Miller COMPUTER INTERFACE II Owner's manual

Brand: Miller

Model: COMPUTER INTERFACE II

Category: Welding System

Type: Owner's manual

This manual is also suitable for

KF959033

Visit our website at

www.MillerWelds.com

Processes

Description

MIG (GMAW) Welding

Pulsed MIG (GMAW-P)

Adaptive Pulsed MIG (GMAW-P)

OM-169 571

September 1995

Automatic Welding

Computer Interface II

OM-169 571 − 9/95

EMF INFORMATION

The following is a quotation from the General Conclusions Section

of the U.S. Congress, Office of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields −

Background Paper, OTA-BP-E-53 (Washington, DC: U.S.

Government Printing Office, May 1989): “. . . there is now a very

large volume of scientific findings based on experiments at the

cellular level and from studies with animals and people which clearly

establish that low frequency magnetic fields can interact with, and

produce changes in, biological systems. While most of this work is

of very high quality, the results are complex. Current scientific

understanding does not yet allow us to interpret the evidence in a

single coherent framework. Even more frustrating, it does not yet

allow us to draw definite conclusions about questions of possible

risk or to offer clear science-based advice on strategies to minimize

or avoid potential risks.”

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 the body.

4. Keep welding power source and cables as far away as

practical.

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

possible.

About Pacemakers:

The above procedures are among those also normally

recommended for pacemaker wearers. Consult your doctor for

complete information.

Considerations About Welding And The Effects Of Low Frequency Electric And

Magnetic Fields

NOTE

mod10.1 4/93

TABLE OF CONTENTS

SECTION 1 − SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − INSTALLATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Connection Diagram 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Rear Panel Connections 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − OPERATIONAL TERMS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − INTRODUCTION TO PROGRAMMING 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Programs 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Pulse Panel Microprocessor Push Buttons 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Selecting Welding Process 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − TEACHING A PULSE WELDING PROGRAM 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Pulse Waveform Explained 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Teach Points Explained 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Teaching A Pulse Welding Program 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − USING THE OPTIONAL DATA CARD 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Installing Data Card 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Using The Data Card 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − SETUP 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Setup Flow Chart 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Using Setup Displays 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Selecting Welding Power Source Range 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-4. Selecting Security Lock 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-5. Selecting Or Changing Access Code 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-6. Selecting Voltage Correction 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-7. Selecting Inductance 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-8. Selecting Purge Time 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-9. Selecting Voltage Sensing Method 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-10. Selecting Regular Or Hot Arc Start 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-11. Resetting Arc Time 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-12. Selecting Units For Wire Feed Speed And Motor Type 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-13. Selecting Wire Type 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-14. Selecting Display 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-15. Resetting Memory 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-16. Selecting Arc Start/Volt Sense Error Shutdown 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-17. Selecting Program Name Feature 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-18. Remote Program Select 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-19. Stick Check Selection 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-20. Arc Voltage Error Selection 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-21. Software Version Number 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − MAINTENANCE & TROUBLESHOOTING 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Routine Maintenance 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Overload Protection 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Front Panel Error Displays 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 − ELECTRICAL DIAGRAMS 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − PARTS LIST 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 11-1. Case Section w/Components 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 11-2. Panel, Center w/Components 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 11-3. Panel, Front w/Components 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 11-4. Panel, Rear w/Components 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-169 571 Page 1

SECTION 1 − SAFETY INFORMATION

mod1.1 2/9

Read all safety messages throughout this manual.

Obey all safety messages to avoid injury.

Learn the meaning of WARNING and CAUTION.

1 Safety Alert Symbol

2 Signal Word

WARNING means possible death

or serious injury can happen.

CAUTION means possible minor

injury or equipment damage can

happen.

3 Statement Of Hazard And

Result

4 Safety Instructions To Avoid

Hazard

5 Hazard Symbol (If Available)

6 Safety Banner

Read safety blocks for each sym-

bol shown.

7 NOTE

Special instructions for best oper-

ation − not related to safety.

NOTE

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Disconnect input power before

installing or servicing.

WARNING

READ SAFETY BLOCKS at start of

Section 3-1 before proceeding.

WARNING

CAUTION

MOVING PARTS can injure.

