Miller ROBOTIC INTERFACE CONTROL Assembly & Owner's Manual

Miller
October 1992
FORM: OM-154 145
Effective With Serial No. KC304685
MODEL:
Robotic Interface Control
Gas/Current
Sensing Control
Spool Support Assembly
OWNERS
MANUAL
IMPORTANT: Read and understand the entire contents of both this manual
and the power source manual used with this unit, with special emphasis on
the safety material throughout both manuals, before installing, operating, or
maintaining this equipment. This unit and these instructions are for use only
by persons trained and experienced In the safe operation of welding equip-
MILLER ELECTRIC
A Miller
Mfg. Co.
Group Ltd.. Company
P.O. Box 1079
Appleton,
WI
54912 USA
Tel. 414-734-9821
ment. Do not allow untrained persons to install, operate, or maintain this unit.
Contact your distributor if you do not fully understand these instructions.
Ref. ST-157 095
PRINTED IN U S.A
I
I
~~1
5*
TRUE BLUETM LIMITED WARRANTY
MILLERS
Effective January 1, 1992
serial number preface of
XC
(Equipment wlth.a
This limited warranty supersedes all previous MILLER warranties and
Sublect
LIMITED WARRANTY
MIg Co
.
fects
to the terms and conditions below.
Wisconsin. warrants to its
dooleton
MILLER equoment sold after
exclusive with
other guarantees
rro
or
warranties expressed
or
implied
Accessory Kits
MILLER Electric
retail purchaser that new
Reolscement Psr.o
the effective date of this limited warranty is freest de
material and workmanship
in
original
is
newer)
or
at the time it is
shipped by MILLER THIS WAR
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR
IMPLIED. INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
MILLERS
True
BluarM
Limited Warranty shall not aoolb to,
by MILLER. but manufactured by others. such as engines or
accessories These items are covered by the manufacturers
warranty, if
Items lurnished
NESS
trade
Within the warranty periods listed below. MILLER wilt repair or replace any war
ranted pans or components that tail due to such defects in material or workmanship
MILLER must be notilied in writing within thirty (30) days of such detect or failure, at
any
Consumable componm3ls: such
2
and
which lime MILLER will provide instructions on the warranty claim procedures to be
as contact
tips,
cutting nozzles, confactors
relays
followed.
Eguipmenl
3,
ment that
MILLER shall honor warranty claims on warranted equipment listed below in the
event of such a failure within the warranty time periods. AtI warranty time periods
start on the date that the equipment was delivered to the
original
retail
based upon
industry standards,
outside of the
5 Years Psrts
-
Original
power rectifiers
In
Plasma Arc
Cutting
a warranty claim covered by this warranty, the exclusive remedies
MILLERS option tI repsir, or (21 replacement, or, where authorized in
at
writing by MILLER
Power Sources
ment stan
in
appropnsfe
Robots
goods
Driven Welding Generators
INOTE. Engines are warranted separately by the engine manufacturer I
Engine
Load Banks
Running Gesr/Trsilers
Field Options
(NOTE. Field options are covered under True Blue
warranty period of the product they are installed in,
whichever is grealer.I
one year
tor the
or
for
remaining
a minimum of
or
reimburse
MIG GunsiTIG
Some slates in the U.S.A. do not allow limitations of how long an implIed warranty
lasts, or the exclusion of incidental, indirect, special or consequential damages, so
the above limitation or esclusion may nol apply to you. This warranty provides spe
cihc
Batteries
legal rights,
and other
Canada. legislation in
rights may be availasle, but may vary from
state to state.
provinces provides to, certain additional warranties
or remedies other Ihan as stated herein, and to the extent that they may not be
waived, the limitations and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other righls may be available. buf may
vary from province to province.
In
Parts and Labor
Plasma
risk and expense. MILLERS
oplion of repair or repfacemenf
at Appleton. Wisconsin. or F 0.8. at a MILLER authorized ser.
determined
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALINO. IN
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS
FOR PARTICULAR PURPOSE. WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
SDX Transformers
*
as
RANT?, 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.
Spot Welders
Days
facility
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
Grids
90
of iepair or replace
or credit for the pur
DAMAGES IINCLUDf NO LOSS OF PROFIT), WHETHER BASED ON CON
TRACt TORT OR ANY OTHER LEGAL THEORY
Systems
HF Units
6 Months
cost
~( payment of
upon actual usel upon return of the
ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECt INDIRECT. SPECIAL, INCIDENTAL OR CONSEOUENTfAL
Process Controllers
5.
Factory
or
TO THE EX7ENT PERMITTED BY LAW, THE REMEDIES PROVtDED HEREIN
Parts and Labor
Motor Driven Guns
6.
13) the reasonable
deprecialion based
by MILLER Therefore no compensation
ment for transportation costs of any kind will be allowed,
vice
Water Coolant
at customers
will be F 0.8
Parts and Labor
2 Years
cases.
authorized MtLLER service station,
chase price Itess reasonable
Year
hss been used for operation
the event of
shall be.
Semi-Automatic and Automatic Wire Feeders
t
eguioment which has not had reasonable
the eouiomenl
THE USE AND MAINTENANCE OF WELDING EGUIPMENT
TrsnslormerlRectiher Power Sources
d.
or
equipment which
Parts and Labor
3 Years
3.
or
specifications for
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
CIAUJINDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
3 Years Labor
main
by any party other than MILLER, or equip
improperly installed, improperly operated or misused
and necessary maintenance,
purchaser.
and are as follows
2
th5t has been modified
has been
Torches
Cutting Torches
Remote Controls
some
1.
i,t
RECEIVING-HANDLING
unpacking equipment, Check carton for any damage that may haVB occurrBd during shipment. File any claims for loss or damage
delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
Before
with the
When
requesting information about this equipment, always provide Model Designation
Use the
or
following
spaces to record Model
Designation
and Serial or
and Serial
Style Number of your unit. The
or
Style
Number.
information is located
on
the
rating
label
nameplate.
Model
_________
Serial
or
Style
No.
Date of Purchase
miller 5192
Deember
FORM: OM-154 145
2, 1992
ERRATA SHEET
After this manual
to data
was
appearing
printed,
refinements in equipment design occurred. This sheet lists exceptions
later In this manual.
AMENDMENT TO SECTION 3INSTALLATION
Amend
Figure
3-2. DVC DIP Switch
Setting
Label
DVC SWITCH SETTINGS
S2
1
Si
2
DELTAWELD 300
3
ON
ON
ON
ON
DELTAWELD 451
0
ON
DELTAWELD 651
0
ON
XMT 200/300
ON
ON
ON
ARC PAK35O
ON
ON
ON
ON
ON
O
On For
A
On For
AMENDMENT TO SECTION 8
8-1. Circuit
Optional Soft Start.
Optional Hot Start.
Turn Off Si -3.
S.150 864~B
3-2. DVC DIP Switch
Amend
Diagram 8-3. Circuit Diagram For
Amend
Diagram
Diagram
Diagram
Interface Board PCi (see
For DVC Board PC8
Diagram
Wiring Diagram
For Robotic Interface Control
Diagram
8-17.
Wiring Diagram
For Gas/Current
Diagram
8-18.
Wiring Diagram
For
Mkgs.
4749-7
494949-25
~First
follows:
Part
..
PC8
..
this Errata
6 and 7 on this Errata
(see Pages
Control (see
8 and 9
Page
on
Sheet)
Sheet)
Sheet)
this Errata
Sheet)
10 on this Errata
ii on this
Sheet)
Errata Sheet)
Replaced
Added
083147
070 371
Deleted
115 092
115 093
152 371
148320
on
PARTS LIST
With
115093
Sensing
2 and 3
4 and 5 on this Errata
Pages
Optional RCSP-R Panel (see Page
No.
115092
Label
(see Pages
(see Pages
8-16.
as
Setting
For Robotic Interface Control
Diagram
AMENDMENT TO SECTION 9
ON
A
ELECTRICAL DIAGRAMS
Amend
8-4. Circuit
ON
ON
ON
Figure
Dia.
ON
ON
PULSTAR 450
Amend Parts List
ON
ON
DIMENSION 400
Add
ON
MAXTRON 450
SHOPMASTER 300
Add
5
ON
MAXTRON 300, 400
Add
4
2
1
Description
.
.
.
.
Quantity
BLANK, snap-in nyl 1.093/1.125 mtg hole black
1
HOUSING PLUG & SOCKETS,
3
(qty chg added PLG24)
HOUSING PLUG & SOCKETS, (qty chg added PLG28)
CIRCUIT CARD, voltage control (Eff w/KC330884)
digit represents page no digits following dash represent item no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
2
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No. SD-i 52 896-B
OM-154 145 Page 3
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OM-154 145
Page
4
8-3. Circuit
Diagram
For Interface Board PCi
C~
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No. SD-146 306-A
OM-154 145 Page 5
8YPASS C~IT~S FOR
P..
PETS FOR CHIPS
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OM-154 145 Page 6
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8-16.
Wiring Diagram
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ARC WELDING SAFETY PRECAUTIONS
WARNING
a
ARC WELDING
be hazardous.
can
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 sate 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.
OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
HAVE ALL INSTALLATION,
QUALIFIED PEOPLE.
ELECTRIC SHOCK
can
kill.
5.
live electrical parts can cause fatal shocks
severe burns. The electrode and work circuit is
or
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
Touching
grounded equipment
hazard.
is a
6.
dry, hole-free insulating gloves and body protection.
yourself from work and ground using dry insulating
2.
Wear
3.
Insulate
Disconnect input power
servicing this equipment.
or
stop engine before installing
or
Arc rays from the welding process produce intense
heat and strong ultraviolet rays that can burn eyes
and skin. Noise from some processes can damage
hearing.
Turn off all equipment when not in
Do not
Use
approved
ear
plugs
or ear
muffs if noise level is
I,
these fumes and gases
health.
.
-.-
Keep
If inside, ventilate the
remove
3.
4.
welding
area
and/or
use
electrical (earth)
Do not touch electrode if in contact with the work
12.
Use
only well-maintained
damaged parts at once.
13.
Wear
Wear
4.
Use protectIve screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
5.
Wear
a welding helmet fitted with a proper shade of filter (see
ANSI Z49. I listed in Safety Standards) to protect your face and
eyes when welding or watching.
approved safety glasses. Side shields recommended.
protective clothing made from durable, flame-resistant
(wool and leather) and foot protection.
material
5.
Work in
a
wearing
an
only if it is well ventilated,
air-supplied respirator. Shielding gases
welding can displace air causing injury or death. Be
breathing
Do not weld in locatIons
form
Do not weld
cadmium
aware that
can cause
area
practical
strike flammable material.
9.
10.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
11.
can
grinding
cause
throw off
flying
metal. As welds
spraying
galvanized,
as
lead.
or
is removed from the
coating
extinguisher nearby.
ceiling, floor, bulkhead,
to
on
or
partition
the hidden side.
closed containers such
prevent welding
unknown
paths
and
as
as
tanks
or
drums.
close to the
welding area as
from traveling long.
current
causing
electric shock and fire
hazards.
Do not
use
welder to thaw frozen
pipes.
Remove stick electrode from holder
or
cut off
welding
wire at
tip when not in use.
Wear oil-free protective garments Such as leather gloves.
heavy shirt, cuffiess trousers, high shoes, and a cap.
contact
I.
Wear approved face shield
recommended.
or
2.
Wear proper
to
injury,
and
or
with vapors to
fire
Do not weld
Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers,
cool, they
on
a
on a
Connect work cable to the work
Do not weld where
I Chipping
fire
welding
7.
2.
can
arc can react
is well ventilated, and if necessary, while
8.
and hot metal.
FLYING SPARKS AND HOT METAL
the
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
3.
cause
degreasing, cleaning,
unless the
Be
can
sure
irritating gases.
Watch for fire, and keep
flying sparks
near
coated metals, such
plated steel,
weld area, the
Protect
~
on
5.
flying sparks
while
.
1.
4
toxic and
highly
6.
and others from
or
used for
air is safe.
operations. The heat and rays of the
possibly
4.
confined space
explosion.
yourself
replace
a safety harness f working above floor level.
Keep all panels and covers securely in place.
Sparks and spatter fly off from the welding arc. The
flying sparks and hot metal, weld spatter, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode or welding
wire to metal obiects can cause sparks, overheating,
or fire,
ground.
or
3.
and cleaners.
or
Repair
Wear
approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDS5) and the
manufacturers instruction for metals, consumables, coatings,
fire
equipment.
ground.
or
2.
7.
can cause
good
a
ARC RAYS
If ventilation is poor, use an
WELDING
poorly spliced
11.
exhaust at the arc to
fumes and gases.
or
body.,
your head out of the fumes. Do not breathe the fumes.
2.
use.
damaged. undersized,
worn,
Do not wrap cables around your
6.
1.
use
Ground the workpiece to
9.
be hazardous to your
can
its
grounding
proper
10.
high.
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing
attach
to
cables.
NOISE
1.
making input connections,
7.
