Miller KE661555 Owner's manual

Miller KE661555 Owner's manual
Miller
September
1995
Form:
OM-141 3220
Effective With Serial No. KE661 555
I
OWNERS
MANUAL
XRTM-30R
Robotic Extended Reach
Hard Wire
Option
System
Available
For GMAW And GMAW-P
For Use With CV Or CC
See
For
Feeding
Aluminum Wire
Specifications
Welding
Welding
Power Source
For 3/64-1/16 in Aluminum And .030-045 in Hard Or Cored Wire
Control Circuit And Motor Overload Protection
Water-Cooled Gun Rated At 400 Amperes At 100% Duty Cycle
Read and follow these instructions and all
blocks carefully.
Give this manual to the operator.
safety
Have
only
trained
install, operate,
or
and qualified persons
service this unit.
For
Call your distributor if you do not understand
the directions.
cover 5/94
1995 MILLER Electric
help,
call your distributor
MILLER Electric Mfg. Co., P.O. Box 1079,
414-734-9621
Appleton, WI 54912
or:
Mfg. Co.
PRINTED IN USA
~-
I
J
MILLERS
TRUE BLUEfi LIMITED WARRANTY
(Equipment
This limited warranty supersedes all
LIMITED WARRANTY
Subject
warrants to its
original
Effective January 1, 1995
serial number preface of KD
a
previous MILLER
to the terms end conditions
Mfg. Co., Appleton, Wisconsin,
with
warranties and is exclusive with
below, MILLER Electric
retail
purchaser
6.
90
other
newer)
guarantees
or
warranties
expressed
or
implied.
Pans and Labor
Days
thst new
MtG Guns/FIG Torches
MILLER equipmenl aold after the effective date ot this limited warranty is tree oI de
Iects in material and workmanship at the time it is shipped by MILLER. THIS WAR
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR
IMPLtED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torchea
Remote Controls
Accessory Kits
Replacement Pans
-
NESS.
Within the warranty
no
or
periods listed below, M1LLER will repair or replace any war
parts or components that tail due to such detects in material or workmanship.
MILLER must be notitied in writing within thirty (30) days ot such detect or lailure, at
which time MILLER will provide instructions on the warranty claim procedures to be
lollowed.
MILLERS
MILLER shall honor warranty claims on warranted equipment listed below in the
event ot auch a tailure within the warranty time periods. All warranty time periods
start on the date that the equipment was delivered to the original retail purchaser, or
2.
True Bluefi Limited
Warranty shall
not
apply
to:
ranted
one
year after the
equipment is
sent to a North American distributor or
months after the equipment Is sent to
1.
5 Years Parts 3
Original
eighteen
but manufactured
are
covered
by
by others, &uch
as
the manufacturers
engines
or
warranty, it
any.
Consumable components: such as contact tips, cutting nozzles, contectors
and relays or parts that tail due to normal wear.
Equipment that has been modified by any party other than MILLER, or equip
improperly installed, improperly operated or misused
based upon industry standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has been used tor operation
outside ot the specifications br the equipment.
3.
lntemational distributor.
ment that has been
Years Labor
(input and output rectitiers only)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
Pans and Labor
3 Years
by MILLER,
trade accessories. These items
main power rectifiers
Inverters
2.
an
Items tumished
1.
Translonner/Rectitier Power Sources
Plasma Arc
Cutting
Power Sources
In the event ot
Inverter Power
Suppliea
Intellitiga
*
3.
Robots
Parts and Labor
2 Years
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the engine manutacturer.)
Air Compressors
1 Year
4.
warranty claim covered by this warranty, the exclusive remedies
option: (t) repair: or (2) replacement; or, where authorized in
writing by MILLER in appropriate cases, (3) the reasonable cost ot repair or replace
ment at an authorized MILLER service station; or (4) payment of or credit for the pur
chase price (less reasonable depreciation based upon actual use) upon retum of the
goods al customers risk and expense. MILLERS option of repair or replacement
will be FOB., Factory at Appleton, Wisconsin, or FOB. at a MILLER authorized ser
vice facility as determined by MILLER. Therefore no compensation or reimburse
ment for transportalion coats of any kind will be allowed.
a
shall be, at MILLERS
Semi-Automatic and Automatic Wire Feeders
Pans and Labor
TO THE EXTENT PERMITFED BY LAW, THE REMEDIES PROVIDED HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDtNG LOSS OF PROFIT), WHETHER BASED ON CON
TRACT, TORT OR ANY OTHER LEGAL THEORY.
Motor Driven Guns
Process Controllers
IHPS Power Sources
Water Coolant
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPUED WAR
RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL
THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN
CLUDING ANY IMPUED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
Systems
HF Units
Grids
Spol Welders
Load Banks
SDX Transtormers
Running Gear/Trailers
Plasma Cutting Torches (except APT, ZIPCUT & PLAZCUT Models)
Tecumseh Engines
Deutz Engines (outside Nonh America)
Field Options
(NOTE: Field options are covered under True Bluefi br the remaining
warranty period ot the product they are installed in, or tor a minimum ot
*
one
5.
year
whichever is greater.)
Batteries
6 Months
Some states in the U.S.A. do not allow limitations ot how long an implied warranty
lasts, or the exclusion ol incidental, indirect, special or consequential demages, so
the above limitstion or exclusion may not apply lo you. This warranty provides spe
cific
legal rights,
and other
rights
may be available, but mey vary trom state to state.
Canada, legislation in some provinces provides br certain additional warranties
remedies other than as staled herein, and to the extent that they may not be
waived, the limitations and escluaions set oul above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be available, but may
vary tram province to province.
In
or
j~i
-
-
-
I
RECEIVING-HANDLING
unpacking equipment, check carton for any damage fhat may have occurred during shipment. File any claims for loss or damage
delivering carrier. Assistance for tiling or settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
Before
with the
When
requesting
following
nameplate.
Use the
or
equipment, always provide
information about this
spaces to record Model
Model
Designation
and Serial
or
Style
Number.
Designation and Serial or Style Number of your unit. The information
is located on the
rating label
Model
_________
Serial
or
Style
No.
Date of Purchase
miller 6/95
ARC WELDING SAFETY PRECAUTIONS
WARNING
AA
ARC WELDING
can
be hazardous.
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL
INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
terminal in disconnect box
kill.
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 touchin9 the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Touching
~
~
1.
Do not touch live electrical parts.
2.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating
3.
big enough to prevent any physical contact with
the work or ground.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input poweraccording
to OSHA 29 CFR 1910.147 (see Safety Standards).
Properly install and ground this equipment according to its
mats or covers
4.
5.
8.
Frequently inspect input power cord for damage or bare wiring
replace cord immediately if damaged bare wiring can kill.
9.
Turn off all
10.
equipment when not in use.
worn, damaged, undersized,
use
or
poorly spliced
11.
Do not
12.
If earth
with
drape cables over your body.
grounding Æf the workpiece is required, ground it directly
do not
separate cable
a
use
work clamp
or
work cable.
13.
Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
14.
Keep all panels and
Always verify the supply ground check and be sure that input
power cord ground wire is properly connected to around
Clamp
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Noise from some processes
can damage hearing. Chipping, grinding, and welds
cooling throw off pieces of metal or slag.
Use
ear
plugs
or ear
muffs if noise level is
FUMES AND GASES
can
2.
3.
approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the
manufacturers instruction for metals, consumables, coatings,
cleaners, and degreasers.
If ventilation is poor,
use
exhaust at the
arc
as
contact
to
oractical.
Wear
a
welding
helmet fitted with
a
proper shade of filter to
Safety Standards).
with side shields.
4.
protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
5.
6.
If inside, ventilate the area and/or
remove welding fumes and gases.
the weld
Wear
out of the fumes. Do not breathe the fumes.
2.
good metal-to-metal
as near
Z49.1 and Z87.1 listed in
be hazardous to your health.
Keep your head
or ~~~~
securely in place.
3.
Welding produces fumes and gases. Breathing these
can
with
protect yourface and eyes when welding orwatching (see ANSI
to your health.
fumes and gases
covers
ARC RAYS
high.
be hazardous
cable
work
workniece
5.
approved
1.
to
7.
use an
approved safety glasses
Use
a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watchperson 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
Work in
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.
4.
Never
high
Shielding gas cylinders
pressure. If damaged, a cylinder can explode. Since
of
the
are
welding
normally part
gas cylinders
process, be sure to treat them carefully.
5.
Never allow
6.
Protect
compressed gas cylinders from excessive heat.
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
8.
mechanical shocks,
9.
on a pressurized cylinder
explosion will result.
only correct shielding 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.
Keep protective cap in place over valve except when cylinder is
CYLINDERS
can
explode if damaged.
contain
3.
Do not
cables.
~
2.
grounding
17.
r
QJ
1.
attach proper
double-check connections.
making input connections,
conductor first
16.
NOISE
4.
When
a
15.
..
1.
7.
is connected to
plug
outlet.
Manual and national, state, and local codes.
/~
-
that cord
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.
Owners
6.
or
properly grounded receptacle
circuits.
gas under
7.
a
a
welding torch over a gas cylinder.
welding electrode to touch any cylinder.
Never weld
Use
in
10.
drape
use or
connected for
use.
Read and follow instructions
on
compressed gas cylinders,
listed in Safety
associatedequipment,andCGApublicationP-1
Standards.
Srl1.I 2194
WELDING
can cause
fire
explosion.
or
Welding on closed containers, such as tanks, drums,
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
or
Be
6.
1.
2.
3.
4.
5.
Protect
yourself
and others from
flying sparks
and hot metal.
flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
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.
Do not weld where
ENGINE EXHAUST GASES
FUEL
can
can
kill.
cause
fire
or
explosion.
Engine
1.
2.
fuel is
welding
on
on a
ceiling, floor, bulkhead,
or
partition
the hidden side.
on
closed containers such
as
tanks, drums,
or
as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock and tire hazards.
8.
Connect work cable to the work
9.
Do not
welder to thaw frozen
use
pipes.
Remove stick electrode from holder
contact tip when not in use.
10.
or
Wearoil-free protective garments such
11.
cut off
as
shirt, cuffless trousers, high shoes, and
welding
wire at
leather gloves,
a
heavy
cap.
Removeanycombustibles, suchasabutanelighterormatches,
welding.
12.
from your person before doing any
ENGINES
Engines produce harmful exhaust gases.
ENGINE
fire
pipes, unless they are properly prepared according t0AWS F4.1
(see Safety Standards).
WARNING
AA
that
Do not weld
7.
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.
aware
can cause
be hazardous.
can
1.
Use
2.
If used in a closed area, vent engine exhaust outside and
away from any building air intakes.
3.
Do not overfill tank
4.