• Keep away from moving parts.

• Keep all panels and covers closed

when operating.

Turn Off switch when using high frequency.

Figure 1-1. Safety Information

OM-169 571 Page 2

SECTION 2 − INSTALLATION

2-1. Connection Diagram

ST-801 354

1 Robot (Will Vary According To

Application)

2 Motor/Drive Assembly

3 Positive (+) Voltage Sensing

Lead

4 Gas Cylinder

5 Gas Hose

6 Robot Control

7 Fiber Optic Cable

8 Remote Program Select

Cable

9 Gas And Motor Control Cable

10 Interface Unit

11 Welding Power Source

12 17-Socket Plug And Intercon-

necting Cord

13 14-Socket Plug And Intercon-

necting Cord

14 Negative (−) Weld Cable

15 Workpiece

16 Negative (−) Voltage Sensing

Lead

17 Positive (+) Weld Cable

Figure 2-1. Connection Diagram

OM-169 571 Page 3

2-2. Rear Panel Connections

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Turn Off robot, welding power source, and interface unit, and disconnect input power before inspecting or installing.

swarn1.1* 2/93

Select proper cord for connection.

To make connections, align key-

way, insert plug into receptacle,

and tighten threaded collar.

1 Current Sensing Connection

This is used only when an older

Deltaweld welding power source is

used in the welding system.

2 Voltage Sensing Connection

3 Fiber Optic Connection

See Robot Owner’s Manual for

connection information if the Com-

puter Interface is not factory

installed.

4 14-Pin Welding Power

Source Receptacle

5 17-Pin Welding Power

Source Receptacle

Choose correct cord or cords for

welding power source.

6 Gas And Motor Control

Receptacle

Connect remaining end of cord to

receptacle at base of robot.

7 Remote Program Select

Connection

Connect remnaining end of cord to

receptacle on robot controller.

Ref. S-0003-A / ST-801 353 / Ref. ST-801 146

Figure 2-2. Rear Panel Connections

OM-169 571 Page 4

SECTION 3 − OPERATIONAL TERMS

The following is a list of terms and their definitions as they apply to this interface unit:

General Terms:

Adaptive Pulse Welding When the “adaptive pulse” welding process is selected, the unit will automati-

cally regulate pulse frequency in order to maintain a constant arc length, re-

gardless 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.

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.

Trim Term used to represent arc length adjustments in pulse programs. Increasing

trim increases the actual arc length. Likewise, decreasing trim shortens arc

length. Trim is replaced by volts in MIG programs.

Pulse Panel Terms:

Card Mode Is used to select use of the optional data card storage and retrieval capabilities.

Process Mode Is used to select the type of process to be used, including Pulse, Adaptive

Pulse, or Mig.

Setup Screen Terms:

Access Code NOTE: The optional Data Card is required to activate this feature. With code

off, access to the setup displays is not restricted. With code on, the operator

must know and enter the access code to access or change any of the setup

displays.

To use code, press Parameter Select button to enter access code. When the

correct letter is entered, the indicator automatically moves to the next character.

When the final access code letter is entered, the display automatically changes

to the initial setup display.

Arc Start NOTE: Do not use the Hot Start setting for .035 in (9 mm) or smaller wire. Use

the Hot Start mode for pulse welding with 450 Ampere Inverter Model when

high initial weld current is necessary to start large diameter welding wires.

When in Hot Start, the 450 Ampere Inverter Model starts the arc in the CV

mode and switches to CC once the arc is started. Do not use Hot Start unless

using 450 Ampere Inverter Model

Arc Time Allows actual arc time up to 9,999.99 hours and weld cycles up to 999,999 to

be accumulated and displayed on the digital display, and can be reset to zero

as required.

OM-169 571 Page 5

Mig Type (Voltage

Correction)

With DVC Voltage Correction On, the unit uses closed-loop feedback from the

17-pin cord or voltage sensing leads to maintain set voltage parameters. With

DVC Voltage Correction Off, feedback from the arc is not used for closed-loop

feedback to maintain voltage parameters. Feedback from the arc is still used for

other functions.

Be sure voltage sensing leads are connected or voltage feedback is available

through the 17-pin receptacle via the welding power source.