14.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing.
When
ground this equipment according
8.
mats or covers.
4.
install and
Manual and national, state, and local codes.
conductor first.
Do not touch live electrical parts.
1.
Properly
Owners
body protection
safety goggles. Side
shields
protect skin.
slag.
,.I
992
CYLINDERS
explode
can
if
damaged.
from any
Keep cylinders away
3.
welding
or
other electrical
circuits.
Shielding 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,
a welding electrode to touch any cylinder.
only correct shielding gas cylinders, regulators. hoses,
fittings designed for the specific application~ maintain them
associated parts in good condition.
Never allow
4.
Use
5.
Install and secure
them
Turn face away from valve outlet when opening cylinder valve
7.
Keep protective
cylinders
ri an
stationary support
prevent falling or tipoing
upright position by chaining
ENGINE EXHAUST GASES
..
ENGINES
can
kill.
.~
Engines
FUEL
can
fire
cause
or
is
can
be hazardous.
Use equipment outside in open, well-ventilated
2.
It used in a closed area, vent engine exhaust outside and
away from any building air intakes.
1.
Stop engine before checking or adding fuel.
Do not add fuel while smoking or it unit is near
2.
explosion.
valve except when cylinder
1.
pr oduce harmful exhaust gases.
ENGINE
over
Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-i listed in Safety
Standards.
8.
epuipment cylinder rack to
or
WARNING
A
cap in place
connected for use.
ri use or
to a
and
6.
mechanical shocks, and arcs
2.
and
areas
any sparks
or
open ftames.
Allow
3.
Engine
fuel
is
highly
flammable.
MOVING PARTS
engine to cool before fueling. If possible,
engine before beginning lob.
check and add
fuel to cold
can cause
injury.
4.
Do not overfill tank
5.
Do not spill fuel. If fuel is spilled, clean up before
engine.
for fuel to
room
expand.
only qualified people remove guards or
troubleshooting as necessary.
Have
3.
allow
starting
covers
for
maintenance and
Moving parts, such as fans, rotors, and belts can
fingers and hands and catch loose clothing,
To prevent accidental
4.
cut
negative () battery
Keep hands, hair, loose clothing,
5.
1.
Keep all doors, panels,
securely in place.
2.
Stop eng
ne
before
covers,
installing
or
and
guards
connecting
closed and
Batteries contain
acid and generate explosive
gases.
STEAM
-~
~
~~~Itii
AND
COOLANT
can
PRESSURIZED HOT
burn face, eyes, and
skin.
The coolant in the radiator
under pressure.
can
disconnect
and tools away from moving
parts.
6.
Reinstall panels or guards and close doors when servicing is
finished and before starting en9ine.
1.
Always
2.
Stop engine
unit.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin,
starting during servicing,
battery.
cable from
wear a
face shield when
before
working
disconnecting
on a
battery.
connecting battery
or
cables.
3.
Do not allow tools to
4.
Do not
5.
Observe correct polarity (+ and )
1.
cause
use welder to
sparks
charge
when
batteries
on
working
or
jump
on a
battery.
start vehicles.
batteries.
Oonotremoveradiatorcapwhenengineishot.Allowengine
to cool.
2.
Wear
3.
Allow pressure to escape before
gloves
and put
a
rag
over
cap
area
when
removing
cap.
be very hot and
completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting, ANSI Standard Z49. 1, from American
Welding Society. 550 N.W. LeJeune Rd. Miami FL 33126
Safety and
Health Standards, OSHA 29 CFR 1910. from
dent of Documents, U.S. Government
Superinten.
Printing Office, Washington,
D.C. 20402.
Recommended Sate Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances. Amen.
Welding Society Standard AWS F4 1, from American Welding So
ciety. 550 N.W. LeJeune Rd. Miami, FL 33126
can
National Electrical Code, NFPA Standard 70. from National Fire Pro
tection Association, Batterymarch Park, Quincy, MA 02269.
~,i 9/92
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 I R3.
Safe Practices For Occupation And Educational Eye And Face Prof ec
tion, ANSI Standard Z87.1, from American National Standards
Institute, 1430 Broadway, New York, NY 10018.
Cutting
And
Welding Processes. NFPA Standard 518. from National
Batterymanch Park. Quincy, MA 02269
Fire Protection Association,
OM-154 145
TABLE OF CONTENTS
Page
Section No.
SECTION 1
SAFETY PRECAUTIONS AND SIGNAL WORDS
-
1.1.
Generai Information And
1-2.
Safety
SECTION 2
2-1.
SECTION 3
3-1.
Symbol
Alert
And
Safety
Signal Words
1
1
SPECIFICATIONS
Description
1
INSTALLATION
Site Selection
3
Installation
3-2.
Equipment
3-3.
Setting
3-4.
Burnback
3-5.
Robot Interface Set Up
YaskawalMotoman Robot Control Unit
Robot Interface Set Up
Hitachi Robot Control Unit
5
3-6.
3-7.
Panasonic Robot Control Unit
7
3-8.
Automatix Robot Control Unit
8
3-9.
9
3-10.
GMF Robot Control Unit
ABB Robot Control UnitRobot
3-11.
Kawasaki Robot Control Unit
3-12.
3-13.
3-14.
3-15.
3-16.
3-17.
3-18.
3
DIP Switches On DVC Board PC8
Voltage And
4
Wire Stick DIP Switch On Interface Board
Robot Interface Set
Up
Robot Interface Set Up
Robot Interface Set Up
Interface Set
Up
6
10
Robot Interface Set Up
SMIC Robot Control Unit
Robot Interface Set Up
Gas/Current Sensing Control Interconnections
11
12
13
Voltage Sensing Connections
Robot Interface
Welding Power Source Connections
Connection For Nonpulse Welding
Optional RCSP-R Set-up For Using Maxtron 300
Welding Wire Installation
SECTION 4OPERATOR
4
14
14
14
14
15
CONTROLS
4-1.
Power Switch And Pilot
4-2.
16
4-3.
Jog Push Buttons
Purge Push Button
4-4.
Voltmeter
16
Speed
4-5.
Wire
4-6.
Ammeter
Light
16
16
Meter
16
17
4-7.
Indicator
4-8.
Preflow Control
17
4-9.
Postflow Control
18
4-10.
Burnback lime Control
18
4-11.
Burnback
18
4-12.
Selector Switch
Manual Controls
4-13.
Lights
17
Voltage Control
18
18
SECTION 5- OPTIONAL RCSP-R OPERATOR CONTROLS
5-2.
Wire Size Select Switch And Standard Mode Indicator
Wire Size Indicator Lights
5-3.
Wire
5-4.
Recommended Shielding Gas Indicator Lights
No Program Indicator Light
5-1.
5-5.
SECTION 6
Type Select Switch
Light
19
19
19
20
20
SEQUENCE OF OPERATION
6-1.
Optional
RCSP-R Gas Metal Arc
6-2.
Shutting
Down
Welding (GMAW)
22
22
No.
10/92
Page
Section No.
SECTION 7- MAINTENANCE & TROUBLESHOOTING
7-1.
Routine Maintenance
23
7-2.
Overload Protection
23
7-3.
Reinstallation Of Hub
7-4.
Circuit Board Handling Precautions
24
7-5.
Troubleshooting
25
7-6.
Use Of Indicator
SECTION 8
Assembly
Lights
For
Troubleshooting
8-1.
Diagram
Diagram
8-5.
Diagram
8-7.
8-2.
8-3.
8-4.
8-6.
Diagram 8-8.
Diagram 8-9.
Diagram 8-10.
Diagram 8-11.
Diagram 8-12.
Diagram
8-13.
Diagram
Diagram
8-14.
8-15.
Circuit
For Robotic Interface Control
Circuit
For
Diagram
Diagram
Circuit Diagram
Circuit Diagram
Circuit Diagram
Circuit Diagram
Circuit Diagram
Analog
Channel Board P04
34
For DVC Board PC8
36
For Motor Board P06
38
For Power
Supply
Board PC5
For Isolation Board PC2
For Gas/Current
40
41
Control
Diagram
Sensing
Diagram For Optional RCSP-R Panel
Circuit Diagram For Feedback Board PC1O
Circuit Diagram For Optional RCSP-R
Offset/Supply Board P05
Circuit Diagram For Selector Board P06
Circuit Diagram For Optional RCSP-R
Circuit
39
40
Circuit Diagram For Display Board PC7
Circuit Diagram For Filter Board P09
Circuit
30
32
For Interface Board PCi
Interface Board PCi
Figure
Figure
Figure
Figure
28
ELECTRICAL DIAGRAMS
Diagram
Diagram
Diagram
Diagram
SECTION 9
23
41
42
42
43
43
44
PARTS LIST
9-1. Main
Assembly
w/Components
Assembly
46
9-2. Control Panel
48
9-3. Door
50
9-4. Control Box, Gas Current
52
No.
SECTION 1
SAFETY PRECAUTIONS AND SIGNAL WORDS
GENERAL INFORMATION AND SAFETY
1-1.
SAFETY
1.2.
ALERT
SYMBOL
AND
SIGNAL
WORDS
A.
General
The
following safety alert symbol and signal words are
throughout this manual to call attention to and iden
used
Information presented in this manual and on various la
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equipment.
B.
operation, maintenance, and trouble
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in
stalled, operated, and maintained only by qualified per
The installation,
in accordance with this manual and all
cautions listed in the Arc
Welding Safety
pre
Precautions.
or
to interface an
designed
Maxtron 300
or
450
gas/current sensing control contains
sensing reed relay, and shunt.
the gas valve,
current
These components function with the robot system when
using the Gas Metal Arc Welding (GMAW) and Gas Met
Welding
-
Pulsed Arc
(GMAW-P)
processes.
optional RCSP-R panel is a synergic control de
signed to be used with the Arc Pak 350 or Maxtron 300 or
450 welding power sources, robot interface, and the ro
bot system. The unit is designed for Gas Metal Arc Weld
ing (GMAW) in both nonpulsed and pulsed dc arc weld
ing modes. The unit is shipped ready for pulsed welding.
The
is used with the
signal
safety
statements.
a
WARNING statements
a
CAUTION statements identify procedures or
practices which must be followed to avoid minor
identify procedures
practices which must be followed
ous personal injury or loss of life.
personal injury
or
damage
to this
or
to avoid seri
equipment.
SPECIFICATIONS
welding
power source to a welding robot. This unit provides digi
tal display of weld volts,wire feed speed, and amperage.
al Arc
symbol
The panel is considered a synergic control because
welding parameters which determine arc power and arc
The robotic interface control is
The
alert
ment.
DESCRIPTION
Arc Pak 350, Deltaweld,
safety
words WARNING and CAUTION to call atten
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip
safety
SECTION 2
2-1.
This
4A
levels of hazard and special instructions,
tion to the
Safety
sons
tify different
programmed for wire type and size selections
adjustment at two controls rather than individual
controls for each parameter. If pulse welding, arc power
parameters are wire feed speed, background amper
age, peak amperage, pulse frequency, and pulse width;
arc length is a fine tuning of pulse frequency. If non-pulse
welding, arc power parameters are wire feed speed, arc
length
are
to allow
voltage,
voltage.
and inductance;
arc
length
is
a
fine
tuning
of
arc
When used with its associated equipment, the optional
RCSP-R panel allows the operator to set welding pa
rameters for
conditions in
situations
and sizes of
and
optimum welding
using various types
shielding gases.
a
majority of
welding
wire
IMPORTANT: When using Maxtron 300 welding power
source, it is recommended that it be equipped with field
kit MILLER Part No. 146722.
OM.154 145 Page
1
in.
mm)
3/8 in.
(10 mm)
25-3/4 in.
(654 mm)
26-1/2 in.
(673 mm)
Opening For
Receptacle Kit
Installation
Overall Dimensions And
Hole Locations
MoUnting
Inches
Millimeters
A
21.7/8
556
B
13.3/4
349
i~i
3
76
D
2.1/2
63.5
E
3.1/2
88.9
F
4-1/2
114
G
10-11/16
275
ST 157 095 / ST080
Figure
OM-154 145
Page
2
2-1. Dimensional Views
486-C
SECTION 3- INSTALLATION
SITE SELECTION
3-1.
Select
1.
an
installation site which
Correct input power
provides
supply (see
unit
4.
Two weld output cables must be routed to the Gas!
Current Sensing control.
5.
Welding
following:
the
rating label)
wire must be routed
so
that it does not
tact the weld control or any other
2.
Shielding gas supply (if applicable)
3.
Water
4.
Adequate ventilation and fresh air
5.
No flammables
6.
A clean and
7.
Proper temperature that avoids
ment.
supply (if applicable)
dry
con
grounded equip
C.
Equipment Installation
supply
Obtain appropriate mounting brackets or adapter plates
necessary and mounting hardware. Prepare struc
ture for equipment installation. Secure weld control,
as
area
Gas/Current Sensing control, and all other equipment
extremes of heat or
onto structures in the
welding
area.
cold
D.
8.