Do not
equipment outside
in open, well-ventilated areas.
allow room for fuel to expand.
spill fuel. If fuel is spilled, clean up before starting
engine.
highly flammable.
Stop engine and let it cool off before checking or adding fuel.
Do not add fuel while smoking or if unit is near any sparks or
open flames.
~
MOVING PARTS
can cause
3.
injury.
Have
only qualified people remove guards or
troubleshooting as necessary.
covers
for
maintenance and
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing,
4.
cut
5.
1.
Keep all doors, panels,
securely in place.
2.
Stop eng
ne
before
covers,
installing
and
guards closed
and
6.
or
connecting unit.
To prevent accidental starting
negative () battery cable from
during servicing, disconnect
battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall
panels
or
guards and close doors when servicing is
starting engine.
finished and before
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
1.
2.
wear a face shield when working on a battery.
Stop engine before disconnecting or connecting battery
Always
cables.
3.
Do not allow tools to cause
4.
Do not
gases.
5.
Observe correct
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
It is best to check coolant level when engine is cold
to avoid scalding.
1.
Batteries contain acid and
generate explosive
If the
use
welder to
engine is
sparks when working on a battery.
charge batteries or jump start vehicles.
polarity (
warm
and
and
checking
on
batteries
is needed, follow steps 2
and 3.
2.
Wear
3.
Turn cap
safety glasses and gloves and put a rag over cap.
slightly and let pressure escape slowly before
completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49.i, from
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
29 CFR 1910, from
Superinten
Documents, U.S. Government Printing Office, Washington,
Safety and Health Standards, OSHA
dent of
American
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances, Ameri
can Welding Society Standard AWS F4.1 from American Welding So
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code, NFPA Standard 70, from National Fire Pro
Batterymarch Park, Quincy, MA 02269.
tection Association,
srl.1.1 2/94
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet
P-i, from Compressed Gas Association, 1235 Jefferson Davis High
way, Suite 501,
Arlington,
VA 22202.
Code for Safety in Welding and Cutting, CSA Standard Wi 17.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou
levard, Rexdale, Ontario, Canada M9W 1 R3.
Safe Practices For Occupation And Educational Eye And Face Protec
tion, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes, NFPA Standard 51 B, from National
Batterymarch Park, Quincy, MA 02269.
Fire Protection Association,
EMF INFORMATION
I
NOTE ~
Considerations About
Magnetic Fields
Welding
following is a quotation from the General Conclusions Section
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.
And The Effects Of Low
The
To reduce
of the U.S.
procedures:
.
magnetic
Frequency Electric
fields In the
cables close
workplace,
1.
Keep
2.
Arrange cables
together by twisting
3.
Do not coil
4.
Keep welding
practical.
5.
Connect work clamp to workpiece
or
use
taping
to one side and away from the
the
And
following
them.
operator.
.
or
drape cables around
power
source
the
body.
and cables
as
as
far away
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.
modlO 1 4/93
TABLE OF CONTENTS
SECTION 1
SAFETY INFORMATION
1
SECTION 2- SPECIFICATIONS
2-1.
1
Duty Cycle
1
SECTION 3- INSTALLATION
2
3-1.
Field Installation Instructions For XR-30R Panel Onto
3-2.
Computer Interface XR-30R Interconnections
Computer Interface/XR-30R Panel Wire Feeder Connection
Preparing Robot For Installation Of XR-30R
Installing XR-30R Gun
Interconnecting Harness Connections To Feeder
3-3.
3-4.
3-5.
3-6.
Computer
Interface
Wire
2
3
4
4
5
7
3-8.
Spool
Installing
Threading Welding Wire
10
3-9.
Coolant Guidelines
13
3-7.
11
SECTION 4-OPERATION
14
SECTION 5- MAINTENANCE & TROUBLESHOOTING
17
5-1.
5-2.
5-3.
5-4.
5-5.
Routine Maintenance
17
Gun Drive Roll
Or
Cleaning
Changing
Changing Feeder And Auxiliary Feeder Drive Roll And Wire Inlet Guide
Replacing Or Cleaning Gun Drive Roll Bearing
Replacing Or Cleaning Feeder And Auxiliary Feeder Drive Roll Bearing
18
19
19
20
Replacing Hub Assembly
Adjusting Hub Tension
20
5-7.
5-8.
Overload Protection
21
5-9.
Water Flow Switch
22
5-10.
Troubleshooting
22
5-6.
SECTION 6
ELECTRICAL DIAGRAMS
21
24
SECTION 7- PARTS LIST
34
Figure
Figure
Figure
7-1. Control Box
34
7-2. Tach Drive/Motor & Wire Drive
37
Figure
7-4. Gun, XR-30R
Figure
7-5.
7-3. Interface
Control, Push/Pull
(MRH Model Illustrated)
Motor, Push/Pull (MRV-6)
Auxiliary
Components
Miscellaneous
38
40
43
45
OM-141 322C9/95
SECTION 1
SAFETY INFORMATION
modl.1 2193
Read all
safety
messages
Obey all safety messages
Learn the
1
meaning
throughout this
to avoid
manual.
injury.
of WARNING and CAUTION.
2
Safety
Alert
2
Signal
Word
2
\
a WARNING
II
I
1
ELECTRIC SHOCK
can
kIII.~
~
Installing
L~
or
input power
servicing,
S
4
before
CAUTION
MOVING PARTS
Do not touch live electflcal parts.
Disconnect
WARNING means possible death
or serious injury can happen.
a CAUTION
3
Keep away
from
Keep all panels
when operating.
4
can
Injure.
moving parts.
and covers closed
/
means possible minor
injury or equipment damage can
happen.
3
Statement Of Hazard And
Result
4
Safety
5
a
READ SAFETY BLOCKS at start of
SectIon 3-1 before proceeding.
WARNING
6
~
~
NOTE
Turn Off switch when
Instructions To Avoid
Hazard
5
Hazard
6
Safety
Read
using high frequency.
1-1.
Safety
safety
blocks for each sym
NOTE
Special instructions
ation
Figure
Symbol (If Available)
Banner
bol shown.
7
~
Symbol
for best oper
not related to
safety.
Information
SECTION 2- SPECIFICATIONS
Table 2-1. Wire Feeder
Specification
Type
Of
Description
Input Power
Control Circuit
Wire Feed
115 Volts
Voltage Provided
At Gun
AC,
3
Amperes
At 50/60 Or 100 Hz Power
30 Volts DC
Speed Range
70-875
ipm (1.9-22.2 mpm)
Overall Dimensions
Length:
Maximum
12 in
Spool Capacity
19 in
(483 mm); Width: 9-1/4 in (235 mm); Height: 15-1/4
in
(387 mm)
(305 mm)
Table 2-2. Gun
Specification
Description
Input Voltage
30 Volts DC
Duty Cycle (Water-Cooled Models)
At 400
Wire Size
3/64 To 1/16 in (1.2 To 1.6 mm) Aluminum Wire
Contact Factory For .035 Specifications
.030 Thru .045 in (0.8 Thru 1.1 mm) Hard Or Cored Wire With Optional Steel Kit:
147 183 For MRV; 147 184 For MRH
2-1.
Range
Amperes,
Using Argon Or Argon
Mixture
Shielding
Gas
(See Section 2-1)
Duty Cycle
a
CAUTION
USING GUN BEYOND DUTY CYCLE RATING
Do
100%
no t use
gun
beyond
rated amperage when
can
damage gun.
using Argon shielding gas.
wfwam8.r 10/91
Duty cycle is how long the gun can operate within a ten minute period without causing overheating or damage. This gun
duty cycle when operated at 400 amperes, allowing continuous welding.
is rated at 100%
OM-141 322
Page
1
SECTION 3- INSTALLATION
3-1.
Field Installation Instructions For XR-30R Panel Onto
a
Computer
Interface
WARNING
__
__
ELECTRIC SHOCK
~
can
STATIC ELECTRICITY can
on circuit boards.
kill
Do not touch live electrical parts.
S
Put on
boards
Turn Off
input
welding power source, and disconnect
power before beginning this installation,
S
Have
only qualified persons familiar with and
following standard safety practices install this kit.
handling
parts.
Use proper
static-proof bags and
boxes.
twaml.1 2J93/fwam5.1 9/91
1
Right Side
Left Side
wrist strap BEFORE
grounded
or
damage parts
Computer
Interface
Remove side panels and top
Save for future use.
cover.
Remove RCSP-XL side panel if in
stalled.
3
2
XR-30R Panel
Remove side
onto
3
panel and install frame
Computer Interface.
Communications Board PC3
Disconnect CN24 from board.
with electrical tape to isolate.
Wrap
Connect plug from XR-30R panel to
receptacle on board where CN24
was removed.
4
4
5
Terminal
Strip
iT
Connect lead 55 from XR-30R panel
to Computer Interface iT terminal F.
5
Grommet
Route
remaining XR-30R leads
through grommet.
6
Interface Board PC4
Disconnect PLG1 from RC1.
Connect 4-position plug with 4 sock
ets from XR-30R
panel
to RC1.
Connect 4-position plug with 2 sock
ets from XR-30R panel to PLG1.
Connect lead 60 to
nal next to board.
7
grounding termi
Terminal Strip 2T
Connect two leads 23 to 2T terminal
A.
8
Side Panel
Reinstall when connections
are
completed.
Reinstall RCSP-XL side
panel
if
applicable.
9
Top Cover
Install correct
supplied top
cover.
1
ST-159 242-A / 5T-139 887-C / Rel. SD-184 013
Figure
OM-141 322
Page
2
3-1
-
Installing
XR-30R Onto
Computer
Interface
3-2.
Computer
Interface
XR-30R Interconnections
I)
Voltage Sensing
RC1 4
Leads
0
PLGI 4
To Computer
Interface RC14
I
1
Computer
2
XR-30R Panel
3
RCSP-XL Panel
Interface
I
To Weld Current
Relay Control
RC9
~
PLG8
0
To Computer
Interface RC8
PLG9
RC1 2
RC8
0
To
Display
Module~
To Computer
Interface RC11
~
Power Source
17-Socket
Receptacle
To RCSP-XL
Rd 6
To Robot
Manipulator
I
RC1 7
ToWelding~~
PLG11
RC18
PLG1 1
To Computer
Interface RC9
RC1O
RC1 9
o~
RC16
0
RC11
RC2O
O\
To XR Control
Rear Panel
To
Welding
~Power Source
14-Socket
Receptacle
Not Used For This
Installation
S-0557-A/ S-O555-A
Figure
3-2.