Name Feature When using the optional Data Card and turning the name feature on, programs

written to the card can be identified by name, number, job number, etc.

Program Reset By selecting program reset in the memory reset mode, the unit defaults to origi-

nal factory program settings for the program last active. All other program and

setup information remains the same.

Range The interface requires that the voltage and amperage range of the welding

power source be entered. Obtain this information from the welding power

source Owner’s Manual.

Security NOTE: The optional Data Card is required to activate this feature. Is used to

limit what the operator can control. This includes accessing the number of the

program, 1 through 8, and the range of welding parameters within the program.

Software Screen Selection of this function will display the software version of the unit. When talk-

ing with factory service personnel, this number may be required.

System Reset By selecting system reset in the memory reset mode, the unit defaults to origi-

nal factory settings for all programs and all set up excluding System, Arc Time,

and Model Type.

Voltage (Control Feedback) Allows voltage to be monitored at the output terminals by two methods. This

can be selected through the 17-pin cord connection if the welding power source

has a 17-pin receptacle, or through the unit’s external voltage sense lead.

If the 17 Pin setting is used, it is recommended that the voltage sensing termi-

nals on the welding power source be used to monitor arc voltage at the work-

piece.

When using the V. Sense setting, arc voltage feedback is through the voltage

sense leads connected to the feeder. Use this setting when there is more than

50 ft (15 m) of weld cable used.

Arc Start/Volt Sense

Shutdown

When this feature is on, the system immediately shuts down if no arc voltage is

sensed. An error message is displayed. When this feature is off, wire feeds

even when there is no arc voltage sensed.

Wire Feed Mode Allows the selection of inches per minute or meters per minute for wire feed

speed. This mode is also used to select motor type; standard speed, low

speed, or high speed. High speed motor is available as factory option.

OM-169 571 Page 6

SECTION 4 − OPERATION

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Always wear dry insulating gloves.

• Insulate yourself from work and ground.

• Keep all panels and covers securely in place.

FUMES AND GASES can be hazardous

to your health.

• Keep your head out of the fumes.

• Ventilate area, or use breathing device.

• Read Material Safety Data Sheets (MSDSs) and

manufacturer’s instructions for material used.

WELDING can cause fire or explosion.

• Do not weld near flammable material.

• Watch for fire; keep extinguisher nearby.

• Do not locate unit over combustible surfaces.

• Do not weld on closed containers.

• Allow work and equipment to cool before handling.

ARC RAYS can burn eyes and skin;

NOISE can damage hearing.

• Wear welding helmet with correct shade of filter.

• Wear correct eye, ear, and body protection.

MOVING PARTS can cause injury.

• Keep away from pinch points such as drive rolls.

• Keep all doors, panels, covers, and guards closed

and securely in place.

MAGNETIC FIELDS FROM HIGH CUR-

RENTS can affect pacemaker operation.

• Pacemaker wearers keep away.

• Wearers should consult their doctor before going

near any welding operations.

See Safety Precautions at beginning of manual for ba-

sic welding safety information.

wfwarn3.1 8/92

Wear the following while welding:

1 Dry, Insulating Gloves

2 Safety Glasses With Side

Shields

3 Welding Helmet With Correct

Shade Of Filter (See ANSI

Z49.1)

sb3.1 1/94

123

Figure 4-1. Safety Equipment

1 Work Clamp

Connect work clamp to a clean,

paint-free location on workpiece,

as close to weld area as possible.

Use wire brush or sandpaper to

clean metal at weld joint area. Use

chipping hammer to remove slag

after welding.

sb4.1* 2/93

Tools Needed:

Figure 4-2. Work Clamp

OM-169 571 Page 7

Front Panel

1 Display

2 Reset Button

After clearing an error, press this

button to reset the display.

3 Contactor On Light

Lights when welding power source

contactor is energized.

4 Wirefeed On Light

Lights when wirefeed motor is On.

5 Gas On Light

Lights when gas flow is On.

6 Purge Button

Push to energize gas valve. If a

purge time value is programmed,

the gas will flow for the pro-

grammed length of time. If a value

is not programmed, the gas flows

until the Purge button is released.