Proper airflow around unit
9.
Adequate space
to open and remove cover and
wrapper for installation, maintenance, and
functions.
Mounting holes provide the capability
the
cure
in a
install it
to install and se
as
follows:
1.
Remove hex nut from end of hub support shaft.
2.
Align keyway
permanent location.
and insert hub support shaft
brake washers
following equipment is supplied
quires installation or assembly:
as
through
selected hole in hub support. Hole selection in hub
support depends on wire spool size. Be sure the
Supplied Equipment
The
(Figure 3-1)
The hub assembly is supplied with the robot interface.
Remove the hub assembly from the shipping carton, and
EQUIPMENT INSTALLATION
3-2.
A.
system components
repair
Hub Installation
standard and
are
properly
seated in the hub.
re
3.
Reinstall hex nut onto support shaft. Tighten hex nut
a slight drag is felt while turning hub.
until
1.
Weld Control with Gas/Current
Sensing Control
Cord and Motor Cord
4.
2.
Gas/Current Sensing Control
3.
Hub and
4.
Hub Support
5.
(3 m) Weld Control
Interconnecting Cords
6.
10 ft.
7.
Voltage Sensing Cord
B.
Equipment
Install
welding
wire
according
to Section 3-18.
Spindle Assembly
10 ft.
Welding
Retaining Ring
Power Source
(3m) Gas Hose
Brake Washer
When
deciding
lowing:
Location
on
equipment location, consider the fol
1.
The equipment must be mounted to a structure ca
pable of supporting the weight of the equipment.
2.
The lead
equipment
can
lengths
Hub
Assembly
of the cords supplied with the
will limit the area in which the
equipment
by us
be located. Some cords can be extended
ing optional extension cords (check with welding
equipment distributor).
ST.126 870.A
3.
interconnecting cords must be routed so that
they are not caught, pinched, or strained during
welding operations.
The
Figure
3-1. Hub
Assembly Installation
OM-154 145
Page
3
DVC SWITCH SETTINGS
51
S2
1
1
2
DELTAWELD 300
2
3
ON
ON
ON
ON
DELTAWELD 451
0
ON
DELTAWELD 651
0
ON
MAXTRON 300, 400
ON
ON
XMT 200/300
ON
ON
ON
ARC PAK 350
ON
ON
ON
O
ON
ON
451 to
ON
3-2. DVC DIP Switch
SETTING DIP SWITCHES ON DVC BOARD
(Figure 3-2)
Setting
a
can
malfunction.
See
Figure 3-2 for DVC DIP switch setting
using another welding power source.
Shut down unit, welding power source, and
robot, and disconnect input power employing
setting
the Interface Board allows
enabling or
voltage front panel control and
wire stick circuitry. To change factory set position of
switches, proceed as follows:
disabling
DIP switches.
on
the burnback
WARNING: ELECTRIC SHOCK
Lockoutltagging procedures consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
circuit breaker
or
when
BURNBACK VOLTAGE AND WIRE STICK DIP
SWITCH ON INTERFACE BOARD
DIP switch Si
before
factory set for operation
welding power source.
kill.
Do not touch live electrical parts.
lockout/tagging procedures
Label
with Deltaweldfi 451
3-4.
WARNING: ELECTRIC SHOCK
864-A
DVC DIP switch is
position of DIP switches from a Deltaweldfi
another welding power source, proceed as fol
lows:
S150
CAUTION: INCORRECT DVC BOARD DIP
SWITCH POSITION can cause equipment
on
set
red-tagging
ing device.
ON
ON
DVC Board PC8 allow set
ting the proper command signal voltage level for control
ling voltage output at a welding power source. To change
factory
ON
On For Optional Soft Start. Turn Off Si -3.
On For Optional Hot Start.
Figure
DIP switches Si and S2
ON
MAXTRON 450
DIMENSION 400
PC8
ON
ON
SHOPMASTER 300
3-3.
5
4
can
kill.
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before setting
other disconnect
DIP switches.
ELECTROSTATIC DISCHARGE
damage circuit boards.
(ESD)
can
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position. re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
Put on properly grounded wrist strap BE
FORE handling circuit boards.
Perform work only at
Loosen
screws
a
static-safe work
and open control
area.
ELECTROSTATIC DISCHARGE
circuit boards.
(ESD)
2.
Locate DVC Board PC8 in lower left portion
rear panel inside the interface.
3.
Set position of DIP switches Si and S2 according
to label inside interface and Figure 3-2 for appro
priate welding power source.
Put on properly grounded wrist strap BE
FORE handling circuit boards.
on
Perform work only at a static-safe work
4.
Close and
OM-154 145
Page
4
secure
door.
can
damage
panel door.
Loosen
2.
screws
and open control panel door.
Locate Interface Board in
rear
area.
right
panel inside the interface.
center
portion
on
Set position of switches
3.
enabling
trol
to Chart 3-i for
voltage
disabling
circuitry.
or
3.
secure
channels
door.
4.
Chart 3-i. Interface Board DIP Switch Settings For
Burn back Voltage Control And Wire Stick Circuitry
2
1
FUNCTION
WIRE STICK
OFF
CIRCUITRY
DISABLE ENABLE
DISABLE
//
ON
(see Chart 3-3
Close and
secure
or
Chart 3-4).
door.
Chart 3-2. Welding Operation Control
Mode Selection
By Type Of
WELDING OPERATION
MODE
SELECTION
DIP SWITCH Si
ENABLE
Set switches No. I thru 5 of DIP switch 51 for de
sired mode selection and the available robot
con
wire stick
or
Close and
4.
according
the burnback
CONTROL
AUTOMATIC
PROGRAM DATA FROM ROBOT CONTROL
SETS WELDING PARAMETERS.
MANUAL
ROBOT INTERFACE FRONT PANEL CON
TROLS SET WELDING PARAMETERS.
SELECTOR
AUTOMATIC
SAME AS ABOVE.
MANUAL
SAME AS ABOVE.
SET UP WELDING OPERATION DRY RUN
USING A SIMULATED CURRENT DETECT
SIGNAL.
-
SWITCH
-
-
/// /~/~//
BURNBACK
VOLTAGE
CONTROL
ON
OFF
SIMILAR TO RUN-IN FUNCTION USING
FRONT PANEL CONTROLS TO SET WELD.
PRESET
YASKAWA/MOTOMAN ROBOT CONTROL
ROBOT INTERFACE SET UP
UNIT
3-5.
a
WARNING:
ELECTRIC SHOCK
can
kill.
SELECTOR
SWITCH AND
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before setting
DIP switches or making interconnections.
Lockout/tagging procedures Consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shuthng off and
red-tagging circuit breaker or other disconnect
ing device.
ELECTROSTATIC DISCHARGE
damage circuit boards.
Put on
Perform work only at
A.
(ESD)
wrist
properly grounded
FORE handling Circuit boards.
a
-
Chart 3-3. Analog Channel Board DIP Switch
Settings For 2 Channel Robot
DIP SWITCH Si
MODE
SELECTION
i
2
3
4
5
OFF OFF
OFF
OFF
OFF
OFF OFF
OFF
OFF
ON
OFF OFF
ON
ON
ON
AUTOMATIC
strap BE
MANUAL INDUCTANCE
MANUAL
static-safe work
area.
Recommended mode selection for 2
and Manual Inductance; mode selection for 3 channel
robot is Selector Switch (see Charts 3-2 and 3-3 or 3-4).
using
-
-
AUTOMATIC
channel Yaskawa/Motoman robot is Selector Switch
When
PRESET
AUTOMATIC
SAME AS ABOVE.
SAME AS ABOVE.
MANUAL
SET UP
SAME AS ABOVE.
can
Setting DIP Switch On Analog Channel Board
(Chart 3-1)
IMPORTANT:
ING PARAMETERS UNTIL ROBOT CON
DETECTS WELD CURRENT AND
SWITCHES TO PROGRAM DATA WELDING
PARAMETERS.
TROL
SELECTOR SWITCH
MANUAL INDUCTANCE*
ON
OFF
ON
OFF
ON
PRESET
MANUAL INDUCTANCE*
OFF
ON
ON
OFF
ON
ON
ON
ON
OFF
ON
SELECTOR SWITCH
AND PRESET
MANUAL INDUCTANCE*
*Mode
only
power
functions with
an
Arc Pak 350
or
Maxtron 450
welding
source.
the selector switch, the inner
to all robot models
settings apply
exceptABB which uses the outer set
Analog Channel Board DIP Switch
Settings For 3 Channel Robot
Chart 3-4.
tings.
DIP switch Si on
Analog Channel Board PC4 allows set
robot interface control function for all automatic, all
manual, selector switch, preset, or manual inductance
ting
for cases where
third
channel is not available at
analog
(see Chart 3-2). To change factory set
position of the DIP switch from all automatic (switches
No. 1 thru 5 all OFF), proceed as follows:
a
MODE
SELECTION
DIP SWITCH Si
1
2
3
4
5
OFF OFF
OFF
OFF
OFF
MANUAL
OFF OFF
ON
ON
ON
SELECTOR SWITCH
ON
OFF
ON
ON
OFF
PRESET
OFF
ON
ON
ON
OFF
SELECTOR SWITCH
ON
ON
ON
ON
OFF
AUTOMATIC
the robot control
1.
2.
Loosen
Locate
screws
and open control panel door.
Analog Channel
Board PC4 in
portion of base inside the interface.
right side
AND PRESET
OM-154 145
PageS
B.
Connection To
Receptacles
On Robot Interface
HITACHI ROBOT CONTROL UNIT
3-6.
1.
Obtain two cords of the proper type and
two
2.
3.
4.
length,
and
a
17-pin Amphenol plugs (not supplied).
Connect conductors at end of
ate
in one
pins
one
Route and connect conductors at
remaining
2 thru 4 for
remaining
DIP switches
circuitry
are as
can
kill.
or
making
interconnections.
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position. re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
end of
cord and
ELECTRIC SHOCK
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before setting
plug.
ELECTROSTATIC DISCHARGE
circuit boards.
The input and output signals at the sockets of receptacle
AC 100 and RC1O1 by means of the robot interface con
trol
ROBOT
Do not touch live electrical parts.
cord to appropri
Align keyway. insert 17-pin plug into matching re
ceptacle on robot interface, and rotate threaded col
lar fully clockwise.
Repeat Steps
WARNING:
plug.
cord to the robot control unit.
5.
-
INTERFACE SET UP
(Figure 3-3)
(ESD)
can
damage
Put
follows:
properly grounded
on
wrist strap BE
FORE handling circuit boards.
Perform work
at a static-safe work area.
only
Receptacle RC100
Socket A:
Voltage signal;
+
0 to 10 volts
=
0 to 50 volts
A.
DIP Switch On
Analog
Channel Board
(Chart 3-1)
output.
Socket B:
Common for Socket A.
Socket C:
Common for Socket D.
Socket D:
Wire feed
speed signal; +0
to 8 volts
=
0 to
800 pm.
Socket E:
Setting
Inductance
signal;
+0 to 10 volts.
IMPORTANT: Recommended mode selection for Hita
chi robot is Automatic and Manual Inductance (see
Chart 3-2 and 3-3 or 3-4). When using the selector
switch, the inner settings apply to all robot models ex
cept ABB which
uses
DIP switch Si
Analog Channel Board P04 allows
on
settings.
set
ting robot interface control function for all automatic, all
manual, selector switch, preset, or manual inductance
for cases where a third analog channel is not available at
Socket F:
Common for Socket E.
Socket K:
Common for Socket L.
Socket L:
Weld
Socket M:
Wire stick check
signal positive (+).
Socket N:
Wire stick check
signal negative ().
the robot control
on
the outer
(Chart 3-2).
To
change factory set posi
(switches No. 1
tion of the DIP switch from all automatic
signal.
thru 5 all
Current detect contact.
Socket B:
Current detect contact.
Socket D:
Gas
Socket E:
Wire
shortage (terminal strip connection
provided for customer).
follows:
Loosen
2.
Board PC4 in
of
base
inside
the
interface.
portion
3.
SetswitchesNo. I thru5ofDlPswitchSi forde
sired mode selection and the available robot
channels (see Chart 3-3 or Chart 3-4).
4.
Close and
B.
shortage (terminal strip
as
1.
connection
screws
and open control panel door.
Analog Channel
Locate
Receptacle RC1O1
Socket A:
OFF), proceed
secure
Connection To
right
side
door.
Receptacle On
Robot Interface
(Figure 3-3)
provided for customer).
1.
Socket F:
Circuit
Socket G:
Jog forward
command.
Socket H:
Jog
command.
Socket K:
Gas control.
common
reverse
for Sockets G and H.
Obtain
Circuit
common
used.
OM-154 145
Page
type and length,
Amphenol plug (not supplied).
3.
Align keyway,
insert
plug into matching receptacle
fully
robot interface, and rotate threaded collar
clockwise.
4.
Route and connect conductors at
cord to the robot control unit.
6
and a
Connect conductors at end of cord to appropriate
sockets in plug.
for Socket K.