Computer Interface
XR-30R Connections
OM-141 322 Page 3
Computer
3-3.
lnterlace/XR-30R Panel
rT~~~1
Wire Feeder Connection
1
Fl
Wire Feeder
Receptacle
RC5
Locate lOft (3m) cord with 1 4-posi
plugs on both ends. Connect
tion
end to RC5. Connect remain
9 on Computer Inter
face/XR-30R Panel. Align keyway,
insert plug, and tighten threaded
collar.
one
ing end to Rd
~ 0000
Ret. ST-159 241-A
Figure
3-4.
Preparing
a
3-3.
Computer Interface/XR-30R
Panel
Wire Feeder Connection
Robot For Installation Of XR-30R
WARNING
__
ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn Off wire feeder,
The
welding wire,
welding power
drive rolls, drive
source, and
robot, and disconnect input power before disassembly.
assembly, and all metal parts touching
the
welding
wire
are
electrically
live when
1
MRH Manipulator
2
Wire
3
Wire Drive
4
Outlet Cable
5
Welding
6
Gun
welding
Spool
Assembly
Gun
Mounting Plate
7
MRV
B
Strain Relief Bracket
9
Gun Mounting Bracket
Manipulator
Remove items from
and retain for future
hardware.
manipulator
use.
Retain
5
9
5
Ref. ST-155 650 / Ref. ST-146 992
Figure
OM-141 322
Page
4
3-4.
Preparing
Robot For XR-30R Installation
3-5.
A.
Installing
Gun
XR-30R Gun
Mounting
1
Gun
2
Bracket
3
Robot
Manipulator
Attach bracket to gun and manipu
lator. Adjust gun position accord
ing to Section 4.5 In the Robot
Owners
Manual.
2
ST-158 869/ ST-159 881
Figure
B.
Interconnecting
Harness Connections To
3-5. Gun
Auxiliary
Mounting
Feeder
Install auxiliary feeder in position
shown in Figure 3-7. Make con
nections as follows:
1
Wire Conduit From Feeder
2
5-Socket Wire Drive Motor
Plug
3
Cover
4
Tach
5
Thumbscrew
Auxiliary Drive
Assembly
Loosen and Insert wire conduits
until tip almost touches drive roll.
Tighten thumbscrews.
6
Auxiliary Wire Drive
Assembly
7
Wire Conduit To Gun
8
Gas Hose To Gun
9
Gun Motor Control
Plug
(MRH Shown)
10
2-Socket Tach Feedback
Plug
To connect plugs, align keyway, In
sert plug into matching receptacle
on auxiliary feeder, and tighten
threaded collar.
11
Shock Sensor
Plug
Connect to matching
bot manipulator.
12
rear
auxiliary feeder.
3-6.
Auxiliary
from
ro
Voltage Sensing Cable
Install onto
Figure
plug
mounting block of
ST.158 972-c
Feeder Connections
OM-141 322
Page
5
C.
Clamping
Harness
A~
CAUTION
INSUFFICIENT SLACK IN HARNESS
Allow sufficient slack in harness between
Hamess needs to be
clamped
so
that it
can
can cause
equipment damage.
clamping points for proper
robot movement.
follow robot movement without
11
16
getting caught
15
or
binding.
8
7
______________
____________
~~___
14
1
Bracket Insulator
2
Nylon Shoulder
3
Cable
4
Interconnecting
5
Rubber Strain Relief
Support
Washer
Bracket
Hamess
6
Rubber Tie
7
Auxiliary
8
Ring
9
Tool Balancer
10
Hanger
11
Adjustable Cable Hanger
12
Bracket
Feeder
4
1
3
2
17
13
13
Insulated Conduit
14
Clamp
15
Stop Collar
16
Spring
17
Gun
Mount
= = =
=
Insulator
according
to
Alternate Harness
Clamp
Figure
3-5.
Routing
ST-160 942-B I ST-160 941-B / ST-800 269-A / ST-800 270-A I ST-800 268
Figure
OM-141 322
Page
6
3-7.
Clamping
Harness
3-6.
Interconnecting
Harness Connections To Feeder
WARNING
£~
ELECTRIC SHOCK
can
kill.
HIGH GAS PRESSURE
gas valve to leak.
Do not touch live electrical parts.
Do not use gas pressure above 50 psi (345
mechanical gas valve in gun can leak.
Turn Off wire feeder, welding power source, and
robot, and disconnect input power before
inspecting
C YLINDERS
OVERHEATING
can
Keep cylinders
explode
away from
if
kPa)
damage
gun parts.
supply to flow
can
and other
S
Maintain minimum 1 qt/min flow rate at all times.
cylinder with welding electrode.
Always secure cylinder to running gear, wall,
other stationary support.
or
wfwam7.I
Wire Conduit And
or
INCORRECT COOLANT FLOW RATE
damage gun parts.
damaged.
welding
can
Make connections from coolant
switch in unit.
electrical circuits.
A.
gun
installing.
or
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding.
Never touch
can cause
Auxiliary
9/91
Feeder Connections
Side View
1
Wire Feeder
2
Wire Conduit
3
Securing Screw
Loosen screw, insert wire conduit
through front panel and into wire
drive. Secure conduit as close to
drive roll as possible without
touching.
4
Auxiliary Feeder Cord
5
Receptacle RC6
To make connection, align keyway,
insert plug Into matching recep
tacle RC6, and
collar.
Internal Water Connections Not Shown
tighten
threaded
Front View
1
4~
5
Ref. 5T-159 241-B / Ref. ST-159 238.A
Figure
3-8. Wire Conduit And
Auxiliary
Feeder Connections
OM-141 322
Page
7
B.
Weld Cable Connections
1
Wire Feeder
2
Weld Cable From Intercon
necting Harness
Route through front panel and con
nect as shown.
3
Front View
Weld Cable From
Power Source
Welding
See welding power source Own.
ers Manual for correct size cable.
Obtain cable with proper size lugs
and connect as shown.
Side View
Rear View
3
Ref. ST-I 59 238-Al ST-159 237-B
Figure
OM-141 322 Page 8
3-9. Weld Cable Connections
C.
Water Connections
1
Wire Feeder
Front View
All
1
fittings
have left-hand threads.
2
Water Hose From Gun
3
WaterHoseToGun
Connect water hoses from inter
connecting harness to fittings on
front panel.
4
Coolant In
Opening
Route hose from coolant system
outfitting, through opening, and to
fitting on rear of front panel. Con
nect hose.
5
2
Coolant Out
Fitting
Connect hose from coolant supply
In
6
fitting
to coolant out
fitting.
Flow Switch SB
The switch has
spring
a
normally-open
contact which closes when
0.25 gpm (0.95 1pm) flows through
it. If the switch contact does not
close, wire does not feed.
Rear View
Side View
3
Internal Water Connections Not Shown
Side View
5
Internal Water Connections Shown
Ref. ST-i 59 236-A I ST-159 238-B I ST-i 59239-B
Figure
3-10. Water Connections
OM-141 322
Page
9
3-7.
Installing
Wire
Spool
Turn Off wire feeder and
power
Spool
1
Wire
2
Tension Ami
3
Gun Contact
If wire
welding
source.
Tip
spool is being replaced,
re
gun cover, open tension arm
in gun, and cut welding wire off at
move
contact
tip.
For
welding power sources without
ontactor, retract wire onto spool.
For
welding power
sources
with
a
contactor, energize power source,
turn On feeder, press Brake Re
lease button (see Figure
retract wire onto spool.
Remove retaining
wire spool oft.
Close gun tension
gun cover.
ring
arm
4
Hub
5
Hub Pin
6
Retaining Ring
4-6), and
and slide
and reinstall
Slide spool onto hub so wire feeds
off bottom. Turn spool until hub pin
fits hole in back of spool. Reinstall
retaining ring.
7
Jog Switch
Thread
welding wire using Jog
switch (see Section 3-8). Close and
latch door.
Tools Needed:
Ref. ST-159 237-B / Ref. ST-072 573-B / Ref. ST-158 974-A
Figure
OM-141 322
Page
10
3-11.
Installing
Wire
Spool
3-8.
Threading Welding
a
Wire
WARNING
ELECTRIC SHOCK
can
Do not touch live electrical
kill.
CYLINDERS
explode
can
from
Keep cylinders away
parts.
If
damaged.
and other
welding
electrical circuits.
The welding wire, drive rolls, drive assembly, and all
metal parts touching the welding wire are electrically
live when welding.
HOT SURFACES
can
Allow gun to cool before
Never touch cylinder with welding electrode.
Always secure cylinder to running gear, wall,
other stationary support.
burn skin.
WELDING WIRE
wounds.
touching.
Do not press gun
can
trigger
or
puncture
cause
until instructed to do
so.
Do not
point gun toward any part of the body, other
people, or any metal when threading welding wire.
wfwaml.r 9/91
A.
Threading Welding
Wire
Through
Feeder And
Auxiliary
Feeder
Be
sure
proper drive roll groove is
position for wire size selected
(see Table 3-1). Change drive roll
to selected wire size according to
in
Tools Needed:
Sections 5-2 and 5-3.
1
Wire
Spool
Loosen wire from
bent wire, and
wire off spool.
7
spool, cut off
pull 6 in (150mm) of
2
Tension Arm
3
Tension Screw
To open tension
and lift arm.
4
arm
loosen
screw
Wire Inlet Guide
5
Drive Roll
6
Wire Conduit
Fitting
Thread wire
through wire Inlet
guide, along drive roll groove, and
Into
fitting.
Close and secure tension arm.
Tighten tension screw all the way
down.
7
Motor
Torque Switch
Place switch in proper position for
wire
size
selected
(see
Figure 4-6).
8
Jog Switch
9
Wire Conduit
At the auxiliary feeder, loosen ten
sion screws and lift tension arms.
Remove conduit from
4
56
rear
assembly. Feed welding wire
10 in (254 mm) extends from
drive
until
wire
conduit.
10
Tach
11
Auxiliary Drive Assembly
Auxiliary
Assembly
Drive
Thread wire through both wire
drive assemblies and Into wire
conduit going to gun. Reinstall wire
conduit. Close and secure tension
arms. Tighten tension screws all
the way down.
Feed wire to gun.
Ref. ST-i 59 240-B / Ref. ST-i Si 7781 Ref. ST-i 58 972.C
Figure
3-12.
Threading Welding
Wire
Through
Feeder
OM-141 322
Page
11
B.
Threading Welding
a
Wire
Through
Gun
READ SAFETY BLOCKS at start of
Section 3-8 before proceeding.
WARNING
1
Wire Conduit
2
Secunng
Loosen
conduit.
Screw
and
screw
3
Tension Arm
4
Tension Screw
To open tension
and lift
5
arm
wire
remove
loosen
screw
arm.
Jog Switch
Feed wire until 5 in (127 mm) of
wire extends from wire conduit.
(See Table 3-1)
6
Drive Roll
7
Contact Tube
Manually
(See Table 3-1)
thread wire
along drive
tip. Re
roll groove and out contact
install wire conduit.
