Miller 9700W User manual

1
OM-9700T-02-2015
8-5-2016 V
AUGUST 2016
Read this manual carefully before installing,
Commissioning, or operating this product.
Miller Welding Automation, 281 E. Lies Rd., Carol Stream, Il 60188
Telephone: [phone] •Fax: [phone]
Web site: www.jetline.com •E-mail: sales@jetline
OPERATION MANUAL
For
9700W Microprocessor
Wire Feed Control
IMPORTANT

2
Blank page

3
Components or parts manufactured directly by Miller Electric Mfg. Co. are subject to Miller’s True Blue® Warranty set
forth at www.millerwelds.com/support/warranty. Seller does not make any warranties for components or parts not
manufactured directly by Jetline Engineering, Miller Welding Automation, and Panasonic Welding Systems Company;
such components or parts are subject to the warranty terms of the respective manufacturer. Components and parts
manufactured by Jetline Engineering, Miller Welding Automation, and Panasonic Welding Systems Company are
subject to the following warranty terms. Terms and Conditions of Sale Seller warrants to Purchaser that the
components or parts manufactured by Seller or Panasonic Welding Systems Company shall be free from defects in
material and workmanship, and shall conform to the Seller’s specifications for the following periods:
a. 12 months from the date of shipment of the Products for components and equipment manufactured by
Panasonic Welding Systems Company including robot manipulator, controller and connecting cables; external
axis components (external axis base unit, servo amplifiers, motors, connecting cables and pre-engineered
positioners); peripheral devices (high voltage touch sensors, thru arc seam trackers); welding power sources
(internally built into the robot controller cabinet); wire feeders (separated design or integrated design, i.e.
Active Wire Torch/Feeder); or
b. 12 months from date of shipment of the Products for equipment manufactured by Jetline Engineering or
Miller Welding Automation.
In the event of a breach of the warranties set forth above, Seller will, at Seller’s option and as Seller’s sole liability and
Purchaser’s sole remedy, repair, replace or credit Purchaser’s account for, any Product that fails to conform to the
above warranty, provided that (i) during the applicable warranty period Seller is promptly notified in writing upon
discovery of such failure with a detailed explanation of any alleged deficiencies; (ii) Seller is given a reasonable
opportunity to investigate all claims; and (iii) Seller’s examination of such Product confirms the alleged deficiencies and
that the deficiencies were not caused by accident, misuse, neglect, improper installment, unauthorized alteration or
repair or improper testing. No Products may be returned to Seller until inspection and approval by Seller. All warranty
work performed shall be FOB Seller’s facility (Incoterms 2010) and freight for returned Products shall be paid for by
Purchaser. The above warranty against defects does not apply to: (1) consumable components or ordinary wear items
including but not limited to torches; or (2) defects due to (i) failure to install and perform maintenance set forth in
Product documentation, (ii) the use of components, parts, peripherals, attachments, accessories, or perishable tooling
not approved by Seller, (iii) accident, misuse, neglect, abuse, mishandling, misapplication, modification, alteration, acts
of God, or (iv) improper installation, service or maintenance. Purchaser and/or the operator of the Products are in full
control of the weld process. Seller makes no warranty regarding the quality or the success of the welds on the Products
due to factors under Purchaser’s and/or operator’s control including but not limited to welding procedures, material
types, material coatings, joint/part fit, part geometry, metallurgy, welding gases, proper machine/process
maintenance, and operator skill. EXCEPT AS SET FORTH ABOVE, SELLER MAKES NO WARRANTY OR REPRESENTATION
OF ANY KIND, EXPRESS OR IMPLIED (INCLUDING NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY
PARTICULAR PURPOSE).
- See more at: https://www.millerwelds.com/automation-terms-of-sale#sthash.l5oRebWB.dpuf
LIMITED WARRANTY

4
The installation, operation and maintenance guidelines set out in this manual will enable you to
maintain the equipment in peak condition and achieve maximum efficiency with your welding operation.
Please read these instructions carefully to become aware of every advantage.
Only experienced personnel familiar with the
operation and safe practice of welding
equipment should install and/or use this
equipment.
NOTICE
CAUTION