IMPORTANT: The remaining sockets in the receptacle
are not
cord of the proper
2.
on
Socket L:
a
24-socket
remaining
end of
The input and output signals at the pins of receptacle
RC100 by means of the robot interface control circuitry
are as
RO
PANASONIC ROBOT CONTROL UNIT
BOT INTERFACE SET UP
3-7.
follows:
WARNING:
Receptacle RC100
Pin A:
Digital
Pin B:
Weld
common
Pin C:
Current detect
DIP switches
signal;
kill.
or
making
interconnections.
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
contact closure with
red-tagging
to Pin A.
respect
Pin D:
contact closure with
to Pin A.
respect
can
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before setting
of Pins B, C, D, and E.
Standby signal;
ELECTRIC SHOCK
Do not touch live electrical parts.
circuit breaker
or
other disconnect
ing device.
normally-open
Arc Failure;
ELECTROSTATIC DISCHARGE
circuit boards.
contact.
(ESD)
can
damage
Pin E:
Wire Stuck
signal;
contact closure with
Put on properly grounded wrist strap BE
FORE handling circuit boards.
re-
spect to Pin A.
Perform work
Pin G:
Water
Cooling
provided for
connection
Pin H:
Shortage:
Low Gas; terminal
vided for customer
Pin J:
Circuit
feed,
terminal
strip
con-
use.
asonic robot is Automatic and Manual Inductance (see
Chart 3-2 and 3-3 or 3-4). When using the selector
switch, the inner settings apply to all robot models
cept ABB which uses the outer settings.
ex
Analog Channel Board PC4 allows
set-
ting
FWD.
Pin P:
Jog
REV,
on
robot interface control function for all automatic. all
manual, selector switch, preset,
for
Jog
Board
for Pins M, N, and P.
signal;
Pin N:
Analog Channel
IMPORTANT: Recommended mode selection for Pan
starts gas flow and wire
and turns on contactor.
Arc On
area.
strip connection pro
DIP switch Si
Pin M:
Switch On
Setting DIP
(Chart 3-1)
A.
use.
Shortage;
common
work
strip
customer use.
provided for customer
nection
Pin L:
Wire
Welding
terminal
only at a static-safe
cases
where
a
third
analog
or
manual inductance
channel is not available at
the robot control (see Chart 3-2). To change factory set
position of the DIP switch from all automatic (switches
signal.
No. 1 thru 5 all
OFF), proceed
as
follows:
signal.
Pin R:
Arc Failure;
Pin S:
Terminal strip connection provided for
normally-closed
contact.
and open control panel door.
i.
Loosen
2.
Locate Analog Channel Board PC4
portion of base inside the interface.
screws
in
right
side
cus
Set switches No. i thru 5 of DIP switch Si for de
3.
tomer use.
sired mode selection and the available robot
Pin T:
Terminal
tomer use.
Pin U:
Terminal
channels (see Chart 3-3
strip connection provided for cus-
Close and
4.
strip connection provided for cus-
B.
1.
Pin V:
Wire feed
Pin W:
Common for Pins V and x.
signal positive (~
Obtain
2.
voltage signal positive (+)
Arc Failure;
IMPORTANT: The
not used.
normally-closed
remaining pins
in the
a
cord of the proper type and
length,
and
a
24-pin Amphenol plug (not supplied).
Connect conductors at end of cord to appropriate
3.
contact.
receptacle
in
plug.
Align keyway, insert plug
on
Pin Y:
door.
Connection To Receptacle On Robot Interface
pins
Arc
Chart 3-4).
(Figure 3-3)
tomer use.
Pin X:
secure
or
into
matching receptacle
fully
robot interface, and rotate threaded collar
clockwise.
are
4.
Route and connect conductors at
remaining
end of
OM-154 145
Page
cord to the robot control unit.
7
The input and output signals atthe sockets of receptacle
Rd 00 by means of the robot interface control circuitry
are as
3-8.
AUTOMATIX ROBOT CONTROL UNIT
BOT INTER FACE SET UP
a
WARNING: ELECTRIC SHOCK
MO
follows:
of Sockets B, C, and G.
Digital
Socket B:
Arc Failure; output
Socket C:
Touch Sense; output
Socket G:
Current Detect; output
common
kill.
Shut down unit, welding power source. and
robot, and disconnect input power employing
lockout/tagging procedures before setting
DIP switches or making interconnections.
Receptacle RC100
Socket A:
can
Do not touch live electrical parts.
Lockout/tagging procedures Consist of padlocking line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
signal.
signal.
ing
device.
ELECTROSTATIC
signal.
DISCHARGE
(ESD)
can
damage circuit boards.
Socket H:
Weld Start
signal;
feed, and turns
on
Put
starts gas flow and wire
contactor.
Perform work only at
Socket J:
A; all circuit voltages referenced to this
Socket L:
a
static-safe work
area.
Circuitcommon for Sockets H, K, M, P, and
A.
point.
Socket K:
wrist strap BE-
properly grounded
on
FORE handling circuit boards.
ets
DIP Switch On
Analog Channel
Board
(Chart 3-i)
IMPORTANT: Recommended mode selection forAuto
Gas Valve; input signal.
Circuit
Setting
common
for input
matix robot is Automatic
signals
at Sock-
H, K, M, P, and R.
(see Chart 3-2 and 3-3 or 3-4).
When using the selector switch, the inner settings apply
to al/robot models exceptABB which uses the outerset
tings.
Socket M:
Socket N:
Touch Sense; input
Circuit
ets
common
signal.
for input
DIP switch Si
signals
at Sock-
H, K, M, P, and A.
Socket P:
Jog FWD.; positive (+) input signal.
Socket 0:
Circuit
on Analog Channel Board PC4 allows setrobot interface control function for all automatic, all
manual, selector switch, preset, or manual inductance
for cases where a third analog channel is not available at
the robot control (see Chart 3-2). To change factory set
position of the DIP switch from all automatic (switches
ting
No. 1 thru 5 all
ets
common
for input
signals
at Sock
H, K, M, P, and R.
Socket R:
Jog REV.; negative () input signal.
Socket S:
Circuit
common
for input
signals
at Sock-
Socket U:
Voltage
control
positive (+) connection.
Voltage control command connection; 0 to
iOV signal
0 to 50V output.
2.
Locate
3.
Set switches No. 1 thru 5 of DIP switch Si for de
sired mode selection and the available robot
channels (see Chart 3-3 or Chart 3-4).
4.
Close and
B.
Socket W:
control
negative ()
connection.
Wire feed speed command connection; 0
to 8V signal
0 to 800 pm.
Analog Channel
secure
Wire feed speed negative ()
2.
3.
10-pin and 24-pin Amphenol plug (not supplied).
Connect conductors at end of
pins
in
one
Align keyway,
PageS
one
cord to appropri
plug.
insert
plug
into
matching receptacle
fully
robot interface, and rotate threaded collar
clockwise.
connection.
IMPORTANT: The remaining sockets in the receptacle
used.
OM-154 145
side
Obtain two cords of the proper type and length, and
on
4.
are not
right
door.
=
Socket Y:
panel door.
Connection To Receptacles On Robot Interface
ate
Socket X:
and open control
Board PC4 in
of
base
inside
the
interface.
portion
a
Wire feed speed positive (+) connection.
screws
(Figure 3-3)
1.
Voltage
follows:
Loosen
=
Socket V:
as
1.
ets H, K, M, P, and A.
Socket T:
OFF), proceed
Route and connect conductors at
remaining
end of
cord to the robot control unit.
5.
Repeat Steps
2 thru 4 for
remaining
cord and
plug.
The input and output signals at the sockets of receptacle
RC1 00 and RC1 01 by means of the robot interface con
trol
circuitry
are as
3-9.
GMF ROBOT CONTROL UNIT
TERFACE SET UP
a
WARNING: ELECTRIC SHOCK
follows:
Receptacle RC100
Socket A:
Inductance; positive (+)
Socket B:
Inductance; signal
Socket C:
Inductance command
for Arc Pak
or
Circuit
FWD.
signal.
DIP switches
common.
ELECTROSTATIC
signal.
Socket L:
Circuit
Socket M:
Weld Start
Socket N:
Circuit common for Socket M.
Socket P:
Wire Feed
Speed; positive (+) signal.
Socket 0:
Wire Feed
Speed; signal
signal
Perform work
positive (+) signal.
(ESD)
Socket S:
Arc
Voltage; positive (+) signal.
Socket T:
Arc
Voltage; signal
Socket U:
Arc
0 to 8V
common.
command
signal;
0 to 1OV
only
at a static-safe work area.
Analog Channel
3-2 and 3-3
or
3-4). When using the selector switch, the
to all robot models except ABB
inner
settings apply
which
uses
the outer
settings.
DIP switch Si on Analog Channel Board PC4 allows set
ting robot interface control function for all automatic, all
manual, selector switch, preset,
50V output.
manual inductance
or
analog channel is not available at
the robot control (see Chart 3-2). To change factory set
position of the DIP switch from all automatic (switches
No. 1 thru 5 all OFF), proceed as follows:
for
cases
where
a
third
Arc Failure contact.
Socket W:
Arc Failure contact.
Socket X:
Current Detect contact.
1.
Loosen
Socket Y:
Current Detect contact.
2.
Locate
Analog Channel Board PC4
portion
of base inside the interface.
IMPORTANT: The remaining sockets in the receptacle
not used.
channels
signal
with respect to Sock
et D.
B.
and open control panel door.
(see Chart 3-3
Close and
4.
Torch Position
screws
in
right side
SetswitchesNo. 1 thru5ofDlPswitchSi forde
sired mode selection and the available robot
3.
Receptacle RC1O1
Socket A:
Board
channel GMF robot is Preset and Manual Inductance;
mode selection for 3 channel robot is Preset (see Chart
Socket V:
are
can
Recommended mode selection for 2
IMPORTANT:
common.
Speed command signal;
ipm.
=
DISCHARGE
Switch On
Setting DIP
(Chart 3-1)
A.
0 to 800
Voltage
signal 0 to
interconnections.
Put on properly grounded wrist strap BE
FORE handling circuit boards.
common.
=
making
circuit boards.
damage
Jog
Wire Feed
or
Lockoutltagging procedures consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
for Socket G.
Socket G:
Socket R:
kill.
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before setting
signal; 0 to 10 volts
Maxtron 450 welding power
common
can
Do not touch live electrical parts.
source.
Socket F:
ROBOT IN
secure
Connection To
or
Chart 3-4).
door.
Receptacle On
Robot Interface
(Figure 3-3)
Socket D:
Torch Position
signal
with respect to Sock
1.
et A.
Obtain
for Socket G.
Circuit
Socket G:
Torch Position initiate
Socket I:
Circuit
common
common
2.
Gas control
IMPORTANT: The
not used.
length,
and
a
Connect conductors at end of cord to appropriate
pins
signal.
3.
for Socket J.
signal.
remaining
sockets in the
in
plug.
Align keyway,
on
are
cord of the proper type and
37-pin Amphenol plug (not supplied).
Socket F:
Socket J:
a
insert
plug
into
matching receptacle
fully
robot interface, and rotate threaded collar
clockwise.
receptacle
4.
Route and connect conductors at
remaining
end of
cord to the robot control unit.
OM-154 145 Page 9
The input and output signals at the sockets of receptacle
RC100 by means of the robot interface control circuitry
are as
Socket h:
Weld Standby; output signal to robot con
trol unit with respect to Socket m (digital
common) indicating the robot interface is in
follows:
a
Receptacle RC100
Socket A:
positive (+) signal from 0 to 10
input from robot control unit with
respect to Socket A (analog common).
Arc Volts;
Socket C:
Analog
for Socket A.
common
Inductance; positive (+) signal from 0 to 10
input from robot control unit with
respect to Socket 0 (analog common).
volts dc
Socket D:
Analog
Socket E:
Wire Feed
Digital
Socket
r:
+24 volts dc supply (option for Karel Con
troller). Only plug into this socket if use of
the option is desired.
Socket
s:
Chassis ground.
common
IMPORTANT: The remaining sockets in the receptacle
are not
used.
3-10.
ABB ROBOT CONTROL UNIT
TERFACE SET UP
a
WARNING: ELECTRIC SHOCK
to 1000 1PM from wire drive mo
for Socket E.
Socket F:
Analog
SocketJ:
Voltage Feedback; 100V (arc voltage)
equals 1OV (feedback signal) with respect
common
Socket K:
Analog
Socket L:
Current Feedback; 1 000A (weld current)
common
for Socket J.
ELECTROSTATIC
(feedback signal)
with
respect
Socket N:
Wire Stuck; return for Socket P.
Socket P:
Wire Stuck; output signal to robot control
unit with respect to Socket N indicating
common
for Socket L.
A.
wire is stuck to work.
DISCHARGE
(ESD)
can
Put on properly grounded wrist strap BE
FORE handling circuit boards.
Perform work
Analog
kill.
damage circuit boards.
to Socket M.