Close and
secure
Tighten tension
tension
screw
arm.
all the way
down.
Turn Off feeder and
welding power
Reinstall gun cover. Close
and latch feeder door.
source.
Ref. ST-i 58 973-A / Ret. ST-158 974-A I Ref. 5-0651
Figure
3-13.
Threading Welding
Wire
Through
Gun
Table 3-1. Gun Part Recommendations For Wire Size
Aluminum Wire
Changing
Parts
Drive Roll Grove A
(small groove)
Drive Roll Grove B
(large groove)
Contact Tip
Part No. 108 786
Contact
Tip
Part No. 108 788
Contact
Tip Part
Contact Tip part
.035 In
.045 In
3/64 in
108 790
Contact
Tip Part No.
125 988
Contact
Tip Part
Contact
Tip
X
X
X
No. 113954
Liner Part No. 141 222
Torque Switch Setting
OM-141 322
12
Page
.035 in
X
X
X
see
Table 2-2.
.045 In
X
0.8 R
0.9 A
1.6 R
1.6 A
1.2 M
1.6 M
.055 in ID
.055 in ID
.055 in ID
.055 in ID
.055 in ID
.055 in ID
Other
Other
Other
.093 in ID
Liner Part No. 141 223
kit
.030 in
1.2 R
Part No. 113955
*Requires optional
1/16 In
No. 108 789
no.
Motor
Hard And Flux Cored Wire*
.035
Other
Other
Other
3-9.
Coolant Guidelines
CAUTION
4~
INCORRECT COOLANT OR COOLANT CONTAINING STOP-LEAK ADDITIVES
feeder cooling passages.
Use
only
Do not
a
use
high quality automotive antifreeze
containing stop-leak additives.
mix of 50% distilled water and 50%
antifreeze
as
can
corrode and/or
proper coolant for this
plug gun/
product.
Use of other coolant voids warranty.
Follow
these
to
guidelines
decrease corrosion In gun/feeder
and cooling system:
I
Coolant
1
50 50
Mix distilled water and high quality
automotive antifreeze. Use anti
Distilled
freeze which does
Water &
Antifreez
not
contain
stop-leak additives.
Use
of
other
coolant
voids
warranty.
2
Coolant
3
Changing Coolant
Change
2~
System
coolant
Add coolant to
FULL
4
only
keep
Tank
if
dirty.
level full.
lighten Connections
Keep gun
connections
tight.
Flume
3
lighten Connections
4
S-o76o
Figure
3-14. Coolant Guidelines
OM-141 322
Page
13
SECTION 4- OPERATION
WARNING
a
ELECTRIC SHOCK
can
kill.
/~
Do not touch live electrical parts.
Always
wear
dry insulating gloves.
Insulate
yourself
Keep
panels and
all
from work and
covers
in
Wear
~
ground.
securely
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
welding helmet
Keep
be hazardous
can
your head out of the fumes.
Ventilate area,
or use
breathing
9~I~IIIIItrii~
can cause
Do not weld
near
Watch for fire;
on
over
from
can cause
injury.
pinch points such
Keep all doors, panels,
and securely in place.
or
I
covers, and
as
drive rolls.
guards
closed
MAGNETIC FIELDS FROM HIGH CUR
RENTS can affect pacemaker operation.
Pacemaker
explosion.
wearers
keep away.
Wearers should consult their doctor before
flammable material.
near
~
keep extinguisher nearby.
Do not locate unit
Do not weld
tire
Keep away
device.
Safety Data Sheets (MSDSs) and
manufacturers instructions for material used.
Read Material
WELDING
body protection.
place.
MOVING PARTS
FUMES AND GASES
to your health.
with correct shade of filter.
Wear correct eye, ear, and
any
going
welding operations.
combustible surfaces.
See
closed containers.
Safety Precautions at beginning of welding power
Owners
Manual for basic welding safety
source
Allow work and
equipment
to cool before
handling.
information.
wfwam3.1 8/92
1
Pilot
2
Power Switch
3
Jog Switch
Light
Ref. ST-159 236~A
Figure
4-1. Front Panel Controls Of Feeder
2
3
/
Wear the
following
while
1
Dry, Insulating
2
Safety Glasses
welding:
Gloves
With Side
Shields
3
______
Helmet With Correct
Shade Of Filter (See ANSI
Welding
Z49. 1)
Bb3.1 1/94
Figure
OM-141 322
Page
14
4-2.
Safety Equipment
1
Work
Clamp
Connect work clamp to
1
paint-free location
as
close to weld
a
clean,
workplece,
as possible.
on
area
Use wire brush or sandpaper to
clean metal at weld joint area. Use
chipping hammer to remove slag
after welding.
Tools Needed:
~==~
sb4.1 2/93
4-3. Work
Figure
Clamp
1
Jog Switch
Use switch to energize drive mo
tors without energizing welding
power source contactor. When
switch is held up in Jog position,
wire feeds.
Ref. ST-157 010
Figure
4-4.
Jog
Switch
1
Power Switch
2
Pilot
Light
Use switch to turn unit and
light On and Off.
pilot
2
1
Figure
4-5. Power Switch
OM-141 322
Page
15
Open
left side door.
Fuse Fl
1
See Section 5-7.
Circuit Breaker CB1
2
See Section 5-7.
Motor
3
Torque Switch
Use switch to select the force used
to push wire (torque). See Table
3-1 for recommended settings.
If welding wire appears to be
kinked, nicked, or damaged, place
switch in lower torque position.
Brake Release Button
.4
Whenever power is On and the
welding power source is ener
gized, button may be pressed torelease spool brake
can
turn
so
wire
spool
freely.
Close and latch door.
Ref. ST- 159 241-B / Ref. S-156 832-A
Figure
a
WARNING
BUILDUP OF SHIELDING GAS
health or kill.
Shut off
4-6. Internal Controls
shielding gas supply
can
when not in
harm
I
Wire feeding system Is designed for
maximum of 50 psi (345 kPa) gas
pressure.
use.
Be sure that
conditions of no
regulator/flowmeter has preset
more than 50 psi (345 kPa) gas
pressure.
waml.r 9/91
1
Shielding
2
Valve
Open valve
welding.
Gas
on
Close valve on
ished welding.
Cylinder
cylinder just before
cylinder
sb5.1
Figure
4-7.
Shielding
k~
Coolant
Turn
eOe
S-0621-c
Supply
on
coolant
guide-
supply before
welding.
Turn off coolant
ished welding.
fi
aCe
~
~
supply when fin.
Ref. ST-150755-A
Figure
16
-
See Section 3-9 for coolant
lines.
1
Page
6/92
Gas
1
OM-141 322
when fin
4-8. Coolant
Supply
SECTION 5- MAINTENANCE & TROUBLESHOOTING
A~
WARNING
ELECTRIC SHOCK
can
HOT PARTS
kill.
Allow
Do not touch live electrical parts.
can cause severe
cooling period
before
burns.
servicing gun
or
unit.
Turn Off wire feeder, welding power source, and
robot, and disconnect input power before
inspecting, maintaining,
MOVING PARTS
or
servicing.
can cause
Injury.
iance
to
be
performed only by qualified
Keep away from moving parts.
Keep
away from pinch
points such
as
drive rolls.
wtwam4.1
5-1.
2/93
Routine Maintenance
Turn Off all power before
3 Months
maintaining.
Replace
~
Cracked
Parts
14-Pin Cord
Gas Hose
Figure
5-1. Routine Maintenance
OM-141 322
Page
17
5-2.
Changing
Or
Cleaning
Gun Drive Roll
~
~
-,
I
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
Turn Off wire feeder, welding pow
er source, and robot. Remove gun
3
2
cover.
/ /
1
Tension Arm
~ J
Cut off wire at wire inlet
~ ~S
2
Setscrew
3
Drive Roll
Loosen setscrews
drive roll.
guide.
and
remove
Use wire brush to clean drive roll.
Install drive roll so that the groove
needed for the desired wire size is
down, and turn drive roll so one
setscrew faces flat side of shaft.
4
5
Drive Roll
Bearing
Liner
Line up drive roll groove with drive
roll bearing groove and liner open
ing. Tighten
If
setscrews.
drive roll in feeder, pro
ceed to Section 5-3.
changing
Thread welding wire through gun,
and adjust drive roll pressure, if
necessary (see Section 3-8).
Close and secure tension arm. Re
install gun cover.
4/\
Tools Needed:
5/16 in
ST-158 973-A
Figure
OM-141 322
Page
18
5-2.
Removing
Gun Drive Roll
5-3.
Changing
Feeder And
Auxiliary
Feeder Drive Roll And Wire Inlet Guide
READ SAFETY BLOCKS at start of
Sectio n 5 before proceeding.
Turn Off wire feeder, welding pow
er source, and robot.
Open gun tension arm, and cut wire
off at contact tip.
1
Tension Arm
2
Wire
Spool
For welding power sources without
contactor, retract wIre onto spool.
6
For
welding power
sources
with
a
contactor, energize power source,
turn On feeder, press Brake Re
lease button, and retract wire onto
spool.
4
Setscrew
5
Drive Roll
Use wire brush to clean drive roll.
Install drive roll with desired groove
in, and turn drive roll so one set
screw faces flat side of shaft.
2
6
Bearing
7
Wire Conduit
FItting
Line up drive roll groove with bear
ing groove and opening in conduit
fitting. Tighten setscrews.
8
8
Wire Inlet Guide
Loosen thumbscrew and pull guide
toward rear of feederto remove. In
stall new guide.
Thread welding wire and adjust
drive roll pressure, If necessary
(see Section 3-8). Close and se
cure tension arm. Close and latch
door.
Tools Needed:
~
5/16 in
z=~ ~:
Close gun tenslo n arm, and rein
stall gun cover.
Ref. ST-159 240- B/Ref. ST.151 781-A
Figure
5-4.
Replacing
Or
5-3.
Cleaning
Changing
Feeder Drive Roll Or Wire Inlet Guide
Gun Drive Roll
-~g~
I 7
Bearing
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
~
Turn Off wire feeder, welding pow
er source, and robot. Remove gun
cover.
1
Tension Arm
2
Washer
3
Drive Roll
4
Screw
Remove
Use
as
Bearing
shown.
wire brush to clean bearing.
Reinstall, and tighten screw.
Tools Needed:
a
Close tension
arm.
Reinstall gun
cover.
~
ST-158 974-A
Figure
5-4.
Removing
Gun Drive Roll
Bearing
OM-141 322
Page
19
5-5.
Replacing
Or
Cleaning
Feeder And
Auxiliary
Feeder Drive Roll
Bearing
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
Turn Off wire feeder, welding pow
er source, and robot.
