Miller Electric OM-180 800 User manual

Miller

The

Power

fBlue.

OM-180

800

Eff.

w/Style

Number

KH17

Processes

Automatic

Welding

Description

Automatic

Welding

System

April

1997

Tooth

wI~~~t~r

OWNERS

MANUAL

From

Miller

You

Thank

you

and

congratulations

choosing

Miller.

Now

you

can

get

the

job

done

and

get

done

right.

know

you

dont

have

time

any

other

way.

Thats

why

when

Niels

Miller

first

started

building

arc

welders

1929,

made

sure

his

products

offered

long-lasting

value

and

superior

quality.

you,

his

customers

couldnt

afford

anything

less.

Miller

products

had

than

the

best

they

could

be.

They

had

the

best

you

could

buy.

Today,

the

people

that

build

and

sell

Miller

products

continue

the

tradition.

Theyre

just

committed

providing

equipment

and

service

that

meets

the

high

standards

quality

and

value

established

1929.

This

Owners

Manual

designed

help

you

get

the

most

out

your

Miller

products.

Please

take

time

read

the

Safety

precautions.

They

will

help

you

protect

yourself

against

potential

hazards

the

worksite.

Weve

_____________

made

installation

and

operation

quick

and

easy.

With

Miller

you

can

count

years

reliable

____________

service

with

proper

maintenance.

And

for

_____________

some

reason

the

unit

needs

repair,

theres

Troubleshooting

section

that

will

help

you

figure

out

what

the

problem

is.

The

parts

list

will

then

help

you

decide

which

exact

part

you

may

need

fix

the

problem.

Warranty

and

service

information

for

your

particular

model

are

also

provided.

Miller

Electric

manufactures

full

line

welders

and

welding

equipment.

For

information

other

quality

Miller

products,

contact

your

local

Miller

distributor

receive

the

latest

full

line

catalog

individual

catalog

sheets.

locate

your

nearest

distributor

call

1-800-4-A-Miller.

ISO

0001

IQUALITY

SYSTEM

Miller

the

tbst

welding

equipment

manufacturer

the

U.S.A.

registered

the

ISO

9001

QualIty

System

Standard.

T~1~ffl~

r~imnr~

L~5

Working

hard

you



every

power

source

from

Miller

backed

the

most

hassle-free

warranty

the

business.

TI/A

Miller

The

Power

fBlue.

Call

-800-4-A-MILLER

for

your

local

Miller

distributor.

Your

distributor

gives

you

Service

You

always

get

the

fast,

reliable

response

you

need.

Most

replacement

parts

can

your

hands

hours.

Support

Need

fast

answers

the

tough

welding

questions?

Contact

your

distributor.

The

expertise

the

distributor

and

Miller

there

help

you,

every

step

the

way.

The

Touch

Sensor

designed

provide

touch

sensing

capability

using

the

welding

wire

and

voltage

sense

leads.

The

robot

controller

sends

signal

the

Touch

Sensor

begin

touch

sensing

operation.

signal

sent

from

the

Touch

Sensor

the

robot

controller

when

the

welding

wire

touches

the

weldment.

The

contactor

the

Touch

Sensor

prevents

any

low

impedance

path

through

the

welding

power

source

during

touch

sensing

operation.

also

operates

during

the

weld

cycle

closing

before

welding

begins

and

remains

closed

during

the

welding

operation

sensing

weld

current.

When

weld

current

detected,

the

contactor

deenergizes.



115

VAC,

Input

Power



170

VDC,

Touch

Sense

Output



Touch

Sensor

And

Input

Power

Pilot

Lights



External

Connections

For

Cords

And

Cables



Product

features

and

specifications

are

subject

change

without

notice

Processes

Automatic

Welding

Miller

offers

Technical

Manual

which

provides

detailed

service

and

parts

information

for

your

unit.

obtain

Technical

Manual,

contact

your

local

distdbuto,

Your

distributor

can

also

supply

you

with

Welding

Process

Manuals

such

SMAW,

GTAW,

GMAVvandGMAW-P

For

practical

formation

welding,

process

applications,

and

Miller

products,

visit

our

website

Descrintlon

To~th

S~c~

Features

Table

Contents

Section

Page

Safety

Precautions

Consignes

sØcuritØ

Introduction

Installation

Operation

Maintenance

and

Troubleshooting

Electrical

Diagram

Parts

List

www.mlllerwelds.com

Warranty

Safety

PrecautioNs



Read

Before

Using

.~.

.~.

,...,...

Symbol

Usage

OM-186

360-

4/97,

safety_som

4/97

Means

Warning!

Watch

Out!

There

are

possible

hazards

with

this procedure!