Socket M:
can
Do not touch live electrical parts.
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
to Socket K.
1 OV
ROBOT IN
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockouVtagging procedures before setting
DIP switches or making interconnections.
tor.
equals
for Sockets d and h.
Speed; positive (+) signal from
0 to 10 volts dc input from robot control unit
with respect to Socket F (analog common)
equals 0
normally-open
m:
for Socket C.
common
a
Socket
volts dc
Socket B:
standby mode. This is
contact.
only at a static-safe
Setting DIP Switch
(Chart 3-1)
On
work
Analog Channel
area.
Board
IMPORTANT: Recommended mode selection for ABB
(see Chart 3-2 and 3-3 or 3-4). When
using the selector switch, the inner settings apply to all
robot models except ABB which uses the outer settings.
robot is Automatic
Socket R:
Contactor Control; contact closure from ro
bot control unit with respect to Sockets a
and b (circuit common).
Socket S:
Gas Control; contact closure from robot
control unit with respect to Sockets a and b
DIP switch Si
(circuit common).
Socket U:
Jog Forward;
contact closure from robot
control unit with respect to Sockets a and b
(circuit common).
Socket V:
Jog Reverse;
on Analog Channel Board PC4 allows set
interface
robot
control function for all automatic, all
ting
manual, selector switch, preset, or manual inductance
for cases where a third analog channel is not available at
the robot control (see Chart 3-2). To change factory set
position of the DIP switch from all automatic (switches
No. 1 thru 5 all OFF), proceed as follows:
1.
Loosen
2.
Locate
contact closure from robot
control unit with
respect to Sockets
a
and b
(circuit common).
Current Detect; output signal to robot
trol unit with respect to Socket
OM-154 145
Page
10
and open control panel door.
Analog Channel
Board PC4 in
right
side
portion of base inside the interface.
Sockets a,b: Circuit common for Sockets R, S, U, and V
all circuit voltages referenced to this point.
Socket d:
screws
m.
3.
Set switches No. 1 thru 5 of DIP switch Si for de
sired mode selection and the available robot
channels (see Chart 3-3 or Chart 3-4).
4.
Close and
con
secure door.
B.
Connection To Receptacle On Robot Interface
Socket Q:
Digital
ets
(Figure 3-3)
1.
Obtain
a
cord of the proper type and
length,
and
a
in
plug
insert
Align keyway,
on
at Sock-
Inductance; positive (+) 0 to 10 volts dc in.
put signal from robot control unit with re
spect to Socket S (analog common).
Socket S:
Analog
common
for Socket R.
plug
into
robot interface, and rotate
matching receptacle
threaded collar fully
Socket W:
Analog
common
for Socket X.
Socket X:
Wire Feed
Speed: positive (+) 0 to 10 volts
input signal from robot control unit with
respect to Socket W (analog common)
equals 0 to 1000 pm.
clockwise.
4.
signals
Connect conductors at end of cord to appropriate
pins
3.
for output
Socket R:
24-pin Amphenol plug (not supplied),
2.
common
K, L, M, N, and P.
dc
Route and connect conductors at
remaining
end of
cord to the robot control unit.
The input and output signals at the sockets of receptacle
AC1 00 by means of the robot interface control circuitry
are as
Socket Y:
Analog
Socket Z:
Arc Volts;
50 volts dc output at
IMPORTANT: The
Socket A:
Provides connection to terminal strip inside robot control unit (customer use).
Socket B:
Current Detect; output signal to robot control unit with respect to Socket D. Isolation
relay CR1 contacts are rated 1A at 120 v.
are
are
+24 volts dc input signal from
robot control unit with respect to Socket J
Jog Forward;
(circuit common).
ELECTROSTATIC
Jog Forward; momentary contact closure
output signal to robot Control unit with respectto Socket 0 (digital common).
Socket M:
to robot control unit
respect to Socket Q (digital common).
Weave
Set-Up; output signal
(digital
common).
Wire Stick
Check; output signal
to robot
control unit with respect to Socket Q (digital common) indicating wire is stuck to
work.
Socket P:
Weld
Standby; output signal
kill.
DISCHARGE
(ESD)
can
A.
Setting DIP
(Chart 3-1)
IMPORTANT:
only ata
Switch On
static-safe work
Analog Channel
area.
Board
Recommended mode selection for Ka
wasaki robot is Selector Switch and Manual Inductance
(see Chart 3-2 and 3-3
or
3-4). When using
the selector
switch, the inner settings apply to all robot models
cept ABB which uses the outer settings.
ex
to robot con
trol unit with respect to Socket Q
Socket N:
Perform work
common
Set-Up; output signal
with
can
RO
-
Put on properly grounded wrist strap BE
FORE handling Circuit boards.
(circuit common).
Socket L:
KAWASAKI ROBOT CONTROL UNIT
BOT INTERFACE SET UP
damage circuit boards.
Gas Control; +24 volts dc input signal from
robot control unit with respect to Socket J
Socket K:
sockets in the receptacle
Lockoutitagging procedures consist of padlocking line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnecting device.
Socket J (circuit common).
for Sockets E, F, G, and H
all circuit voltages referenced to this point.
source.
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before setting
DIP switches or making interconnections.
rated 1 A at 120 V.
Socket J:
power
Do not touch live electrical parts.
Contactor Control; +24 volts dc input signal from robot control unit with respect to
Circuit
remaining
welding
WARNING: ELECTRIC SHOCK
Current Detect; output to robot control unit
respect to Socket B. Isolation relay
CR1 contacts
Socket G:
input
not used.
3-11.
with
Socket F:
to 10 volts dc
control unit with respect
to Socket Y (analog common) equals 0 to
Receptacle RC1 00
Socket E:
positive (+) 0
signal from robot
follows:
Socket D:
for Socket Z.
common
DlPswitchSl on Analog Channel Board PC4allows set
ting robot interface control function for all automatic, all
manual, selector switch, preset, or manual inductance
cases where a third analog channel is not available at
the robot control (see Chart 3-2). To change factory set
position of the DIP switch from all automatic (switches
No. 1 thru 5 all OFF), proceed as follows:
for
to robot con-
trol unit with respect to Socket 0
1.
Loosen
2.
Locate
(digital
common) indicating robot interface is
standby mode.
in
screws
and open control
panel door.
Analog Channel Board PC4 in right side
portion of base inside the interface.
OM-154 145
Page
~1
SetswitchesNo. 1 thru5of DIP switch Si forde-
3.
3-12.
sired mode selection and the available robot
channels (see Chart 3-3 or Chart 3-4).
Close and
4.
SMIC ROBOT CONTROL UNIT
TERFACE SET UP
ROBOT IN-
WARNING: ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
secure door.
Shut down unit. welding power
B.
source, and
robot, and disconnect input power employing
lockout/tagging procedures before setting
DIP switches or making interconnections.
Connection To Receptacle On Robot Interface
(Figure 3-3)
1.
Locate
2.
Align keyway,
on
supplied
cord.
Lockout/tagging procedures Consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
plug into matching receptacle
fully
insert
robot interface, and rotate threaded collar
ing device.
clockwise.
3.
Route and connect conductors at
remaining
ELECTROSTATIC DISCHARGE
circuit boards.
end of
cord to the robot control unit.
Put
follows:
can
properly grounded wrist strap
handling circuit boards.
Perform work
A.
BE
on
FORE
The input and output signals at the pins of receptacle
RC1 00 by means of the robot interface control circuitry
are as
(ESD)
damage
only at a static-safe
Switch On
Setting DIP
(Chart 3-1)
work
Analog Channel
area.
Board
IMPORTANT: Recommended mode selection for SM/C
Receptacle RC1 00
robot is Selector Switch and Manual Inductance
(see
3-4). When using the selector
switch, the inner settings apply to all robot models ex
cept ABB switch which uses the outer settings.
Chart 3-2 and 3-3
Pin A:
Circuit
Pin B:
Arc On
feed,
for Pins B, C, and L.
common
signal;
starts gas flow and wire
turns on contactor.
DIP switch Si
on
or
Analog Channel
Board PC4 allows set
robot interface control function for all automatic, all
manual, selector switch, preset, or manual inductance
ting
Pin C:
Jog
REV.
Pin D:
Jog
FWD.
Pin E:
Current
signal.
for
from
cases
where
a
third
signal.
Detect
signal;
robot control
unit
closure
contact
with
respect
No. I thru 5 all
to
1.
Loosen
2.
Wire stick check
from
signal;
robot control
Locate
contact closure
unit with
Current
from
Detect
signal;
Wire stuck
right
side
closure
4.
Close and
respect
to
secure
door.
B.
Connection To Receptacle On Robot Interface
1.
Obtain
(Figure 3.3)
signal;
Pin K:
Circuit
Pin L:
Gas Valve; input
common
contact closure from ro-
signal;
0 to 8V
signal
=
length,
and
a
Connect conductors at end of cord to appropriate
pins in plug.
3.
Align keyway,
insert
plug
into
matching receptacle
fully
robot interface, and rotate threaded collar
clockwise.
0 to 800
ipm.
cord of the proper type and
2.
for Pin D.
signal.
a
24-pin Amphenol plug (not supplied).
on
Wire feed
Channel Board PC4 in
Set switches No. 1 thru 5 of DIP switch Si for de
sired mode selection and the available robot
channels (see Chart 3-3 or Chart 3-4).
bot control unit with respect to Socket G.
Pin M:
panel door.
3.
Socket E.
Pin J:
follows:
to
respect
contact
robot control unit with
Analog
as
and open control
portion of base inside the interface.
Socket j.
Pin H:
channel is not available at
OFF), proceed
screws
Socket H.
Pin G:
analog
the robot control (see Chart 3-2). To change factory set
position of the DIP switch from all automatic (switches
4.
Route and connect conductors at
remaining
end of
cord to the robot control unit.
Pin P:
Analog
Pin R:
Arc
common
for Pins M and A.
voltage signal; 0
to 1OV
signal
=
0 to
Theinputandoutputsignalsatthesocketsof receptacle
RC100 by means of the robot interface control circuitry
are as
50V output.
follows:
Receptacle RC100
IMPORTANT: The
not used.
OM-154 145 Page 12
remaining pins
in the
receptacle
are
Socket A:
Wire Feed
signal
=
Speed command signal:
0 to 800 ipm.
Oto 8V
The
input and output signals at the sockets of receptacle
by means of the robot interface control circuitry
RC1 00
are as
(See
follows:
Circuit Breaker CB1
(See Section 7.2)
0
signal
=
19-Socket Motor/Gas
Control Receptacle
RC2
signal;
command
Speed
Wire Feed
0
RC100
Receptacle
Socket A:
Fuse Fl
Section 7-2)
0~
0 to 8V
ipm.
0 to 800
14-Pin
Source
Speed
Socket 5:
Wire Feed
Socket C:
Arc Volts command
Welding Power
Receptacle RC1
common.
17-Pin
signal
Socket D:
=
Socket F:
Circuit
RC4
4-Pin Arc
Sensing
Receptacle Rc5
B
common.
FWD.
Jog
Receptacle
0 to by
0 to 50V output.
Arc Volts
Socket E:
signal;
Location Of Receptacle(s)
For Robot Control
Unit Connections
signal.
S1.57
Arc On
Socket G:
for Socket E.
common
signal;
feed, and turns
Figure
starts gas flow and wire
contactor.
on
Circuit
Socket J:
Jog
Socket K:
Circuit
common
for Socket J.
Socket L:
Circuit
common
for Socket M.
Socket M:
Arc detect
1.
REV,
signal.
Align keyways.
on
common
B.
for Sockets P and Q.
Wire Stuck
Socket 0:
Arc Failure
Socket R:
Touch Sense
Sensing
fully
Align keyways,
insert
interface,
Control
and
19-pin plug into matching re
gas/current sensing control, and
collar fully clockwise.
on
Weld Cable Connections
(DCEP), proceed
follows:
signal.
signal.
signal;
1.
Remove wrapper from
2.
Connect
a
minal
welding power
contact closure from
robot control unit with respect to Socket S.
3.
on
gas/current sensing
weld cable to
Route cable
through
positive (+)
Touch Sense
signal;
control.
weld output ter
source.
reed
relay,
and connect to
shunt terminal marked POWER SOURCE
Socket Sr
re
rotate
Clockwise.
For Direct Current Electrode Positive
as
Socket P:
096
View
19-pin plug into matching
robot
threaded collar
ceptacle RC3
signal.
insert
RC2
rotate threaded
Circuit
Gas/Current
Robot interface
ceptacle
2.
Socket N:
Right Side
Connections
for Socket G.
Socket H:
common
A.
3-3.
+.
contact closure from
robot control unit with respect to Socket A.
4.
Route
a
weld cable
through opening
on
opposite
end of control, and connect to shunt.
IMPORTANT: The
are
remaining
sockets in the receptacle
5.
not used.
3-13.
GAS/CURRENT SENSING CONTROL INTER
CONNECTIONS
Connect remaining end of weld cable to weld cable
on wire drive assembly (see Motor/Drive
Assembly Owners Manual for location).
terminal
(FIgure 3-3)
6.