1
Tension Arm
2
Retaining Ring
Assembly
3
Tension Arm
4
Hinge
5
Screw
6
Shoulder Washer
7
Drive Roll
Remove
Use
a
Pin
Bearing
shown.
as
wire brush to clean
Reinstall, and tighten
Close tension
door.
arm.
bearing.
screw.
Close and latch
Ref. ST-159 240-B/Ret. ST-151 781-A
Figure
5-6.
a
Replacing
Hub
5-5.
Replacing
Or
Cleaning
Feeder Drive Roll
Bearing
Assembly
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
Turn Off wire feeder, welding pow
er source, and robot.
gun tension arm, and cut
wire off at contact tip.
Open
For welding power sources without
contactor, retract wire onto spool.
For
welding
sources
power
with
a
contactor, energize power source,
turn On
feeder, press Brake Re
lease button, and retract wire onto
spool.
Take hub apart
1
as
shown.
Metal Brake Washer
2
Flat Washer
3
Brake Washer
4
Hub
Washer
5
Keyed
6
Spring
7
Cap Screw
8
Retaining Ring
broken or worn parts and
slide parts onto shaft as shown.
Replace
Tighten
cap screw all the
down. Thread welding wire
way
(see
Section 3-8). Close and latch door.
Close gun tension
stall gun cover.
arm
and rein
Ret. ST-159 240-B / Ref. ST-I 43 223-A
Figure
OM-141 322
Page
20
5-6. Hub
Assembly
5-7.
4A
Overload Protection
READ SAFETY BLOCKS at start of
Section 5 before proceeding.
WARNING
Turn Off wire feeder, welding pow
er source, and robot.
If Fl opens, the unit shuts down. To
check or change Fl, proceed as
follows:
3
1
Fuse Holder Cover
2
Fuse Fl
(See
Parts List For
Rating)
3
Circuit Breaker CB1
If CB1 opens, the gun drive motor
and contactor does not operate,
but gas flows when a weld program
is started. The gun drive motor op
erates in the Jog mode with CB1
open.
Check for blocked gun liner.
Check for jammed wire, binding
drive gear or misaligned drive rolls
in feeder. Correct problem.
Allow
reset
Push And Turn
cooling period and manually
breaker.
Close
and
latch
door.
Ref. ST-159 241-B I Ref. ST-80O 185.A
Figure
5-8.
5-7. Fuse Fl And Circuit Breaker CB1
Water Flow Switch
The water flow switch protects the gun from overheating. If coolant flow rate drops below 1 qt/min (0.9 LJmin), the water
flow switch opens and stops the welding wire from feeding. See Table 5-1 for remedies to this trouble.
OM-141 322
Page
21
5-9.
Troubleshooting
WARNING
a
ELECTRIC SHOCK
can
Do not touch live electrical
kill.
HOT PARTS
Allow
parts.
can cause severe
cooling period
before
burns.
servicing gun
or
unit.
Turn Off wire feeder, welding power source, and
robot, and disconnect input power before
inspecting, maintaining,
MOVING PARTS
or
servicing.
can cause
injury.
shooting
to be
performed only by qualified
Keep away from moving parts.
Keep
away from
pinch points
such
as
drive rolls.
wfwam4.1
2/93
Table 5-1. Wire Feeder Trouble
Trouble
Inching wire at robot Program Module
does not energize feeder. Welding wire
is not
energized. Shielding gas
Section
Remedy
i
-~
Check and
Interface.
connections between feeder and
Computer
--~
3-3
Computer Interface and
---
3-2
Check and replace fuse Fl.
-~
5-7
Check and correct water connections.
--~
secure
flows.
Check and
secure
welding power
Check and
connections between
source.
straighten
kinked water hoses. Be
sure
that
nothing
3-6C
--~
rests on water hoses that would restrict flow.
Turn
on
Have
water
Factory
supply.
--~
Authorized
Station/Service
Service
Distributor
--~
check water flow switch.
Wire feeds, shielding gas flows, but
welding wire is not energized.
~
-~
See welding power
Manual.
--~
--
--~
--
I
See
Wire feeds erratically.
Owners
source
Computer Interface Owners
Manual.
Place Motor Torque switch in proper position for wire size and
type.
-~
Check coolant level or have Factory Authorized Service Station/
Service Distributor check water flow switch.
Check and correct drive roll pressure.
Replace drive
Clean drive rolls and check
alignment.
5-2, 5-3
---~
5-2, 5-3
---~
Clean spatter from nozzle
---~
replace
contact tube.
3-8
--~
Clean gun liner and blow out wire conduit.
or
Replace drive roll bearing.
---
5-4, 5-5
Check and adjust hub brake tension.
--~
5-6
--~
3-5C
Check routing of wire conduit. Be
sure
that
nothing rests on conduit
that could restrict wire feed.
Check to be
OM-141 322
Page
22
4-6
--
-~
rolls.
Figure
sure
wire unwinds
freely
from
spool.
-0.
3-7
Trouble
Arc oscillates and welding wire is kinked
when it feeds out nozzle.
Remedy
~
I
-~
Section
Place Motor Torque switch in the proper position for wire size and
type.
_____________________________________________________
Check and correct drive roll pressure. Tension
tightened all the way down.
Check drive roll
Inching wire at robot Program Module
does not energize feeder. Welding wire
is energized. Shielding gas flows.
Shielding
gas coverage.
~
-~
screw
should be
1
-~
---~
Reset circuit breaker CB1.
---~
Clean
--~
replace
contact tube.
Replace
drive roll
Be
that gas pressure does not exceed 50
sure
bearing.
Table 3-1
---~
alignment.
or
I
J
--~
psi (345 kPa)
at
--~
regulator/f lowmeter.
Nozzle should be
Check
fittings
Change
torch
long enough
at gun and
angle.
to cover contact tube.
replace any necessary parts.
--~
--~
---~
OM-141 322
Page
23
SECTION 6- ELECTRICAL DIAGRAMS
!.)
o
o
C
Q~J~
C
I
)
X
..i
I
~~JUJ~
0
0
0
0
0
U
U.
2
C,
x
~i
I
C.)
U
C
SC-168 177
Figure
OM-141 322
Page
24
6-1. Circuit
Diagram
For Wire Feeder
Fl
RC6
BRAKE
BL~D(FL
I
-LOAD)
I
(I, a
U a, a, V a, I
0
0~ C)
Cu U,
RC2
C
>
B
>
I
I
/VHT
A~
2
CR/V
PCI
~
~
SLK
RCI
CR/V
:~~
BL
A
E<
~io
BL/(
SA-156 891
Figure
6-3. Circuit
Diagram
For
Auxiliary
Wire Feeder
I ISVAC
RETL~N
I ISVAC
TO FEStER
TO
WF
C~4O~
WF
C~w~C
WF
START
TADI
FEEDBAtX
~CT~ SENSE(-)
iCT~
SEAREI.)
FROM RtEOT
TO
INTERFAOE
ABCDE
IT
000000
/4356
7~2
SB-168 611
Figure
OM-141 322
Page
26
6-4. Circuit
Diagram
For XR-30R Panel
~J-~
I
cflI~I~4A;-
(PLGlO5)~~
LPLGIO6lL~
LI. .L~
I
j~CRI~~3A(INIEpFAC~ J~)
58(11-C)
L
Dl
PC2
238(IN1EPFAcE-2TA
26A(RCI8-D)
211
27A(RCI9-J)
6OA(INTER~AcE-GC S
55A(IN~FAcE-j~1~~1
IT
I 4C
PCI
(
>
48(F).))
1001
3~A~
8
36(RC 19-B)
3B(P11)
__________
22A(cRI-9)
~I~.Ac~PLc
3C(FLI)
GROUND
STUD
PLGIO/
RC I
( I)
~
420(cRI-5)
5A(RC7-B)
SB(~I-I3)
42C(PC 18-C)
II~
6A (PC 18-C)
6CIPCI9-LLI~
PLG8
B
0
76 (PC
7CIRCI8-J)
N
A
9-H)
I::~
I
iti ~t 61
l~~f~r4~1
HOl ~
4Z)P(,620- I)
I~
2
OPN(TIJ~
7fi(6I~4-Sl
42B(RCI9-D)
42A(Pt.GI-I)
3
I)
£Rtrsna..al
1~0~
4~E~
~]
4~L
~i~e.LowTI)
I
PLG2O/
RC2
PLA1~(I IT-f~I
1001
246(5dB-I) )
p
B
PLG9
42E( Il-F)
Afi
~
~L~1
13A(PL.GI-i
12A(PLGI -2)
PLG2
3A
RW(RC2O-J)
/
96
G
4
RCI9 K)
GPEENIGR~J~D SILO
(thcgY~\
PLGI I
Ifi fi ' ' )
\ ~ fi ' J
F
12A(PL62-21
/
E
78( II-E)
68(11-0)
WHIlE) ITA)
if~1
CN24
16A(RCI9-H)
610-4
ISA(PCI9-G)
46
LII
LAD)
WHI
69-
RC 18
A
c
~
-
9A(PLGI-3)
6C)IT-D)
~
r.Dsy(T.JtrDrsrc_
flIdfl
CrIflI
I4C( Il-A)
K
fi~
36)11-B)
~ SILO
PC 19
(L._~fi
\\&~.
(H)
fi
ii
I7Ah1T
~
428(11-F
~o
15A(cN24I)
I6A(D~4-2)
I
GROUND
STUD
28EN(GRc6R~STLO
I-..)
1/
fi ~ fi
\26(FLI
RC2O~f-''fifi1
~ fi ' JIA(FLI
GPNIPLG2O-7)
WHIIE/OLACKIPICI I-E)
LBL~PIGI
3C
II-
I-D
65N(PL620-8)
H H
L.~
BLK(~I
TI
____
SC-168 812
Figure
6-5.
Wiring Diagram
For XR-30R Panel
OM-141 322
Page
27
~.TS SEt&
EXT
_
~C
21~
INT
.39
TLFJ
JOG SWITCH
1 H
0(14 TRIO.
~
WOGTE/T0SWE I9TOG
:
OGEDOGLAY
Figure
OM-141 322
Page
28
6-6. Circuit
Diagram
For Wire Feeder Motor Control Board PCi
UII~SPEED
914 IN
19.0
WIRN9
WIPER
WIPER
TO 1ETER
I1U~fED
TO ItTEA
L t i~ t
T~T~T~
BYP~S CW~IT~
P~ER/C~)
lETS F~ OIIPS
R2
l..lSU,1l.~~
R4
4.*19J,1I.01
PS
UI
ISI5U,84lE
SD-142 056-B
OM-141 322
Page
29
XR-30R PANEL
(B- 57006-A)
<I
I
C~
~
()
w
C,)
0
0
0
0
0
~
I
r
x
c~
I
C~
1
m
0
I
PUSH/PULL
CONTROL BOX
(C-168177)
~
~
I
0
I
I
4
0
5
/6
6
acP/
II
/
CR
A
ABCOEF
IT
000000
/4J56
74~2
TO POWER SQJ~CE
Figure
OM-141 322
Page
30
6-7.