This button allows purging of air

from gun shielding gas line, and

adjusting shielding gas regulator

without energizing the welding

circuit.

7 Advance Button

Push to feed welding wire without

energizing welding circuit or

shielding gas valve.

Pulse Panel

8 Display

9 Data Card Slot

Insert optional data card here. See

Section 7 for information on using

the data card.

10 Increase Button

11 Decrease Button

12 Parameter Select Button

13 Mode Select Button

See Section 5 for information on

using pulse panel controls.

Rear Panel

14 Power Switch

User power switch to tun unit On

and Off.

ST-801 352 / ST-801 353

Front Panel

Pulse Panel

Rear Panel

Figure 4-3. Controls

OM-169 571 Page 8

WARNING

BUILDUP OF SHIELDING GAS can harm health or kill.

• Shut off shielding gas supply when not in use.

warn1.1 9/91

1 Shielding Gas Cylinder

2 Valve

Open valve on cylinder just before

welding.

Close valve on cylinder when fin-

ished welding.

sb5.1* 6/92 − S-0621-C

Figure 4-4. Shielding Gas

Install & Connect

Interface Into

Welding System

Put On

Personal Safety

Equipment

Set All Controls

And Verify

Program Selection

Turn On Shielding

Gas

Turn On

Welding System

Equipment

Adjust Weld

Parameters

ssb6.1* 9/92

Perform Test

Weld

Begin

Welding

As Needed

Figure 4-5. Sequence Of Gas Metal Arc (GMAW), Gas Metal Arc - Pulse (GMAW-P),

And Flux Cored Arc Welding (FCAW)

Ref. ST-150 171-C / Ref. SC-154 197

Set switches as shown for all

welding processes when using

this interface unit.

Figure 4-6. Setting Switches On 450 Ampere Inverter Model Welding Power Source

OM-169 571 Page 9

SECTION 5 − INTRODUCTION TO PROGRAMMING

5-1. Programs

A. General

ST-801 351

1 Interface Unit

The interface unit is designed for

use in pulse MIG welding (adaptive

or standard), or MIG welding.

The unit is factory-equipped with

eight programs for pulse MIG weld-

ing (see Figure 5-2). The programs

contain parameters that maximize

welding performance for each

combination of wire and shielding

gas.

Figure 5-1. Interface Unit

B. Pulse MIG Programs

The eight pulse programs are

shown in the table. Each program

can be used in standard pulse MIG

or adaptive pulse MIG.

In an adaptive pulse MIG program,

the unit manipulates certain weld

variables to hold arc voltage

constant.

The factory-set parameters for

each program can be changed to

customize them for an application

(see Section 6).

Program

Hardwire Selected*

.035” Steel, Argon − Oxy

.045” Steel, Argon − Oxy

.035” Steel, Argon − CO2

.045” Steel, Argon − CO2

.035” 309, Argon − CO2

.045” Steel, 309, Argon − CO2

7 3/64” 5356, Argon

8 .035” SIB, Argon

Softwire Selected*

.045” Steel, Argon − Oxy

.035” 4043, Argon

.045” Steel, Argon − CO2

1/16” 4043, Argon

Selecting hardwire or softwire is

done during setup (see Section 8)

.045” 4043, Argon

.045” 5356, Argon

.035” 5356, Argon

1/16” 5356, Argon

Figure 5-2. Pulse MIG Programs

OM-169 571 Page 10

5-2. Pulse Panel Microprocessor Push Buttons

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Control circuit and interface operational power are

On when using or changing the microprocessor

settings.

WELDING WIRE can cause puncture

wounds.

• Do not point gun towards any part of the body, other

people, or any metal when programming.

The welding wire can be electrically live and move out

of the gun during programming.

Ref. ST-154 109

>P r o c e s s

Card

Process

>C a r d

>Prg 1

Pu l s e

03 5 ” S t e e l

Ar gon − Oxy

1 Mode Display

2 Mode Select Button

Press Mode Select button to move

indicator in left window display.

Go to Figure 5-4.

Pulse Panel

Figure 5-3. Mode Select Button

OM-169 571 Page 11

Ref. ST-154 109

1 Parameter Display

2 Moving Line

Moving line is under value that can

be changed.