Connect a weld cable to
minal
a
WARNING: ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before making in
terconnections.
Lockoutltagging procedures Consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
7.
on
welding
negative ()
power
weld output ter
source.
Connect remaining end of weld cable to workpiece.
For Direct Current Electrode
cable connections at
C.
Negative (DCEN),
welding power source.
reverse
Gas Connections
Connect hose from gas
supplied)
regulator/flowmeter (customer
fitting on gas/current sens
at gas source to IN
ing control. Connect gas hose from wire drive assembly
fitting on gas/current sensing control. The gas flow
must be accurately controlled by a regulator/flowmeter
to
at the source.
OM-154 145
Page
13
0.
Sensing
Gas/Current
Motor Connec
Control
tions
A.
REMOTE 14 ConnectIons
1.
Align keyway,
Align keyways, insert 14-socket plug
cord into matching receptacle RC5 on gas/current sens
ing control, and rotate threaded collar fully clockwise.
VOLTAGE SENSING CONNECTIONS
3-14.
One lead should be connected to the wire drive as
sembly, along with the weld cable from the welding
power source,
as
shown in
Figure
rotate
B.
REMOTE 17 Connections For Arc Pak 350 And
Maxtron 450
-
Place the REMOTE
IMPORTANT:
switch in the REMOTE 14
2.
matching
and
Align keyway, insert 14-pin plug into matching re
ceptacle on welding power source, and rotate
threaded collar fully clockwise.
(Figure
Align keyway, insert 4-socket plug from voltage
sensing cord into matching receptacle RC5 on robot
interface, and rotate threaded collar fully clockwise.
into
plug
2.
3-4)
1.
insert 14-socket
receptacle RC1 on robot interface,
threaded collar fully clockwise.
from motor control
position,
14/17 selector
and make connec
tions to both the REMOTE 14 and REMOTE 17 recep
tacles. For the Maxtron 450 welding powersource, place
the Arc Force/Inductance And CC/C V Control Switch in
3-4.
the REMOTE 17 position.
3.
Connect remaining lead to the workpiece.
1.
Align keyway,
insert 17-socket
receptacle RC4
Nut
threaded collar
2.
threaded
Flat Washer
plug
into
matching
interface, and
rotate
clockwise.
fully
insert 17-pin plug into matching re
welding power source, and rotate
collar fully clockwise.
on
CONNECTION FOR NONPULSE WELDING
3-16.
Terminal
robot
Align keyway,
ceptacle
Voltage Sensing
Lead Ring
on
WARNING: ELECTRIC SHOCK
a
can
kill.
Do not touch live electrical parts.
Shut down robot and welding power source,
and be sure equipment cannot be accidently
energized before inspecting or installing.
Weld Cable Lug
Location
equipped with the optional RCSP-R panel, it
ready for pulsed welding when jumper link on terminal
strip 2T is across terminals M and N. If nonpulsed weld
ing is desired, proceed as follows:
If this unit is
Wire
Drive
Assembly
is
Loosen
1.
screws
and open control panel door.
S-0401
Figure
Voltage
Sensing Connections
At Wire Drive
3-15.
ROBOT INTERFACE
side of control
Assembly
-
WELDING POWER
SOURCE CONNECTIONS
strip 2T in center left portion
panel door.
Locate terminal
2.
3-4.
Move jumper link from 2T terminals M and N to
terminals K and L.
4.
Close and
secure
OPTIONAL RCSP-R
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before making in
terconnections.
a
supplied for interconnection
robot interface and welding power source.
three cords
between the
Examine cords and select the proper cord(s) for
connection.
OM-154 145
Page
14
the
SET-UP
(Figures
FOR
3-5 And
WARNING: ELECTRIC SHOCK
USING
3-6)
can
kill.
Do not touch live electrical parts.
Shut down robot and welding power source,
and be sure equipment cannot be accidently
energized before inspecting or installing.
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging Circuit breaker or other disconnect
ing device.
are
door.
(Figure 3-3)
MAXTRON 300
There
in
3.
3-17.
a
on
CAUTION: ELECTROSTATIC DISCHARGE
(ESD)
can
Put
on
damage circuit boards.
properly grounded
BEFORE
handling
A.
DIP switch
circuit boards.
changing
RCSP-R Unit DIP Switch
IMPORTANT:
changed
strap
or
Setting
Both DIP switch positions must be
to the OFF position before
the Maxtron 300
wrist
positions
using
welding power source.
this unit with
Interface Circuit
Board PCI
DIP Switch
SW 1
SB
Figure
3-5. DIP Switch Location On
an internal DIP switch SW1 on Interface
Circuit Board PCi which consists of two switches. Both
switches are factory set in the ON position for use with
the Arc Pak 350 welding power source. Both switches
This unit has
must be
placed
in the OFF
position
when
using
this unit
welding power source. To check or
positions of the DIP switch, proceed as fol
with the Maxtron 300
change
the
lows:
1.
2.
Loosen
screws
and open control
panel door.
Locate Interface Circuit Board PCi, the third cir
cuit board behind the operator control
3.
Locate DIP switch SW1
on
the
right
side of PCi
Place switches in the desired positions. The posi
are factory set in the ON position and only
tions
need to be
changed for use with
Close and
secure
IMPORTANT:
When
this unit with the Maxtron
using
300, the welding power source Mode Switch on the front
panel must be set in the CC position for pulsed welding
or
CVfornonpulsed welding.
welding power source.
Inductance/s controlled
by
the
If the Maxtron 300 is
equipped with field kit MILLER Part
CCposi
tion for all welding applications and CV/CC switching is
done through the 17-position connection. If the Mode
switch is in the CV position, only CV applications are
No. 146722, the Mode Switch can remain in the
available.
the Maxtron 300.
B.
MAXTRON 300 GTAW/GMAW-P Switch
The main control board in the Maxtron 300 has a GTAW/
GMAW-P switch which is in the GTAW position when it is
shipped from the factory. To do pulsed welding with the
RCSP-R and robot system, this switch must be placed in
the GMAW-P
5.
interface Board PCi
panel.
(see Figure 3-5).
4.
Optional RCSP-R
36 265
door.
position. To change switch position, pro
ceed as follows:
of Maxtron 300.
1.
Remove top
2.
Locate main control board. The switch is between
receptacles RC4 and RC5 on the front edge of the
board
cover
(see Figure 3-6).
3.
Place the switch in the GMAW-P position.
4.
Replace top
3-18.
cover.
WELDING WIRE INSTALLATION (Figure 3-7)
A.
Installation Of
1.
Remove
2.
Slide spool of wire onto hub
Spool-Type
Wire
retaining ring.
so
that wire feeds off
bottom of spool.
3.
Rotate spool until hole in spool aligns with pin in hub.
Slide spool onto hub until it seats against back
flange of the hub.
4.
Reinstall retaining
Pef SC~l5O 689
Figure
3-6. GTAW/GMAW-P Switch Location
ring
onto hub.
OM-154 145
Page
15
Installation Of
B.
Type
Wire Retainer
Wire Reel And Reel-
Optional
Wire
if
1.
Remove retaining ring and,
assembly from hub.
2.
Lay wire reef assembly flat
3.
Remove spanner nut from wire reel assembly.
4.
Remove wire retainer, and install wire onto wire reel.
Be sure that wire feeds off bottom of reel.
5.
Reinstall wire retainer and spanner nut onto wire
reef.
applicable, wire reel
Wire Reel
Hub
table
or
floor.
Slide wire reel assembly onto hub, and rotate
6.
sembly
Hub
on a
until hub
guide pin
7.
Reinstall
C.
Adjustment Of Hub Tension (Figure 3-1)
Support
retaining ring
as
is seated in reel.
onto hub.
Check the hub tension by slowly rotating the wire spool
reel. The wire should unwind freely, but hub tension
or
SC 127 308
should be sufficient to
keep
lash when the wire feed
Figure
3-7.
Wire Reel And
Optional
Reel-Type
Wire
loosen
SECTION 4OPERATOR
POWER SWITCH AND PILOT LIGHT
tighten
the hex nut
on
the end of the hub sup
port shaft accordingly.
Installation
4-1.
or
wire taut and prevent back
If adjustment is required,
stops.
(Figure
4-3.
CONTROLS
PURGE PUSH BUTTON
(Figure 4-1)
4.1)
ON
POWER
PURGE
OOFF~
Placing the POWER
The
switch in the ON position
the robot interface. The
energizes
pilot light comes on when the
ON position, indicating that the
POWER switch is in the
unit is energized. The interface must be on for the robot
to weld. Placing the POWER switch in the OFF position
shuts down the interface and turns off the pilot
4-2.
energizing
4-4.
JOG
JOG
REVERSE
a
momentary-contact
the
energizes
welding
VOLTMETER
circuit.
(Figure 4-1)
VOLTS
V
The voltmeter
of
0~
push button is
the gas solenoid and
purges the shielding gas line of the gun. The PURGE
push button allows the flow meter to be adjusted without
light.
JOG PUSH BUTTONS (Figure 4-1)
010
PURGE
switch. This switch
a
4-5.
volt while
displays weld voltage to the nearest tenth
welding and preset voltage while idling.
WIRE SPEED METER
(Figure 4-1)
WIRE SPEED 1PM
FORWARD
The JOG FORWARD and JOG REVERSE push buttons
are momentary-contact switches. Push the JOG FOR
WARD button to feed welding wire from the gun. Push
the JOG REVERSE button to retract wire into the gun.
OM-154 145
Page
16
010
The wire speed meter displays preset wire feed speed to
the nearest inch per minute while welding and idling. Ac
tual and preset wire feed speed are the
wire feed speed feedback circuit.
same
due to the
AMMETER
4-6.
The WIRE FEED light turns
(Figure 4-1)
is
AMPS
on
when the wire drive motor
to indicate that wire is
energized
feeding.
The CURRENT
light turns on when the current detect
relay is energized to indicate that an arc is established.
A
The ARC FAILURE
light
turns on when there is
an arc
outage while welding.
The ammeter indicates amperage draw through the
shunt in the gas/current sensing control during welding;
PREFLOW CONTROL
4-8.
however, the amperage value may not necessarily be
actual welding amperage.
INDICATOR LIGHTS
4-7.
There
are
five indicator lights
(Figure 4-1)
on
the interface. These are
PREFLOW
visual indications of various process functions.
IMPORTANT:
PREFLOW is used by all robot models
except ABB.
The GAS light turns on when the gas valve is energized
to indicate shielding gas flow.
The PREFLOW control is located
The CONTACTOR
er source
light
contactor is
turns on when the
energized
welding
allow
pow
to indicate that weld
arc
Voltmeter
Wire Speed
1PM Meter
Gas
Indicator
Light
Contactor
Indicator Light
Current
Indicator Light
Arc Failure
Indicator Light
Purge
Pilot
Light
\
o\
Wire Feed
Indicator LighL~
the front panel to
flows before the
can
be varied from approxi
0 to 6 seconds.
Push Button
\
\
\
/
Ammeter
on
shielding gas
is started. Preflow time
mately
output is available.
the time that
setting
Power
Switch
\
I
I
I
1
1
~\
Reverse
Push Button
Jog
1111
~lI~lI
0
Jog Forward
Push Button
'
'
RCSP.R
Panel
_~(See Figure
5.1)
Preflow
Control
Postf low -~
Control
0
Burnback Tlme
Burnback~~
Voltage
0
0
00000
VoltagelArc
Power Manual
Control
~!\
o/
OPTIONAL
I
WFS/Arc Length
Manual Control
0
o~,
\
I
Selector
Switch
Figure
Inductance
Manual Control
ST.157 097
4-1. Front Panel Controls
OM-154 145
Page
17
4.9.
on the front panel that are acti
Board DIP switch Si is set
Channel
Analog
to provide all manual operation or Selector switch opera
tion using the MANUAL position: VOLTAGE/ARC POW
ER, WFS/ARC LENGTH, and INDUCTANCE.
There
POSTFLOW CONTROL
are
three controls
vated when
IMPORTANT: POSTFLOW is used by al/robot models
except ABB.
VOLTAGE/ARC POWER Control
A.
V
VOLTAGE!
POSTFLOW
The POSTFLOW control is located
on
the front
panel
ARC POWER
to
setting the time that shielding gas flows after burn
back. Postftow time can be varied from approximately 0
to 6 seconds. Postf low time starts after burnback time
allow
The VOLTAGE/ARC POWER control provides selection
of the arc voltage when the RCSP-R panel is not opera
tional.
ends.
Preset
4.10.
Rotating the control clockwise increases voltage.
voltage will be displayed on the voltmeter.
BURNBACK TIME CONTROL
When the RCSP-R panel is
..~.