System Diagram
z
H
9
3
3d
PU
H
3
3
a
9
V
3
0
9
V
~
0
0 0 0 0 0 0
3
0
3
3
I
£
6
0 0
~, ,r
NO
£~
~ # ~ 0? 61 a
9
OP
9
0
0P0 oco
~
~OI3I
V
0 0
~t
9-t~13>)
_
~
L
~
OdYO9
60WIDO~(90LGI LO1d/I~O
0
r) m
~
C)
0
Cl, 9
0
-J
I) -D
II
V
P09 I,oV
18
a
U
.
v
3
a
I-~13>)
9
V
3d
H
1~
IP
+1su
-1St)
IAIA~
~ND ~ND
-isv
12
POWER/GROUND NETS FOR CHIPS
A
1415U
8=+ISU
SA-140 878
Figure
OM-141 322
Page 32
6-8. Circuit
Diagram
For Wire Feeder Motor
Reversing
Board PC2
NOTES
OM-141 322
Page
33
SECTION 7
PARTS LIST
c~J
I
N
0)
CD
N.
cJ
C~)
N
It)
CD
Figure
OM-141 322
Page
34
7-1. Control Box
ST.145 172-B
Item
No.
Part
No.
Dia.
Mkgs.
Description
Figure
169 165
3
4
6
7
8
9
10
11
12
1
1
1
1
1
x
1.250
Ig
1
602 233... WASHER, flat stl .250 ID x .875 OD x .O62thk
169895... SPRING, cprsn .480 OD x .045 wire x 1.500
1
113 168... WASHER, locking
058428... HUB,spool
2
058 628... WASHER, brake stl
010191
WASHER,fbr.656lDx1.5000Dx.l25thk
151 697... STRIP, brake surface anti-turn
1
SHROUD, spool wire 12 in
141 380... HOSE, water (consisting of)
141 382... HOSE, water (consisting of)
1
1
1
1
...
13
14
1
112 198...
15
15
010 607
FILTER, line pwr 115/250V 50-400Hz at 2A
1
CONNECTOR, clamp cable .500
CONNECTOR, circ 14 pin rcpt Amphenol MS-3102A-22-19P
CONNECTOR, circ l4skt plug Amphenol MS-3106A-22-19S
CONNECTOR, circ clamp str rlf sz 20-22 Amphenol MS-3057-1 012
CAPACITOR, polye film 2.3uf 25OVAC
2
030 170...
17
139 678...
18
057357...
047 838...
134 201
...
PC2...
140 675...
PLG8..
131 052...
113 746
035 759...
23
073 302...
24
113 161
25
113165...
...
120 396...
27....
MP1
....
28
FL1
29
....
113 899...
...
115 104...
30
....
RC5
....
140 839...
140 840...
116 964...
32
C9
114215...
605 741
33
34...
R35-38
PCi
PLG1
...
....
...
...
...
115 092... CONNECTOR &
...
3
3
2
1
4
1
1
16
1
2
1
4
1
1
1
1
1
8
core
115 094...
115 091
...
4
1
SOCKETS, (consisting of)
1
8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR,
113 746
PLG3
CLIP, mtg
resistor .312 ID
1
2ft
030 087... RESISTOR, WW fxd 25W 200 ohm
142 053... CIRCUIT CARD, motor speed control
113 746
PLG2
1
084 171
16
26
1
113 900...
134 834
T2....
1
FITTING, hose brs ferrule .425 ID x .718 Ig
HOSE, SAE .187 ID x .410 OD (order by ft)
BUSHING, snap-in nyl .750 ID x 1 .000mtg hole
FITTING, water
BUSHING, snap-in nyl .937 ID x 1.l25mtg hole
BLANK, snap-in nyl 1 .000mtg hole
STAND-OFF SUPPORT, PC card .3121.375
CIRCUIT CARD, motor reversing
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-lBga Molex 39-00-0038
TRANSFORMER, control mintr 115/36VCT
BEARING, ball rdl sgl row .669 x 1.378 x .39
BLOCK, bearing front
STAND-OFF, .250-20 x 1.000 Ig
SHAFT, spool
BRAKE, w/terminals
BLOCK, bearing rear
056 108
...22
1
FITTING, hose brs barbed nipple 3/l6tbg
FITTING, hose brs nut .625-18 LH
056 851
35
general precautionary
058 427... RING, retaining spool
605 276... BOLT, stl tap hexhd .250-20
5
31
7-1. Control Box
134327... LABEL, warning
126 415... CLAMP, saddle
126416... HANDLE, chest
+113 569... WRAPPER
1
2
Quantity
rect skt 24-i
8
1
4
1
CONNECTOR, red skt 24-l8ga Molex 39-00-0038
083 147... GROMMET, scr No 8/10 panel hole .312sq .500 high
113 746
36
37.... SN1,2
iT
38
39
Ci4
40
4T
CB1
S4
41
42
...
10
4
110158... SNUBBER
2
BLOCK, term 20A 12P
601 219... LINK, jumper term blk 20A
044 602... CAPACITOR, polye film .47uf 400VDC
3
1
038 783...
....
....
038 785... STRIP, term 3P
011 002... CIRCUIT BREAKER,
011 232... SWITCH, PB SPDT
1
1
man
reset 1P .7A 25OVAC
1
1
OM141
322
Page
35
Item
No.
Dia.
Part
No.
Mkgs.
Description
169 165
43
Ti
44
.
.
.
Figure
46
iii 152
.
.
090 465
.
.
2
.
.
2
.
.
.
47
010 910
.
.
48
117498
.
.
49
117 496
.
.
50
605 970
.
.
51
090 439
.
.
52
089 573
.
.
53
113 166
.
.
S2
56.... RC6
...
.
011 609
.
.
..
.
.
120 400
.
.
.
.
.
035 523
.
.
039 273
.
.
039 685
.
.
+157 070
.
.
57
58
59....
PL1
..
074 188
.
.
.
.
.
112 167
.
.
113 565
.
.
165 678
.
.
089 120
.
.
7-2
.
.
141 251
.
.
010 493
.
.
*012 663
.
.
046 432
.
.
60
089 572
61
62
S8
63
.
.
.
.
64
65
Fig
S7
66
.
.
.
.
67
Fl
68
...
69
+When
ordering
*Recommended
a
2
WASHER, fbr .312 ID x .750 OD x .O62thk
WASHER, shldr nyl .310 OD x .252 ID x .064
LABEL, warning electric shock can kill
PLATE, keeper link-lock
INSULATOR, term
SWITCH, tgl SPDT i5A 125VAC
SWITCH, tgl 3PDT MC 15A 125 VAC
CONNECTOR, circ 5skt rcpt Amphenol MS-3102A-16S-8S
CONNECTOR, circ 5 pin plug Amphenol MS-3106A-16S-8P
CONNECTOR, circ clamp str rlf sz 16-16S Amphenol 97-3057-8
CABINET, control
NAMEPLATE, (order by model and serial number)
2
2
1
Page
36
3
1
2
1
1
1
1
1
1
LIGHT, md red lens
CATCH, link-lock
INSULATOR, door
2
DOOR, right side
SWITCH, flow w/fittings
CLAMP, hose .375-.450c1p dia slfttng
1
2
MOTOR & WIRE DRIVE
1
SWITCH, tgl DPIT iSA 125VAC
BUSHING, snap-in nyl .625 ID x .875mtg hole
FUSE, mintr gI slo-blo 3A 125V
1
HOLDER, fuse mintr
1
a
precautionary label,
1
1
1
the label should also be ordered.
Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-141 322
1
NUT, sti hex full .375-i6
WASHER, flat stl SAE .375
TERMINAL, power weld
component originally displaying
Spare
1
1
.
.
55
2
.
601 872
Si
(Continued)
SKID, base
TRANSFORMER, signal 115V 24VCT 4A
079240.. SCREW, .375-16x1.750hexhd
075 150
WASHER, shldr nyl 1.000 OD x .375 ID
602 213
WASHER, lock stl split .375
151 542
WASHER, flat sti std .438
.
45
54
7-1. Control Box
Quantity
1
1
Item
No.
.
.
.
.
.
.
.
.
Part
No.
Dia.
Mkgs.
1
2
3
4
5
6
7
8
9
9
10
11
12
13
13
14
7-2. Tach Drive!Motor & Wire Drive
+141 616... DRIVE
ASSEMBLY, tach/wire (consisting of)
17
18
19
19
20
..
..
Ml
Quantity
Figure
15
16
20
21
22
23
Description
...
(Fig
7-1 Item 65 &
FIg
7-5 Item
9)
1
167 664 SCREW, tension adjustment
167676 SPRING, cprsn .48000 x .045 wire x .625
058 968 RING, rtng ext .125 shaft grv x .O25thk E style
167 663 ARM, tension
605798 WASHER, shldr nyl .375 00 x .168 ID x .O8Othk
112 887 PIN, hinge
058 409 BEARING, drive roll
054 263 SCREW, .250-20 x .500 winghd stl (wire drive assembly)
054 263.... SCREW, .250-20 x .500 winghd stl (tach drive assembly)
147 627.... COVER, gear wire drive
602306.... PIN,spnngCS.125x.500
008 667.... BEARING, ball rdl dbl row .250 x .687 x .31
113 170.... GEAR & SHAFT~ motor (wire drive assembly)
168 174.... SHAFT, encoder (tach drive assembly)
147624.... CASE, gear wire drive
120398.... ROLL, drive V groove .030-1/16 wire (consisting of)
604 612
SCREW, set 8-32 x .125 cup pt sch sti
147 625.... BLOCK, anchor conduit
000364.... RING, rtng ext .145 shaft grv x .O25thk E style
605 971
WASHER, shldr nyl .187 ID (wire drive assembly)
605 971
WASHER, shldr nyl .187 ID (tach drive assembly)
113 162... INSULATOR, motor (wire drive assembly)
170 366... INSULATOR, motor (tach drive assembly)
113 178... MOTOR, torque 115VAC
113 169... GEAR, driver
604 612... SCREW, set 8-32 x .125 CU~ pt sch sti
157711
GUIDE, wire
1
1
1
1
2
1
1
2
1
1
2
2
1
1
1
1
2
1
1
...
3
...
2
1
1
1
1
3
1
...
14
17
includes Items 14 thru 18
22
ST-114 188-H
+When
ordering
this
assembly,
be
Figure
7-2. Tach Drive/Motor & Wire Drive
sure to
specify
which shaft
(Item
No.