The

possible

hazards

are

shown

the

adjoining

symbols.

This

group

symbols

means

Warning!

Watch

Out!

possible

ELECTRIC

SHOCK,

MOVING

PARTS,

and

HOT

PARTS

hazards.

Consult

symbols

and

instructions

below

for

necessary

actions

avoid

the

hazards.

Arc

Welding

Hazards

The

symbols

shown

below

are

used

throughout

this

manual

call

attention

and

identify

possible

hazards.

When

you

see

the

symbol,

watch

out,

and

the

instructions

avoid

the

hazard.

The

safety

information

given

below

only

summary

the

complete

safety

information

found

the

Safety

Standards

listed

Section

1.4.

Read

and

all

Safety

Standards.

Only

qualified

persons

should

Install,

operate,

maintain,

and

repair

this

unit.

During

operation,

keep

everybody,

especially

children,

away.

can.kIiL.

Touching

live

electrical

parts

can

cause

fatal

shocks

severe

burns.

The

electrode

and

work

circuit

electrically

live

whenever

the

output

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

on.

semiautomatic

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

Incorrectly

installed

improperly

grounded

equipment

hazard.



not

touch

live

electrical

parts.



Wear

dry,

hole-free

insulating

gloves

and

body

protection.



Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

covers

big

enough

prevent

any

physical

contact

with

the

work

ground.



not

use

output

damp

areas,

movement

confined,

there

danger

falling.



Use

output

ONLY

required

for

the

welding

process.



output

required,

use

remote

output

control

present

unit.



Disconnect

input

power

stop

engine

before

installing

servicing

this

equipment.

Lockout/tagout

input

power

according

OSHA

CFR

191

0.147

(see

Safety

Standards).



Properly

install

and

ground

this

equipment

according

its

Owners

Manual

and

national,

state,

and

local

codes.



Always

verify

the

supply

ground



check

and

sure

that

input

power

cord

ground

wire

properly

connected

ground

terminal

disconnect

box

that

cord

plug

connected

properly

grounded

receptacle

outlet.



When

making

input

connections,

attach

proper

grounding

conductor

first



double-check

connections.



Frequently

inspect

input

power

cord

for

damage

bare

wiring



replace

cord

immediately

damaged



bare

wiring

can

kill.



Turn

off

all

equipment

when

not

use.



not

use

worn,

damaged,

undersized,

poorly

spliced

cables.



not

drape

cables

over

your

body.



earth

grounding

the

workpiece

required,

ground

directly

with

separate

cable



not

use

work

clamp

work

cable.



not

touch

electrode

you

are

contact

with

the

work,

ground,

another

electrode

from

different

machine.



Use

only

well-maintained

equipment.

Repairor

replace

damaged

parts

once.

Maintain

unit

according

manual.



Wear

safety

harness

working

above

floor

level.



Keep

all

panels

and

covers

securely

place.



Clamp

work

cable

with

good

metal-to-metal

contact

workpiece

worktable

near

the

weld

practical.



Insulate

work

clamp

when

not

connected

workpiece

prevent

contact

with

any

metal

object.

SIGNIFICANT

VOLTAGE

exists

after

removal

input

power

inverters.



Turn

Off

inverter,

disconnect

input

power,

and

discharge

input

capacitors

according

instructions

Maintenance

Section

before

touching

any

parts.



Keep

your

head

out

the

fumes.

not

breathe

the

fumes.



inside,

ventilate

the

area

and/or

use

exhaust

the

arc

remove

welding

fumes

and

gases.



ventilation

poor,

use

approved

air-supplied

respirator.



Read

the

Material

Safety

Data

Sheets

(MSDSs)

and

the

manufacturers

instructions

for

metals,

consumables,

coatings,

cleaners,

and

degreasers.



Work

confined

space

only

well

ventilated,

while

wearing

air-supplied

respirator.

Always

have

trained

watch-

person

nearby.

Welding

fumes

and

gases

can

displace

air

and

lower

the

oxygen

level

causing

injury

death.

sure

the

breathing

air

safe.



not

weld

locations

near

degreasing,

cleaning,

spraying

operations.

The

heat

and

rays

the

arc

can

react

with

vapors

form

highly

toxic

and

irritating

gases.



not

weld

coated

metals,

such

galvanized,

lead,

cadmium

plated

steel,

unless

the

coating

removed

from

the

weld

area,

the

area

well

ventilated,

and

necessary,

while

wearing

air-supplied

respirator.

The

coatings

and

any

metals

containing

these

elements

can

give

off

toxic

fumes

welded.

Marks

special

safety

message.

Means

Note;

not

safety

related.

a

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

hazardous

your

health.

OM-186

360

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