BURN BACK
The BURNBACK time control is located
el. Burnback time
can
be varied from
on
and set for puls
the front pan
approximately 25
If the unit is set for
wire feed
to 250 milliseconds.
speed,
tions 5-i and
4-11.
operational
ing,
power parameters are wire feed speed, back
ground amperes, peak amperes, pulse frequency, and
pulse width (see Sections 5-1 and 5-3).
arc
nonpulsing, arc power parameters are
voltage, and inductance (see Sec
arc
5-3).
BURNBACK VOLTAGE CONTROL
WFS/ARC LENGTH Control
B.
V
010
BURNBACK
The BURNBACK
voltage
panel. Burnback voltage
wire after the drive motor
control is located
on
is the
voltage
the
stops
at the end of a
welding
welding
electrically ener
on
operation. The welding wire remains
gized for the time set on the BURNBACK time control.
The numbers around the control are not voltage values
and are for reference only.
4-12.
WFS/
ARC LENGTH
the front
The WFS/ARC LENGTH control provides selection of
the wire feed speed when the RCSP-R panel is not op
erational.
Rotating
the control clockwise increases wire
feed speed. The wire feed
wire speed meter.
speed will be displayed
on
the
SELECTOR SWITCH
IMPORTANT:
Si must be set
Selector switch
Analog Channel Board DIP switch
correctly to allow use of the front panel
(see Charts 3-2, 3-3, and 3-4).
The
The Selector switch has three
positions: MANUAL,
AUTO, and SETUP.
In MANUAL mode, the robot interface front
panel
con
When the RCSP-R
ing,
arc
panel is operational and set for puls
tuning of pulse frequency (see
and 5-3).
length
Sections 5-i
is a fine
If the unit is set for
of
arc
C.
nonpulsing, arc length is
voltage (see Sections 5-1 and 5-3).
a
fine
tuning
INDUCTANCE Control
trols provide the weld parameters (see Section 4.12).
IMPORTANT: The INDUCTANCE control only functions
In AUTO mode, the robot control
with
provides
the weld pa
rameters.
In SETUP mode, the robot will
run
through programs but
the welding power source contactor does not close and
the gas valve is not energized. A current detect signal is
sent to the robot control.
4.13.
MANUAL CONTROLS
IMPORTANT: The Analog Channel Board DIP switch
SI must be set correctly to allow use of the front pane!
controls (see Section 3-8).
OM-154 145
an
source
Page
18
Arc Pak 350
and the
or
Maxtron 450
Analog Channel Board
welding
power
DIP switch Si
setting provides manual inductance control (see Charts
3-2, 3-3, and 3-4).
Jy~
INDUCTANCE
The INDUCTANCE control allows manual
adjustment of
inductance at the robot interface front panel.
OPTIONAL RCSP-R OPERATOR CONTROLS
SECTION 5
Standard Mode
Indicator
Light
wire Type
Selector Switch
Wire Size
Indicator
Lights
Wire Size
Selector Switch
No
Recommended
Shielding Gas
Program
Light
Indicator
Indicator
Figure
5-1.
5-1.
WIRE SIZE SELECT SWITCH AND STAN
When the WIRE SIZE SELECT Switch is
DARD MODE INDICATOR LIGHT
STD position, the STANDARD MODE Indicator Light wifi
come on, indicating that the Synergic Pulse panel is in
SELECT Switch set the output range of the welding pow
er source
and robot wire drive for the
size of wire chosen.
Together,
relationship of the various
specific type and
IMPORTANT:
When
placed
in the
standard mode and cannot be used to set the output pa
rameters for the welding power source or robot wire
drive.
the switches determine
arc
power parameters.
IMPORTANT: Position the WIRE SIZE SELECT Switch
in the .045
using this
unit with the Maxtron
300, the welding power source Mode Switch
on
the front
position for pulsed welding
or CV for noripu/sed welding. inductance is controlled
from the welding power source front panel control.
panel
098
Operator Controls
The WIRE SIZE SELECT Switch and the WIRE TYPE
the
ST.57
Lights
welding
5-2.
position when welding with .047 in. diameter
wire.
WIRE SIZE INDICATOR LIGHTS
(Figure 5-1)
must be set in the CC
The top
(light on)
on
If the Maxtron 300 is
equipped
with field kit MILLER Part
No. 146722, the Mode Switch can remain in the CCposi
tion for all welding applications and CV/CC switching is
done through the 17-position connection. If the Mode
switch is in the CV
position, only CV applications
are
available.
If the unit is operated in
pulse condition, arc power pa
speed, background amperes,
peak amperes, pulse frequency, and pulse width. Arc
length is a fine tuning of pulse frequency.
a
rameters are wire feed
light
or
when the
nonpulse condition, arc power
parameters are wire feed speed, arc voltage, and induc
tance. Arc length is a fine tuning of arc voltage.
operated
in a
corresponding
wire size is selected by the
WIRE SIZE SELECT switch.
5-3.
WIRE TYPE SELECT SWITCH
(Figure 5-1)
The WIRE TYPE SELECT Switch is functional when the
WIRE SIZE SELECT Switch is not in STD. The WIRE
TYPE SELECT Switch and the WIRE SIZE SELECT
Switch set the output range of the welding power source
and robot wire drive for the specific type and size of wire
chosen.
Together,
ship of the various
If the unit is
If the unit is
indicates whether the unit is set to pulse
(light off). The remaining lights turn
is in STD
the switches determine the relation
arc
power parameters.
in a
pulse condition, arc power pa
speed, background amperes,
peak amperes, pulse frequency, and pulse width. Arc
length is a fine tuning of pulse frequency.
operated
rameters are wire feed
OM-154 145
Page
19
operated
are
tance. Arc
nonpulse condition, arc
speed, arc voltage, and
fine tuning of arc voltage.
in a
If the unit is
parameters
wire feed
length
is
a
After
power
induc
this unit with the Maxtron
power source Mode Switch on the front
When
300, the welding
does not
light
the wire size and type, the indicator
using
shielding gas
light
will come on. If
a
and the NO PROGRAM Indica
come on,
light does not come on, refer
shielding gas.
tor
IMPORTANT:
selecting
for the recommended
to Table 5-1 for the rec
ommended
If the NO PROGRAM Indicator
must be set in the CC position for pulsed welding
CV for nonpulsed welding. Inductance is controlled
from the welding power source front panel control.
panel
without
or
a
Light
with or
comes on
RECOMMENDED SHIELDING GAS Indicator
reselect the wire type and size to be used (see
Light,
Section 5-5).
If the Maxtron 300 is
equipped
No. 146722, the Mode Switch
with field kit MILLER Part
can
INDICATOR LIGHT
(Figure
5-1)
we/ding applications and
through the 17-position connection. If the Mode
switch is in the CV position, only CV applications are
tion for all
Pulse panel has been programmed to pro
optimum welding conditions in a majority of situa
tions using various types and sizes of welding wire and
various shielding gases. The NO PROGRAM Indicator
Synergic
The
done
vide
available.
5-4.
NO PROGRAM
5-5.
CCposi
C V/CC switching is
remain in the
RECOMMENDED SHIELDING GAS INDICA
Light
TOR LIGHTS
been
(Figure 5-1)
allows the operator to determine if the unit has
programmed for the conditions set by the WIRE
TYPE SELECT and WIRE SIZE SELECT switches. If
RECOMMENDED
The
Lights represent
mended for
use
SHIELDING
GAS
Indicator
the NO PROGRAM Indicator
types of shielding gases recom
with the Synergic Pulse panel. The
the
panel is programmed to select the shielding gas that will
provide optimum welding conditions in a majority of situ
ations for the type and size of wire selected on the WIRE
Synergic
comes on,
the control
IMPORTANT: Use of a nonrecommended shielding gas
SIZE SELECT and WIRE TYPE SELECT switches.
Table 5-1.
light
programmed for the conditions set by the two
switches; therefore, it will be necessary to reselect the
type and size of wire to be used.
is not
could
change
weld characteristics.
Welding Schedules
Pulse Panel
PULSE WELDING
Wire
Type
STL1
STL2
NI
SS1
SS2
ALl
AL2
SI BR
CUST.
030
*
*
*
*
*
*
*
*
*
.035
*
98Ar/2 02
75Ar/25
*
Ar
Ar
Ar
*
Ar
*
98Ar/2 02
HE
.045
*
98Ar/2 02
75Ar/25
HE
98Ar/2 02
*
Ar
Ar
.062
*
*
*
*
*
Ar
Ar
ALl
AU
SI BR
CUST.
*
*
*
*
NONPULSE WELDING
Wire
.030
STLI
STU
CO2
75Ar/25
NI
Type
SSI
SS2
SPCL
98Ar/2 02
SPCL
98Ar/2 02
Ar
Ar
Ar
~
SPCL
98Ar/2
02
Ar
Ar
~
*
Ar
Ar
CO2
.035
CO2
75Ar/25
CO2
.045
CO2
.062
*
75Ar/25
CO2
*The
Synergic
OM-154 145
Page
*
Pulse panel is not
20
*
*
programmed for type
*
and size of
welding
wire indicated.
*
DEFINITION OF TABLE 5-1 DATA
Wire
Type:
STL1
Mild Steel
=
(Used with 002 shielding gas for short circuit welding from minimum
to maximum wire feed
speed.)
STL2
Mild Steel
=
mum
(In PULSE mode, STL2 is used with ~8 Ar/2 02 shielding gas for pulse spray welding from mini
speed. In NONPULSE mode, STL2 is used with 75 Ar/25 002 shielding gas
to maximum wire feed
for short circuit
welding
from minimum to maximum wire feed
speed.)
-
NI
.
SSI
Nickel
Alloy
=
High
=
Stainless Steel
(In PULSE mode, SS1 is used with 98 Ar/2 02 shielding gas for spray transfer welding from
speed. In NONPULSE mode, SS1 is used with Tn-Mix shielding gas for
transfer welding from minimum to maximum wire feed speed.)
minimum to maximum wire feed
short circuit
Stainless Steel (SS2 is used with 98 An/2 02 shielding gas for spray transfer
mum wire feed speed.)
SS2
=
ALl
=
4043 Aluminum
AL2
=
5356 Aluminum
SI BR
=
Silicon-Bronze
*CUST.
=
=
.045 409 flux-cored stainless steel
*NONPULSE Welding
=
welding
.045 AWS class E71T-l flux-cored
wire
welding
wire
Gas:
CO2
75 Ar/25
from minimum to maxi
Position usually reserved for programming a welding schedule not included in the standard programming
of the unit. At this time, the welding schedule programmed for this position is as follows:
*PULSE Welding
Shielding
welding
CO2
=
Carbon Dioxide
=
75%
Argon
25% Carbon Dioxide
SPCL
=
Tn-Mix:
90% Helium
7.5%
Argon
2.5% Carbon Dioxide
AR
98 An/2
02
=
Argon
=
98%
2%
~75 Ar125 HE
=
75%
Argon
Oxygen
Argon
25% Helium
~This
shielding gas is
not included on
nameplate of the Synergic Pulse panel.
OM-154 145 Page 21
SECTION 6
6.1.
SEQUENCE OF OPERATION
OPTIONAL RCSP-R GAS METAL ARC WELD
ING
Install and connect robot system according to its
Manuals.
1
Owners
(GMAW)
WARNING:
ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
Do not touch live electrical parts.
Keep all covers and panels
operating.
Do not touch
contact with
in
IMPORTANT:
panel
this unit with the Maxtron
using
must be set in the CC
CV for nonpulsed
or
position
on
for pulsed
the front
welding
welding.
place while
If the Maxtron 300 is
welding wire or any metal part in
it while welding.
welding wire and all metal parts in contact
with it carr)f weld output when the welding power
source contactor is energized.
The
is void if any of the equipment is oper
ated with any portion of the outer enclosure
removed.
Warranty
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage
equipped with field kit MILLER Part
can remain in the CCposi
tion for all welding applications and pulse/non pulse
switching is done through the 17-position connection. If
the Mode switch is in the CV position, only CV applica
No. 146722, the Mode Switch
tions
are
welding
2.
3.
hearing.
available. Inductance is controlled from the
power source front
panel control.
Connect robot interface according to Section 3.
Position WIRE SIZE SELECT Switch for size wire
(see Section 5-1).
used
Wear correct eye, ear, and
FUMES AND GASES
your health.
Keep
When
300, the welding power source Mode Switch
can
body protection.
seriously
harm
4.
Position WIRE TYPE SELECT Switch for type
wire used
(see Section 5-3).
your head out of the fumes.
Ventilate to
keep from breathing fumes
and
5.
Place welding power
ment
gases.
If ventilation is
inadequate,
use
6.
can
cause
setting.
Rotate MAXTRON 300 inductance control to de
sired
WIRE
front panel adjust
approved
breathing device.
WELDING
control(s)
source
to the maximum
setting.
puncture
wounds.
Do not point gun toward any part of the body,
any conductive surface, or other personnel.
MAGNETIC FIELDS FROM HIGH CURRENTS
can aftect pacemaker operation.
7.
Turn
8.
Energize
9.
Begin welding.
on
shielding gas
at its source.
robot system.
Wearers should consult their doctor before
going near arc welding, gouging, or spot weld
6-2.
ing operations.