13)
is needed.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-141 322
Page
37
Item
No.
Dia.
Mkgs.
Part
No.
157 002
Figure
134464
141 667
157003
047 544
039828
....RC18.
7-3. Interface
Control, Push/Pull
COVER, (used with 1 option)
COVER, (used with 2 options)
LABEL, warning general precautionary
NAMEPLATE, (order by model and serial number)
CASE SECTION, front/bottom
RECEPTACLE, w/components
CONNECTOR, circ 4 pin plug Amphenol MS-3106A-14S-2SX
CONNECTOR, circ clamp str rlf sz 14 Amphenol AN-3057-6
CONNECTOR, circ l0skt rcpt MS-3102A-18-1S
CONNECTOR, circ 10 pin plug Amphenol MS-3106A-18-1P
CONNECTOR, circ clamp str rlf sz 18 Amphenol AN-3057-10
+139465
+140 125
RC7,PC1
Quantity
Description
039718
039716
073 332
1
1
1
1
1
1
1
2
14
4
11
20
~%
.%
28
27
23
26
22
25
STS-145 358-B
Figure
OM-141 322
Page
38
7-3. Interface Control, Push/Pull
Item
No.
Part
No.
Dia.
Mkgs.
157 002
..7....RC19... 073 973
073 982
116 964
..8....RC2O...
152 492
134731
143 426
079 534
079 739
143 922
iT....
.9
038 772
10
157 008
11
134201
027811
12
.13...CR1.... 095521
079 844
14
.15....D1....
026 202
16
17
049 970
18
141 666
048 029
.19...PC2....
168 189
131 056
PLG1O
113 746
PLG2O...
115091
113 746
20
141 449
21
157 007
22
...FL1...
084 171
23
139041
24
110015
116 964
25
26
27
094 482
PLG11
PLG9
039716
28
073331
29
049 455
139 040
30
31
PLG8
047 544
.
039 828
32
007 826
33
34
074 188
PL1
PLG1
115094
113 746
PLG2...
115 090
CN24...
114 656
165 885
125 748
+When
ordering
a
Quantity
Description
Figure
7-3. Interface
Control, Push/Pull (Continued)
CONNECTOR, l4skt rcpt MS-3102A-22-19S
CONNECTOR, circ 14 pin plug Amphenol MS-3106A-22-19P
CONNECTOR, circ clamp str rlf sz 20-22Amphenol MS-3057-1012
CONNECTOR w/PINS, (consisting of)
CONNECTOR, circ pin push-in 14-l8ga Amp 213603-1
CONNECTOR, circ l4skt plug Amp 213652-1
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 (or)
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3
BLOCK, term 20A 6P
BRACKET, mtg PC card
STAND-OFF SUPPORT, PC card .312/.375
SOCKET, relay 14 pin
RELAY,
end
24VDC 4PDT
1
1
14
1
1
4
1
1
SPRING, hold down relay
DIODE, rect 1A 400V SP
BRACKET, mtg relay
CLIP, retaining socket relay
PANEL, rear
1
CIRCUIT CARD, tach feedback
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-1 Bga Molex 39-00-0038
1
1
1
1
1
1
14
1
10
PANEL, side
TRANSFORMER, control
FILTER, line pwr 115/250V 50-400Hz at 2A
BUSHING, strain relief .455/.629 ID x 1.ll5mtg hole
CABLE, port No. 18 7/c (order by ft)
CONNECTOR, circ clamp str rlf sz 20-22 Amphenol 97-3057-1012
CONNECTOR, circ l4skt plug Amphenol MS-3106A-20-27S
CONNECTOR, circ 10 pin plug Amphenol MS-3106A-18-1P
CONNECTOR, circ clamp str rlf Amphenol 97-3057-10-6
CABLE, port No. 18 2/c (order by ft)
BUSHING, strain relief .231/.394 ID x .733mtg hole
CONNECTOR, circ 4 pin plug Amphenol MS-3106A-14S-2SX
CONNECTOR, circ clamp str rlf sz 18 Amphenol AN-3057-6
CABLE, port No. 18 3/c (order by ft)
LIGHT, md red lens
CONNECTOR & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
CONNECTOR & PINS, (consisting of)
CONNECTOR, rect pin 24-1 8ga Molex 39-00-0040
CONNECTOR & SOCKETS, (consisting of)
a
precautionary label,
1
I
1
4ft
1
1
1
1
3ft
2
1
1
3ft
1
1
4
1
4
1
CONNECTOR, rectskt22-18gaJSTSVH-21T-1.1
component originally displaying
1
5
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-141 322
Page
39
17
26 27
23
21
37
38
20
39
40
41
42
44
64
For MRV Model
47
58
48
52
Figure 7-4. Gun, XR-30R
(MRH Modet
OM~141322 Page4o
ST-158 904-B
Illustrated)
Quantity
Item
No.
Part
No.
Model
Description
Figure
..
..
..
..
..
1
1
1
1
2
..
3
3
3
3
3
3
4
5
6
..
7
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
8
9
10
11
11
12
13
..
13
14
14
15
16
..
17
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
.
.
.
.
.
.
135877
142 641
.
.
.
144 077
.
.
.
.
.
.
144 076
135 878
.
.
.
.
.
.
.
.
7-4.
Gun, XR-30R
NOZZLE
NOZZLE, .500 ID
water cooled
x
.
NOZZLE, .500 ID
NOZZLE, .625 ID
.
SPATTER SHIELD
x
3.1
3.1
Ig
Ig
I
MRH
dry
water cooled
water cooled
dry
dry
MRV
157703
159792
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
..
+108 788
.
.
..
+108 789
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
CONTACT TIP, (Q0.8)
CONTACT TIP, (Q0.9)
CONTACT TIP, (Q1.0)
CONTACT TIP, (Q1.2)
CONTACT TIP, (Q1.6)
CONTACT TIP, (.045 wire)
GAS DIFFUSER, M6 x 16G tip
PRESSURE RING
NOZZLE HOUSING ASSEMBLY
.
.
0-RING
1
1
CONDUCTOR TUBE w/INSULATORS
1
CLAMP,hose
HOSE, SAE .187 ID x .410 OD (order by if)
FITTING, hose brs barbed nipple 3/l6tbg
FITTING, hose brs nut .625-18 LH
FITTING, hose brs ferrule .425 ID x .718 Ig
BRACKET, mtg torch
2
1
2
..
..
..
..
..
.
.
.
.
.
.
.
.
.
.
.
.
.
...
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
..
.
.
.
.
.
.
.
+108
+108
+108
+113
131
135
140
792
786
790
954
921
879
670
135880
135882
082368..
134 834
056 851
010 607
056 108
161 105
141 281
141 220
141 223
141 222.
162 358
140 983
112 727
000 364
058 420
089 120
134 834
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
18
19
20
143 836
21
168 162
22... 112887
23
058 968
24
141 282
24
156 386
25... 112886..
26
115 843
27
112 888
28... 134799..
29..
143997
29..
141 283
29..
161 772
30..
167663
31
167 676
32
167 664
33
605 798
34
058 409
35
604 612
162 357
36
141 594
36
37
140 988
38
140 989
141 337
39
40
140 984
40
156 385
41
168 328
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
..
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
..
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
..
.
.
.
.
.
.
.
.
HEAT SHIELD
BARREL, torch
LINER, teflon .045-.062 wire x 6.562
LINER, teflon .030-.035 wire x 6.562
CASE, RH side
CASE, right side
COVER, drive roll
RING,rtg ext .145 shaft grv x .O2Sthk E style
THUMB SCREW, knurled .250-20 UNC-2B
CLAMP, hose .375-.45Oclp dia slfttng
HOSE, SAE .187 ID x .410 OD (order by if)
SPRING, cprsn .445 OD x .023 wire x .370 Ig
ROLL, drive VK groove .030-1/16 wire
PIN, hinge
RING, ring ext .125 shaft grv
HOUSING, wire drive
HOUSING, wire drive
x
.O25thk E
style
As
1
1
1
1
1
1
1
1
1
Reqd
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
9ft
....
2
1
1
7ft
1
1
1
I
1
1
1
1
1
1
FITTING,gas
1
1
1
SCREW, retaining liner
0-RING, .176lDx.O7OCS
CONDUITw/FITTING, 80 in
CONDUITw/FITTING, 68 in
CONDUIT w/FITTING, lOft
ARM, tension
1
1
1
1
SPRING, cprsn .480 OD x .045 wire x .625
SCREW, tension adjustment
WASHER, shldr nyl .375 OD x .168 ID x .O8Othk
BEARING, drive roll
SCREW, 8-32 x .125 cup pt sch stl
CASE, LH side
CASE, LH side
PLUG, nylon No. 1
PLUG, nylon No. 2
CAP, vinyl 1.500 ID x .065 wall x 1.187 deep
BRACKET, mtg unit
BRACKET, mtg unit
BLOCK, bearing
1
SCREW, set 10-24
x
.312 cup
pt sch stl
1
1
1
1
1
1
1
1
2
1
2
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
OM-141 322
1
Page
41
Quantity
Item
No.
Model
Part
No.
Figure
42.... 168 161
...
7-4.
I
Description
MRH
Gun, XR-30R (Continued)
157 703
159 792
1
1
1
1
2
1
2
MOTOR, w/terminals (consisting of)
135 635.... CONNECTOR & PINS, (consisting of)
114 656
CONNECTOR, rect pin 24-lBga Molex 39-00-0040
43.... 157 708
CABLE, shock sensor (consisting of)
...
43.... 159 899
CABLE, shock sensor (consisting of)
157 704.... CABLE, control
165 971
CONNECTOR & PINS, (consisting
MRV
1
1
...
of)
pin 20-l4ga JST SLM-61T-2.0
CONNECTOR & PINS, (consisting of)
CONNECTOR, circ pin push-in 14-l8ga Amp 66359-6
CONNECTOR, circ clamp str rlf sz 11 Amp 206358-2
CLAMP, strap rbr 5 holes .375 wide x 4.625 Ig
....
CONNECTOR,
126 084
079 878....