5
CONTENTS
SECTION I ........................................................................................................................................................ 1
SAFETY PRECAUTIONS –READ BEFORE USING (som 2013-09) .................................................................... 1
1.1 Symbol Usage ...................................................................................................................................... 1
1.2 Arc Welding Hazards................................................................................................................................. 1
1.3 Additional Symbols for Installation, Operation, And Maintenance.......................................................... 4
1.4 California Proposition 65 Warnings .......................................................................................................... 6
1.5 Principal Safety Standards ........................................................................................................................ 6
1.6 EMF Information....................................................................................................................................... 6
Section II.......................................................................................................................................................... 7
Introduction .................................................................................................................................................... 7
A. Description .............................................................................................................................................. 8
B. Specifications.......................................................................................................................................... 9
Section III....................................................................................................................................................... 12
Operation Mode 9700W ............................................................................................................................... 12
1. RUN SCREENS ........................................................................................................................................ 13
2. PROGRAM SCREENS .............................................................................................................................. 13
3. AUX1-3 SCREENS ................................................................................................................................... 16
4. PULSED SCREENS................................................................................................................................... 16
Section IV....................................................................................................................................................... 19
Weld Screen .................................................................................................................................................. 19
Section V........................................................................................................................................................ 20
ESTOP Screen ................................................................................................................................................ 20
Section VI....................................................................................................................................................... 20
Mechanical Installation ................................................................................................................................. 20
Section VII...................................................................................................................................................... 22
Electrical Installation ..................................................................................................................................... 22
A. Input Power........................................................................................................................................... 22

6
B. Output Connections .............................................................................................................................. 22
C. Interconnections ................................................................................................................................... 26
Travel Addition.............................................................................................................................................. 27
Travel & ALC Addition ................................................................................................................................... 28
Section VIII..................................................................................................................................................... 30
Maintenance ................................................................................................................................................. 30
A. Calibration ............................................................................................................................................. 30
Initial Calibration .................................................................................................................................. 30
Touch-up Calibration ............................................................................................................................ 30
B. Regular Maintenance ............................................................................................................................ 30
Section IX....................................................................................................................................................... 32
Parts Lists ...................................................................................................................................................... 32
Section X........................................................................................................................................................ 37
PCB Descriptions ........................................................................................................................................... 37
Section XI....................................................................................................................................................... 41
Electrical Diagrams........................................................................................................................................ 41
Appendix A 9700W Calibration Sub Menu Mode ......................................................................................... 44
Appendix B 9700W Configuration Sub Menu Mode..................................................................................... 50
Appendix C 9700W Auto Calibration............................................................................................................. 54

1
SECTION I
SAFETY PRECAUTIONS –READ BEFORE USING (som 2013-09)
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
explained 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 symbols 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 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.
Additional safety precautions are required when any of the following 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 unavoidable or accidental contact with the work piece 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 voltage. In most situations, use of a DC, constant voltage wire welder is
recommended. And, do not work alone!
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).
Properly install, ground, and operate 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.
Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
Frequently inspect input power cord and ground conductor for damage or bare wiring –replace immediately if damaged –bare
wiring can kill.
Protect yourself and others from injury –read, follow and save these important safety precautions and operating instructions.
ELECTRIC SHOCK can kill.

2
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired 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 touch electrode if you are in contact with the work, ground, or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or 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.
Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use.
Use GFCI protection when operating auxiliary equipment in damp or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before
touching any parts.
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
Keep your head out of the fumes. Do not breathe the fumes.
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.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
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 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.
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).
Wear approved safety glasses with side shields under your helmet.
Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.
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.
HOT PARTS can burn.
ARC RAYS can burn eyes and skin.
FUMES AND GASES can be hazardous.

3
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.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
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).
Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline).
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.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
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.
Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.
Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables,
coolants, degreasers, fluxes, and metals.
Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.
Wear approved safety glasses with side shields even under your welding helmet.
Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
Wearers of Pacemakers and other Implanted Medical Devices should keep away.
Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise level is high.
WELDING can cause fire or explosion.
FLYING METAL or DIRT can injure eyes.
BUILDUP OF GAS can injure or kill.
ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices.
NOISE can damage hearing.

4
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.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the
valve.
Keep protective cap in place over valve except when cylinder is in use or connected for use.
Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication
P-1 listed in Safety Standards.
1.3 Additional Symbols for Installation, Operation, And Maintenance
Do not install or place unit on, over, or near combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.
Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and support unit.
If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.
Keep equipment (cables and cords) away from moving vehicles when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manually
lifting heavy parts or equipment.
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before starting to weld again.
Do not block or filter airflow to unit.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.
Sparks can cause fires —keep flammables away.
Put on grounded wrist strap BEFORE handling boards or parts.
Use proper static-proof bags and boxes to store, move, or ship PC boards.
CYLINDERS can explode if damaged.
FIRE OR EXPLOSION hazard.
FALLING EQUIPMENT can injure.
OVERUSE can cause OVERHEATING
FLYING SPARKS can injure.
STATIC (ESD) can damage PC boards.