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
to
You
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 which
exact
part
you
may
need
to
fix the
problem.
Warranty
and
service
information
for
your
particular
model
are
also
provided.
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
call
1-800-4-A-Miller.
ISO 0001
IQUALITY
SYSTEM
Miller Is the
tbst
welding
equipment
manufacturer IN
the U.S.A.
to
be
registered
to
the ISO 9001
QualIty
System
Standard.
T~1~ffl~ r~imnr~
L~5
Working
as
hard
as
you
do

every power
source
from
Miller Is
backed
by
the
most
hassle-free
warranty
In
the
business.
TI/A
Miller
The
Power
fBlue.

Call
1
-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
be
in
your
hands
in 24 hours.
Support
Need fast
answers
to
the
tough
welding
questions?
Contact
your
distributor.
The
expertise
of the
distributor
and Miller is
there
to
help
you,
every
step
of the
way.
The
Touch
Sensor is
designed
to
provide
touch
sensing capability using
the
welding
wire and
voltage
sense
leads. The robot
controller sends
a
signal
to
the Touch
Sensor
to
begin
touch
sensing
operation.
A
signal
is
sent
from the Touch
Sensor
to
the robot controller
when
the
welding
wire
touches the weldment.
The
contactor
in the Touch
Sensor
prevents
any
low
impedance path
through
the
welding
power
source
during
touch
sensing
operation.
It
also
operates
during
the weld
cycle by
closing
before
welding begins
and
remains closed
during
the
welding
operation by sensing
weld
current.
When
no
weld
current
is
detected,
the
contactor
deenergizes.

115
VAC,
2
A,
60
Hz
Input
Power

170
VDC,
5
mA
Touch
Sense
Output

Touch
Sensor
And
Input
Power Pilot
Lights

External
Connections For Cords And
Cables

Product
features and
specifications
are
subject
to
change
without notice
Processes
Automatic
Welding
Miller
offers
a
Technical Manual
9
which
provides
more
detailed
service
and
parts
information for
your
unit. To obtain
a
Technical
9
Manual,
contact
your
local
distdbuto,
Your distributor
can
also
12
supply
you
with
Welding
Process
Manuals such
as
SMAW,
GTAW,
12
GMAVvandGMAW-P
For
practical
in formation
on
welding,
14
process
applications,
and
Miller
products,
visit
our
website
at
Descrintlon
To~th
S~c~
Features
Table
of
Contents
Section
Page
1
5
1.
Safety
Precautions
1.
Consignes
de
sØcuritØ
2.
Introduction
3.
Installation
4.
Operation
5.
Maintenance and
Troubleshooting
6.
Electrical
Diagram
7.
Parts
List
16
www.mlllerwelds.com
Warranty

1.
Safety
PrecautioNs

Read Before
Using
.~.
.~.
,...,...
~
~1 1
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
in the
adjoining symbols.
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
A
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
1.4. Read and
follow all
Safety
Standards.
A
Only qualified
persons
should
Install,
operate,
maintain,
and
repair
this unit.
A
During operation,
keep everybody,
especially
children,
away.
~
can.kIiL.
~
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.

Do
not
touch
live electrical
parts.

Wear
dry,
hole-free
insulating gloves
and
body protection.

Insulate
yourself
from
work
and
ground
using dry insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with the
work
or
ground.

Do
not
use
AC
output
in
damp areas,
if
movement
is
confined,
or
if
there is
a
danger
of
falling.

Use
AC
output
ONLY if
required
for
the
welding
process.
 If AC
output
is
required,
use
remote
output
control if
present
on
unit.

Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
191
0.147
(see
Safety
Standards).

Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.

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.

When
making input
connections,
attach
proper
grounding
conductor first

double-check
connections.

Frequently inspect
input
power
cord
for
damage
or
bare
wiring

replace
cord
immediately
if
damaged

bare
wiring
can
kill.

Turn
off
all
equipment
when
not
in
use.

Do
not
use
worn,
damaged,
undersized,
or
poorly spliced
cables.

Do
not
drape
cables
over
your
body.

If earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable

do
not
use
work
clamp
or
work
cable.

Do
not
touch
electrode
if
you
are
in
contact
with the
work,
ground,
or
another
electrode
from
a
different machine.

Use
only
well-maintained
equipment.
Repairor
replace damaged
parts
at
once.
Maintain unit
according
to
manual.

Wear
a
safety
harness
if
working
above
floor
level.

Keep
all
panels
and
covers
securely
in
place.

Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
or
worktable
as
near
the
weld
as
practical.

Insulate
work
clamp
when
not
connected
to
workpiece
to
prevent
contact
with
any
metal
object.
SIGNIFICANT
DC
VOLTAGE exists after
removal
of
input
power
on
inverters.

Turn
Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors according
to
instructions
in
Maintenance Section
before
touching
any
parts.

Keep
your
head
out
of the fumes. Do
not
breathe
the
fumes.

If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.

If
ventilation is
poor,
use
an
approved air-supplied
respirator.

Read
the
Material
Safety
Data
Sheets
(MSDSs)
and the
manufacturers instructions
for
metals, consumables,
coatings,
cleaners,
and
degreasers.

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
breathing
air
is safe.

Do
not
weld in locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.

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.
a
A
Marks
a
special safety
message.
f~
Means
Note;
not
safety
related.
a
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
OM-186 360
1