079 535
rect
079 531
073 476
45.... 143 991
COVER, cable 25ff
45.... 141 429
COVER, cable 25ff
46.... 133 859
CABLE, shield No. l8ga 1/c (order by ft)
47.... 157 049
CABLE, feedback motor (consisting of)
47.... 159 651
CABLE, feedback motor (consisting of)
047 636.... CONNECTOR & PINS, (consisting of)
079 535
CONNECTOR, circ pin push-in 14-lBga Amp 66359-6
079 739.... CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2
134858.... CONNECTOR & PINS, (consisting of)
134 184
CONNECTOR, rect pin 20-l6ga JST SLM-41T-1 .3E
604 525.... CABLE, port No. 18 2/c (order by ft)
131 054.... CONNECTOR & SOCKETS, (consisting of)
113 746
CONNECTOR, rect skt 24-l8ga Molex 39-00-0038
007 826
CABLE, port No. 18 3/c (order by if)
039 828
CONNECTOR, circ clamp str rlf sz 14-14S Amphenol AN-3057-6
052 236.... CONNECTOR, circ 3 pin plug Amphenol MS-3106A-14S-1 P
48
056 851
FITTING, hose brs barbed nipple 3/l6tbg
49
010 606... FITTING, hose brs nut .625-18RH
056 108... FITTING, hose brs ferrule .425 ID x .718 Ig
50
1
1
2
1
4
....
1
36
....
6ff
....
44
.
.
.
.
...
...
36
1
1
...
...
...
8ff
1
1
...
....
....
.
.
.
.
.
.
.
.
.
.
.
.
...
141 431
CONDUITw/FITTING,2Oft
52.... 141 068... CABLE, extension (consisting of)
53
097 994.... CONNECTOR, circ Sskt plug Amphenol MS-3106A-16S-8S
54
039 685.... CONNECTOR, circ clamp str rlf sz 16-16S Amphenol AN-3057-8
600 343.... CABLE, port No. 16 5/c (order by if)
55
039273.... CONNECTOR, circ 5 pin plug Amphenol MS-3106A-16S-8P
56
57.... 143 992... HOSE, water (consisting of)
57.... 142 183... HOSE, water (consisting of)
056 851
FITTING, hose brs barbed nipple 3/l6tbg
51
....
...
1
14
1
1
8ff
1
2
2ff
1
1
1
1
.
.
.
.
2
.
.
.
.
.
.
.
.
...
...
.
...60....157193...INSULATOR,shocksensor
61
158 279
MOUNT, safety robot heavy duty
156 682... BLOCK, clamp mtg torch
62.... 156 383... CLAMP, torch mount
602 177
63
SCREW, set .250-20 x .25Oknrl pt sch stl
64.... 156 683... BLOCK, mtg torch
161 085... BRACKET, mtg gun
64
140 982
65
NUT, brs hex .750-16
140 985
66
COUPLER, bolt
...
....
..
.
1
1
1
1
2
1
.
....
1
1
1
.
20ff.... 20ff
1
1
2
2
2
2
2
2
2
2
8ff
7ff
2
2
53ff.... 53ff
....
1
1
1
1
1
1
1
1
1
...
.
1
1
....
67
....
...
....
...
....
131 926
...
CONDUCTOR TUBE/BLOCK INSULATOR
1
1
1
1
1
1
+See Table 3-1 for recommended gun parts for wire size.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-141 322 Page 42
2ff
1
1
1
.
....
2
....
1
.
010 607.... FITTING, hose brs nut .625-18 LH
056 108.... FITTING, hose brs ferrule .425 ID x .718 Ig
134834
HOSE,SAE.l87lDx.4100D(orderbyft)
057 020... FITTING, hose brs coupler .625-18 LH/.625-18 LH
600 320
58
CABLE, weld cop strd No. 1 (order by if)
59.... 156 886... BRACKET, mtg shock sensor
59.... 156 384... BAR, mounting torch
....
6
7ff
1
Item
No
Part
No.
Dia.
Mkgs.
Description
7-5.
Quantity
168 367
Figure
1
602 358...
FASTENER,
2
010 855... RETAINER, screw No. 12
168 506... COVER, tach drive assembly
114215... CAPACITOR, polye film 2.3uf 25OVAC
006 019... CONNECTOR, circ 5 pin rcpt Amphenol MS-3102A-16S-8P
097 994... CONNECTOR, circ 5skt plug Amphenol MS-3106A-165-8S
039 685... CONNECTOR, circ clamp str nt sz 16-16S Amphenol 93-3057-8
073383... CONNECTOR, circ 3skt rcpt Amphenol MS-3102A-14S-O1S
052236... CONNECTOR, circ 3 pin plug Amphenol MS-3106A-14S-1P
039 828... CONNECTOR, circ clamp str rlf sz 14-14S Amphenol AN-3057-6
3
4
Gb
....
5
....
RC2
....
6
....
RC3
...
.
7
072253...
8
168 171
9
Fig
10
...
Auxiliary Motor, Push/Pull
screw
knrl hd No. 12
STUD, connection single 10-32
COVER, auxiliary box
x
1
.500
x
1
1
1
1
1
1
1.2SOmtg
1
7-2... TACH DRIVE
144 058...
BRACKET,
1
2
motor mount
11
110 733... OPTICAL ENCODER DISC
1
12
168 173... BRACKET, mtg encoder
115 440... STAND-OFF, 6-32 x .687
2
13
14
PCi
....
157 171
...
1
Ig
CIRCUIT CARD, tachometer
123 314... WASHER, shldr nyi .687 OD
Fig 7-2... MOTOR & WIRE DRIVE
15
16
1
x
.266 ID
x
.359dia shldr
2
1
Fig
7-2
10
15
120
22
19
181
17
21
22
*
Includes Item 21
ST-800 773
Figure
7-5.
Auxiliary Motor,
Push/Pull
OM-141 322 Page 43
Item
No.
Dia.
Part
No.
Mkgs.
Figure
168 367
134 171
17
18.... PLG1
...
134 860
...
134184
19
20
21
....
RC1
604
010
048
079
....
571
116
282
534
079 532...
079 535...
079 531
22.... PL1 ,2
...
117 160...
...
23
24
*115 276
144 629...
25
168479...
26
605 670...
168 476...
136 673...
*Recommended
Spare
Quantity
Description
7-5.
Auxiliary Motor, Push/Pull (Continued)
CABLE, shock
sensor & lights (consisting
CONNECTOR & PINS, (consisting of)
of)
CONNECTOR, rectpin2o-16gaJSTSLM-41T-1.3E
CABLE, port No. 184/c (order by ft)
GROMMET, rbr .375 ID x .500mtg hole
CONNECTOR w/SOCKETS, (consisting of)
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
CONNECTOR, circ 4 pin plug Amp 211882-1
CONNECTOR, circ pin push-in 14-l8ga Amp 66359-6
CONNECTOR, circ clamp str nt sz 11 Amp 206358-2
PILOT LAMP, (consisting of)
BULB, LED red 28V mm bayonet
BRACKET, shock sensor & lights
BRACKET, motor
NUT, 12-24 speed stl
ANGLE, mtg auxiliary box (MRH model only)
PLUG, insulating .568hex x .22Othk
Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-141 322
Page
44
1
1
4
ift
1
1
4
2
1
1
1
1
1
2
Quantity
Model
Part
No.
Description
Miscellaneous
,140
855
073 982
116964
096813
140840
.109293
.026202
.126083
.010296
.056423
010603
010606
CABLE, interconnecting (Interface Panel to Control Box) (consisting of)
CONNECTOR, circ 14 pin plug Amphenol MS-3106A-22-19P
CONNECTOR, circ clamp str nt sz 20-22 Amphenol MS-3057-1012
CABLE, pwr shld No. lBga 15/c (order by ft)
CONNECTOR, circ l4skt plug Amphenol MS-3106A-22-19S
VALVE, 24VDC 2 way 1/4 IPS port 1/8 orf (back of Robot)
DIODE, rect 1A 400V SP (attached to valve)
FITTING, pipe brs nipple hex 1/4NPT x 1/4-19 PSP (attached to valve)
FITTING, hose brs elbow M l/4NPT x .625-18RH (attached to valve)
HOSE ASSEMBLY, gas (attached to valve) (consisting of)
FITTING, hose brs barbed nipple 1/4tbg
FITTING, hose brs nut .625-18RH
FITTING, hose brs ferrule .475 ID
051 297
ADAPTER
+126112
+135165
.127813
,134
011
,123
314
,133
879
+071 892
079 534
+079 739
.604525
+605 156
.166075
126084
.127
854
,089
256
,158
278
,157
194
,134
518
,134
529
,,159 765
,,143 352
,,159 604
,,149 109
,,157 173
,157
175
x
.718
Ig
.170
BAR, extension
322
,159
605
,159
599
907
MRV
Components included with Factory Kit only.
. .Components are common to the Factory Kit
1
1
1
2
2
loft lOft
1
1
1
1
1
1
1
2
2
2
1
,,159 731
173
,600
1
33ft
HOSE, nprn brd No. 1 x .250 ID (order by ft)
1
FITTING, hose brs bushing 1/4BSP x .625-I8RH (attached to valve)
1
BRACKET, support motor (supports Aux. Motor box)
1
BRACE, (supports motor support bracket)
INSULATOR, bracket motor (under shock sensor & light bracket)
WASHER, shldr nyl .687 OD x .266 ID x .359dia shldr (helps insulate
Aux. Motor box support bracket)
2
1
PLATE, ident (order by model and serial number) (on Robot pedestal)
CONNECTOR w/SOCKETS, (back LH side of Robot) (consisting of)
1
14
CONNECTOR, circ skt push-in 14-l8ga Amp 66358-6
CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2 (goes w/connector)... 1
2ft
CABLE, port No. 18 2/c (order by ft) (goes w/connector)
2ft
CABLE, port No. 18 4/c (order by ft) (goes w/connector)
CONNECTOR & PINS, (consisting of) (back LH side of Robot)
1
4
CONNECTOR, rect pin 20-l4ga JST SLM-61T-2.0
4
CLAMP, stl cush 1.3l2dia x .343mtg hole (back LH side of Robot)
2
CLAMP, stl cush 1 .750d1a x .531 mtg hole (under Aux Motor box)
TOOL BALANCER, 5 lb (for hanging cable)
1
1
RING, split stl 1.062 ID x 1.250 OD x .l3Othk (for hanging tool balancer)
HANGER, cable assembly (holds tool balancer)
INSULATOR, cable hanger
STRIP, nprn .125 x 4.000 x 6.000 (goes w/tool balancer)
4
CLAMP, cable (for hanging cable)
CLAMP, cable (for hanging cable)
INSULATOR, cable restraint
1
HOLDER, cable (mounted on back of Robot)
2
COLLAR, stop (located on cable hanger bar)
SCREW, set 10-32 x .250 cup pt sch stl (used w/stop collar)
CABLE, weld cop strd No. 2/0 (grd cable) (order by ft)
STRIP, nprn .125 x 9.500 x 26.000 (cushions gun assembly)
SUPPORT, cable (on back of Robot top)
STRAIN RELIEF, cable (on base of Robot)
,602
I
Components
056112
603106
MRH
1
8
1
3
2
2
1
1
2
1
1
4
15ft
1
2
1
1
1
and the Field Kit.
OM.141 322
Page
45
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