3 Pulse Panel Parameter Se-

lect Button

Press pulse panel parameter se-

lect button to move indicator in

right window display.

>P r o c e s s

Card

>Prg 1

Pu l s e

03 5 ” S t e e l

Ar g on − O x y

Prg 1

u l s e

035”Steel

A r g on − O x y

Pu l se

035”Steel

A r g on − O x y

>T e a c h Off

Pulse Panel

Figure 5-4. Pulse Panel Parameter Select Button

OM-169 571 Page 12

Ref. ST-154 109

Use mode select button to select

mode to be changed (see

Figure 5-3).

Use pulse panel parameter select

button to select parameter to be

changed (see Figure 5-4).

1 Increase Button

Press button to increase value that

is underlined by the moving line.

2 Decrease Button

Press button to decrease value

that is underlined by the moving

line.

Increase

Decrease

>P r g 1

Pu l se

035”Steel

Argon−Oxy

>P r g 2

Pu l se

045”Steel

A r g on − O x y

>P r g 3

Pu l se

052”Steel

A r g on − O x y

>P r g 2

Pu l se

045”Steel

A r g on − O x y

Increase

Pulse Panel

Figure 5-5. Pulse Panel Parameter Increase And Decrease Buttons

OM-169 571 Page 13

5-3. Selecting Welding Process

1 Pulse Panel Display

Default display when unit is first

turned On, at other times use mode

select button to select Process.

Mode Select

>P r o c e s s

Card

>P r g 1

Pu l se

035”Steel

Argon−Oxy

Parameter

Select

>P r o c e s s

Card

Prg 1

>P u l s e

035”Steel

Argon−Oxy

Increase/

Decrease

>P r o c e s s

Card

Prg 1

>A d a ptPu lse

035”Steel

Argon−Oxy

Increase/

Decrease

>P r o c e s s

Card

Prg 1

>M I G

Figure 5-6. Selecting Process

OM-169 571 Page 14

1 Pulse Panel Display

Default display when unit is first

turned On, at other times use mode

select button to select Process.

Mode Select

Parameter

Select

Increase/

Decrease

>P r o c e s s

Card

>P r g 1

Pu l se

035”Steel

Argon−Oxy

>P r o c e s s

Card

Prg 1

>P u l s e

035”Steel

Argon−Oxy

>P r o c e s s

Card

Prg 1

I G

OM-169 571 Page 15

SECTION 6 − TEACHING A PULSE WELDING PROGRAM

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Control circuit and interface operational power are

On when using or changing the microprocessor

settings.

WELDING WIRE can cause puncture

wounds.

• Do not point gun towards any part of the body, other

people, or any metal when programming.

The welding wire can be electrically live and move out

of the gun when programming.

Ref. S-0271

Preflow Time

Wire Speed

Weld

Start

Speed

Start Time

Weld Speed

Weld Time

Crater

Speed

Crater Time

Postflow Time

Burnback Time

Time

Weld

Stop

Arc

Start

Arc

Out

All sequence times are controlled by the robot controller, not the interface unit.

Start time is set to 20 ms. Start speed and voltage are set by Hot Start parameters in robot controller weld

parameter menu.

See GMAW-P (Pulsed MIG) Process Guide supplied with unit for more

information.

NOTE

OM-169 571 Page 16

6-1. Pulse Waveform Explained

The interface, not the welding pow-

er source, controls weld output for

pulsed welds.

1 ApK − Peak Current Of

100-565 Amperes

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.

2 AbK − Background Current

Of 10-200 Amperes

AbK is the low weld current. Back-

ground current preheats welding

wire and maintains the arc. When

background current is too low, the

arc is unstable and hard to

maintain.

3 PPS − Pulses Per Second Of

20-400

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.

4 PWms − Pulse Width Of

1.0-5.0 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.

Ref. S-0259

2 41

Amps (Current)

Time

Figure 6-1. Pulse Waveforms And Explanation Of Terms

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Miller COMPUTER INTERFACE II Owner's manual

Brand: Miller

Model: COMPUTER INTERFACE II

Category: Welding System

Type: Owner's manual

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KF959033

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Miller COMPUTER INTERFACE II Owner's manual

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Miller COMPUTER INTERFACE II Owner's manual

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