds

L= Total Weld Length in centimeters

. Arc Data Pro PDM1 will calculate and save the average val-

ue for each sensor. To evaluate the heating input value the

system requires a manual setting of the weld length. The

heat input is calculated using the adjacent formula:

4-2. Installing PDM1 Shunt Filter For Amperage/Voltage Measurement

956172203_2-A

! Turn Off and disconnect input

power.

A PDM1 shunt filter allows you to connect

the system directly for all welding

process. It consists of a Hall−Effect clamp

current sensor and a probe device volt-

age sensor. The current sensor must be

installed to ensure the current flows in the

direction indicated by the probe. The

PDM1 shunt filter includes these features:

• Impact resistant flame retardant case to

protect components from moisture,

dust, and other contaminants.

• 700mm cable (400A shunt only) to con-

nect the shunt filter to the welding pow-

er source.

• 5 pin receptacle to connect the shunt fil-

ter to the Arc Data Pro PDM1 ( 5 pin ca-

ble is not supplied).

1 Positive weld output Terminal

2 Negative weld output Terminal

3 Shunt Filter (400A Shown)

4 5-Pin RCPT Cable

5 +/− Volt Sense Cables

To connect the PDM1 shunt filter to the

unit, proceed as follows (TIG process

shown):

• Connect shunt filter 5−pin receptacle to

the Arc Data Pro PDM1. Ref. TA/TV re-

ceptacle.

• Connect PDM1 shunt filter stud to pow-

er source negative weld output

terminal.

• Connect TIG torch to PDM1 shunt filter

weld output terminal.

• Connect work clamp to positive weld

output terminal.

• Connect volt sense cables to positive

and negative weld output receptacle.

• Turn power on. Allow time for unit com-

plete its start-up cycle.

. See shunt filter Owner’s manual for

additional information.

OM-273 221 Page 8

4-3. Amperage/Voltage 5-Pin Receptacle Information

Ref. 956172203_7-A

123

Socket Socket Information

1 +15 volts DC

2 -15 volts DC

3 Voltage Signal

4 Common GND

5 Amperage Signal

4-4. Temperature Sensor Installation

A. Infrared Sensor Installation

! Turn Off and disconnect input

power.

1 Sensor Setup Electronics Box

2 Sensing Head

3 Sensor Mounting Bracket

4 Pyrometer Connector

To connect infrared sensor to the unit,

proceed as follows:

• Connect the sensor 3−pin receptacle

to the Arc Data Pro PDM1.

• Use mounting bracket to install sen-

sor as recommended by the manu-

facturer’s manual.

• Place the sensor in vicinity of the

weld area.

. The support bracket and sensor

have to be insulated from the weld-

ing power source.

Refer to the manufacturer’s manu-

al for installation of this device.

956172203_3-A

OM-273 221 Page 9

B. Infrared Sensor 3−Pin Receptacle Information

Ref. 956172203_7-A

Socket Socket Information

1 +5 volts DC

2 Common GND

3 Signal

956172203_4-A

C. Thermocouple Installation

. The PYRO Optical tempera-

ture sensor is used for

non-contact high temperature

measurements. It allows the

surface temperature to be cal-

culated based on the infrared

energy emitted by an object.

! Turn Off and disconnect

input power.

1 Thermocouple Connector

2 Thermocouple

3 Workpiece

To install thermocouple to the unit

proceed as follows:

• Connect thermocouple 2−pin re-

ceptacle to the Arc Data Pro

PDM1.

• Use a capacitive electric dis-

charge device to weld the ends of

the thermocouple to the

workpiece.

D. Thermocouple 2−Pin Receptacle Information

Ref. 956172203_7-A

−

Socket Socket Information

1 (+) Plus

2 (−) Minus

OM-273 221 Page 10

4-5. Process Table

Arc Data Pro PDM1 is designed to display the signals for the following welding processes.

Process (+) Lead (−) Lead Shunt Filter Type

MIG (GMAW) Electrode Work 400A

TIG (GTAW) Work Electrode 400A

Stick (SMAW) Electrode Work 400A

Flux Cored (FCAW) Electrode Work 400A

Sub Arc (SAW) Electrode Work 1000A

Electroslag (ESW) Electrode Work 2000A

4-6. Connecting Input power

956172203_5-A

. This equipment is capable of

operating on 115 or 230VAC

1−phase 50/60 Hz input power.

! Installation must meet all

National and Local Codes −

have only qualified persons

make this installation.

! Special installation may be

required where gasoline or

volatile liquids are present −

see NEC Article 511 or CEC

Section 20.

For 115 or 230 volts AC input

power, a 15 or 20 ampere individual

branch circuit protected by

time-delay fuses or circuit breaker

is required.

1 Power Cord

Unit is supplied with a 230 VAC

cord. A customer supplied cord is

required to operate from 115 VAC.

2 115 Or 230 VAC Receptacle

Match power cord to receptacle for

available input power.

3 Machine Receptacle

Connect input power cord to ma-

chine receptacle.

OM-273 221 Page 11

SECTION 5 − OPERATION

5-1. Controls

956172203_6-A

1 Auxiliary Output

2 2-Pin Thermocouple

Receptacle

Use this receptacle to connect K

thermocouple. See section 4-4C.

3 Power On/Off Receptacle

See section 4-5.

4 5−Pin Amps/Volts Receptacle

Use this receptacle to connect

PDM1 shunt filter. See section 4-2.

5 3−pin Infrared Sensor

Receptacle

Use this receptacle to connect the

PYRO Optical pyrometer tempera-

ture. See section 4‐4A.

6 Storage Box

7 Monitor

8 Ethernet Port

Allows remote connection of smart-

phone, tablet, or similar device.

9 USB Port

10 Power On/Off Push Button

Used to turn unit on/off.

11 Keyboard

OM-273 221 Page 12

5-2. Arc Data Pro Starting Procedure

A. Turning The Unit On

956172203_6-A

1 Power On/Off Push Button

Press and hold button for one

second until LED lights. Wait ap-

proximately forty seconds until dis-

play lights and the software applica-

tion is displayed in the main display.

Select Welding Portable Acquisi-

tion System software.

Main Graphic Window

OM-273 221 Page 13

B. Main Graphic Windows Display Controls

1 Exit Button

Press button to close main window screen.

2 Voltage Display

Displays the rated voltage value while welding.

3 Amperage Display

Displays the rated amperage value while welding.

4 Temperature 1 display

Displays rated the temperature value with infrared sensor while welding.

5 Temperature 2 display

Displays rated the temperature value with infrared sensor while welding.

6 Temperature TC1 Display

Displays the rated temperature value with K−thermocouple while welding.

7 Temperature TC2 Display

Displays the rated temperature value with K−thermocouple while welding.

8 Total Time Display

Displays total weld time.

9 Memory Display

Displays the status of weld data storage.

10 Test Time Display

Displays the instantaneous weld time. Arc Data Pro stores the arc weld time. Total time is obtained by totaling the sum of the single weld tests.

11 Start/Stop Display

Displays the activation of weld data acquisition.

12 Review Test Display

Allows stored weld data to be displayed while welding. See Section 5-2C.

13 Weld Test Date Display

Displays date and hour of test data.

. NA is displayed for voltage, amperage and temperature if device is not connected.

OM-273 221 Page 14

C. Main Graphic Windows Display Data Information

. The main graphic display consists of two windows: real time data acquisition and data storage.

1 Real time data acquisition window

Displays real-time evolution of the amperage/voltage acquisition.

2 Data Storage Window

Displays data stored while welding.

Both display windows show the acquired signals in function of the weld time.

X−axis: weld time

Y−axis: measured variable

. The data acquisition process begins when the start button is pressed.

. Since data storage occurs at a frequency rate of 5 points per second, the window shows the updated signal of the last 1,000

seconds of weld data (about 15 minutes). After that period, the acquisition starts from the beginning.

OM-273 221 Page 15

Notes

OM-273 221 Page 16

5-3. Creating And Saving Welding Acquisition Data

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Miller ARC DATA PRO PDM1 WELDING DATA MONITOR Owner's manual

Brand: Miller

Model: ARC DATA PRO PDM1 WELDING DATA MONITOR

Category: Welding System

Type: Owner's manual

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Miller ARC DATA PRO PDM1 WELDING DATA MONITOR Owner's manual

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Miller ARC DATA PRO PDM1 WELDING DATA MONITOR Owner's manual

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