HOT
METAL, SPATTER, AND SLAG
cause
SHUTTING DOWN
can
tire and burns.
1.
Stop welding.
2.
Shut down robot system.
3.
Turn off
Watch for fire.
Keep
a
fire
extinguisher nearby,
how to
use
Do not
use near
and know
it.
flammable material.
shielding gas
at the source.
Allow work and equipment to cool before
handling.
See Section 1
Safety Rules For Operation Of
Arc Welding Power Source in the welding power
source Owners Manual for basic welding safety
information.
-
OM-154 145
Page
22
a
WARNING:
HIGH CONCENTRATION OF
SHIELDING GAS can harm health or kill.
Shut off gas
supply
when not in use.
SECTION 7- MAINTENANCE & TROUBLESHOOTING
Wire Drive Motor Circuit Breaker CB1
A.
ROUTINE MAINTENANCE
7-1.
(Figure
3-3)
Eveny six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
IMPORTANT:
See Parts List for part number of
when necessary.
precautionary labels.
Usage and shop conditions determine the frequency
and type of maintenance. At minimum, inspect equipment every three months as follows:
WARNING: Read and follow safety informa
tion at beginning of Section 7-2 before pro-
ceeding.
Circuit breaker CB1 protects the wire drive motor from
overload. If CB1 opens, the wire feed motor would stop.
Should
as
1.
a
WARNING: ELECTRIC SHOCK
can
Check for
correct
kill.
2.
Do not touch live electrical parts.
overload
a motor
occur
and CB1 open, proceed
follows:
jammed
wire
problem. If wire
If motor overload
or
clogged gun liner,
and
jams often, replace gun liner.
often, repair or replace wire
occurs
drive motor.
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before inspect-
ing, maintaining,
or
3.
4.
serious
can cause
before
Maintenance to be performed
breaker
can
be reset.
5.
Resume operation.
B.
Main Fuse Fl
injury.
(Figure 3-3)
ceeding.
burns.
servicing.
only by qualified
persons.
Fuse Fl protects the robot interface and RCSP-R panel
from an internal short or excessive overload. If fuse Fl
opens, the robot interface and RCSP-R shuts down. If
problem and replace
the fuse opens, correct the
follows:
1.
Repair
or
replace,
give particular
Iation and
as
frayed
and cracked insu-
1.
where it enters equipment.
Remove grease and grime from components; moisture from electrical parts and cable.
7-2.
OVERLOAD PROTECTION
a
WARNING: ELECTRIC SHOCK
can
kill.
or
servicing.
INCORRECT FUSE
can
damage
unit.
onlyreplacement fuse of same size, type,
rating (see Parts List).
cover
when fuse holder
fuse into fuse holder
3.
Insert
4.
Install fuse with fuse holder
5.
new
Depress and
cover
is
is
back into unit.
rotate fuse holder cover clockwise until
secure.
If it becomes necessary to
reinstall the
(Fig.
replace part or all of the hub
hub assembly as follows:
new
assembly from hub support, and disas
discarding worn or broken parts.
Remove hub
semble
2.
cover
7-1)
ure
1.
cover.
REINSTALLATION OF HUB ASSEMBLY
7-3.
assembly,
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnecting device.
rotate fuse holder cover counterciock
Pull out fuse with
cover
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before inspect-
ing, maintaining,
Depress and
free.
Do not touch live electrical parts.
Use
and
as
wise.
2.
2.
Fl
required, all hose and cable;
attention to
areas
drive
WARNING: Read and follow safety informa
tion at beginning of Section 7-2 before pro-
can cause severe
cooling period
Allow
misaligned
or
Reset circuit breaker by depressing the button. A
cooling period may be necessary before the circuit
Keep away from moving parts.
HOT SURFACES
drive gear
binding
rolls, and correct problem.
servicing.
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnecting device.
MOVING PARTS
Check for
Slide the following items onto the hub support shaft
in order
given.
a.
Spring
b.
Keyed Washer
c.
Fiber Washer
OM-1 54 145
Page
23
Retaining Ring
Spanner
Nut
Fiber
Washer
Keyed
Washer
Wire Retainer
Fiber
Washer
Wire Reel
Hub
Support
Shaft
Spring
Hex Nut
Hub
Hub
Support
R&
Figure
d.
SD-045 31 7J
7-1. Hub And Reel Assemblies
ELECTROSTATIC
Brake Washer
DISCHARGE
(ESD)
can
damage circuit boards.
e.
Hub
f.
Brake Washer
g.
Fiber Washer
Put
properly
on
Transport circuit boards
shielding
3.
and insert hub support shaft
selected hole in hub support.
Align keyway,
through
4.
Install hex nut onto hub support shaft. Tighten hex
nut until a slight drag is felt while turning hub.
5.
Install
7-4.
welding
wire
according
strap
can
Be
kill.
ing, maintaining,
before inspect
servicing.
a
proper static-
static-safe work
sure
that
plugs
are
properly
EXCESSIVE PRESSURE
board.
area.
installed and
can
break circuit
only minimal pressure and gentle move
when disconnecting or connecting
board plugs and removing or installing board.
Use
ment
Shut down unit, welding power source, and
robot, and disconnect input power employing
or
in
packages.
aligned.
Do not touch live electrical parts.
lockout/tagging procedures
or
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
to Section 3-18.
ELECTRIC SHOCK
carriers
Perform work only at
CIRCUIT BOARD HANDLING PRECAUTIONS
WARNING:
wrist
grounded
BEFORE handling circuit boards.
IMPORTANT: The circuit boards in THE RCSP-R panel
Interface Circuit Board PCi, Logic Circuit Board PC2,
Circuit Board PC3-are installed stacked
and Memoi,
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
panel. PC2 is
red-tagging circuit breaker
ing device.
operator control panel), PC3 is in the middle, and PCI is
at the top of the stack.
OM.154 145
Page
24
or
other disconnect
on
top of each other on the inside of the operator control
at the bottom of the stack
(closest
to the
7-5.
a
TROUBLESHOOTING
It is assumed that the unit
WARNING: ELECTRIC SHOCK
manual, the operator is familiar
with the function of controls, the robot interface was
can
ing
kill.
Do not touch live electrical parts.
or
The
following table
remedies for
Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
circuit breaker
or
is
designed
can cause
Keep away from
circuit
HOT SURFACES
these
and
provide
diagram while performing troubleshooting
procedures,
contact the nearest
proce
performing
Factory Author
of equipment malfunc
tion, strictly follow the manufacturers procedures and
instructions.
injury.
moving parts.
can cause severe
diagnose
dures. If the trouble is not remedied after
other disconnect
serious
to
some
ized Service Station. In all
MOVING PARTS
accord
of the troubles that may develop in
this robot interface. Use this table in conjunction with the
servicing.
red-tagging
ing device.
properly installed
and that the trouble is not related to the
working properly,
welding process.
Shut down unit, welding power source, and
robot, and disconnect input power employ~rig
lockout/tagging procedures before inspecting
was
to Section 3 of this
cases
burns.
cooling period before servicing.
Troubleshooting to be performed only
qualified persons.
Allow
by
Table 7-1. Robot Interface
Troubleshooting
REMEDY
PROBABLE CAUSE
TROUBLE
Welding power
Unit does not operate.
source
Turn
off.
welding power source on (see welding
er source
~
Owners
pow
Manual.
14-pin receptacle on interface Check and secure connections (see Section
14-socket receptacle on 3-15 and welding power source Owners Manu
aI).
welding power source.
.
or
.
Check CB1, and reset if necessary (see Section
7-2). Correct overload problem before Continu
Circuit breaker CB1 tripped.
ing operation.
Check Fl, and replace if necessary (see Section
7-2). Correct overload problem before continu
Fuse Fl open.
ing operation.
No weld output.
Power switch on welding power
in OFF position.
Place POWER switch in ON position.
Fuse Fl open.
Check Fl, and replace if necessary (see Section
7-2). Correct overload problem before Continu
source
ing operation.
Improper regulation of
age.
arc
volt-
Work connection loose
complete due
on
or
paint,
surface of workpiece.
to rust,
AMPERAGENOLTAGE
trol switch
source
on
inetc.
con-
welding
power
front panel in PANEL p0-
Check work connection for good metal-to-metal
contact.
Place AMPERAGENOLT/~GE control switch in
the REMOTE 14
source
Owners
position (see welding power
Manual).
sition.
14-pin receptacle on interface Check and secure connections (see Section
14-socket receptacle on 3-15 and welding power source Owners Manu
al).
welding power source.
or
Receptacle connections inside Check and
secure
connections.
interface.
Incorrect DIP switch
settings.
Check DIP switch settings on Analog Channel
Board PC4 (see Charts 3-2,3-3, and 3-4, and ap
propriate setup section for correct robot model).
OM-154 145
Page
25
Table 7-1. Robot Interface
PROBABLE CAUSE
REMEDY
Incorrect robot command volt-
Check robot command voltage at DVC Board
PC8. Voltage should be 0-10 vdc between
RC1 -16 and lead 17 at terminal G (common) on
TROUBLE
Improper regulation of
arc
volt-
age. (Continued)
Troubleshooting (Continued)
age.
terminal strip iT.
Analog Channel Board PC4
working.
Voltage Board PCi
not
not
working.
Replace PC4 (see Section 7-4 and contact
Factory Authorized Service Station).
near
Replace PCi (see Section
near
est
est
Wire feeds at maximum
only.
Tach Board at wire drive motor
not
Incorrect robot command volt-
meter goes to
wire feed operation.
age.
Not meter
display.
Display Board PC4
speed (1PM)
7-4 and contact
Authorized Service Station).
Replace Tach Board (see motor/drive assembly
Manual).
Owners
working.
zero or no
Wire
Factory
not
working.
Check robot command voltage at Analog Chan
nel Board PC4. Signal should be 0-8 vdc be
tween RC4-l 3 and lead 85 (common) at terminal
B on terminal strip 2T.
Replace PC4 (see Section 7-4 and contact
Factory Authorized Service Station).
near
est
No wire stick check.
Wire stick connection.
Be
Incorrect DIP switch
OM-154 145
Page
26
settings.
that leads from robot
sure
correct
receptacle
Check DIP switch
are
connected to
at interface.
settings on Interface Board
PCI (see Chart 3-1 and appropriate set up sec
tion for correct robot model).
Table 7-2.
REMEDY
PROBABLE CAUSE
TROUBLE
Synergic pulse panel
OptIonal RCSP-R Troubleshooting
not opera-
Panel connections inside Inter-
Check and
secure
connections.
face.
tional.
See Section 7-4 and contact nearest Factory Au
Interface Circuit Board PCi
thorized Service Station.
See Section 7-4 and contact nearest Factory Au
Memory Circuit Board PC3.
thorized Service Station.
See Section 7-4 and contact nearest
thorized Service Station.
Logic Circuit Board PC2.
Factory Au
~
Erratic
weld:
weld
incorrect
Incorrect DIP switch
Check DIP switch settings
PCi (see Section 3-17).
settings.
characteristics.
Synergic pulse panel
not profor
weld
conditions
gramrned
set by WIRE SIZE SELECT and
on
Interface Board
Reselect wire type and wire size to be used.
WIRE TYPE SELECT switches
(NO PROGRAM
will be
indicator
light
on).
Incorrect
arc
Adjust
length.
ARC LENGTH control
on
the robot inter
face.
~
Weld
in
voltage goes
pulse mode.
to maximum
Work connection loose
or
in-
.
complete
Check routing of voltage sensing cable and
connections.
Check work connection for good metal-to-metal
due to rust,
paint, etc.,
surface of workpiece.
contact.
Welding
power source in CV
Change
mode for
pulsing operation.
(see Sections
on
Arc
sensing
se
cure
mode of
Check and
connections.
welding
5-1 and
secure
power
source
to CC
5~3)*.
connections (see Section
3-14).
No pulsing; pulse
light off.
in CV
Welding
power
mode for
pulsing operation.
Incorrect
jumper
terminal strip 2T.
source
link
position
Change
mode of
welding
power
source to
CC
(see Sections 5-1 and 5~3)*.
at
Move jumper link
across
terminals M and N for
pulsing.
*Ma~ron 300 CV/CC front panel switch must be in the CC position; Arc Pak 350 and Maxtron 450 must have 17-socket
receptacle connection; Maxtron 450 CV/CC front panel switch must be in the REMOTE position.
OM-154 145
Page
27
7-6.
USE OF INDICATOR LIGHTS FOR TROUBLE
SHOOTING
Gas Indicator
On
Gas flows:
System
normal
(on.)
Off
Light
Gas does not flow
Gas flows:
Gas does not flow
Check gas valve operation.
Check gas valve Operation
and gas line for leaks.
System
normal
(off).
Check interface board PCi.
Contactor Indicator
On
Contactor closed:
System
normal
(on).
Light
Off
Contactor open:
Contactor closed:
Contactor open:
Check
cords.
Check display board PC7.
System
interconnecting
normal
(off).
Check interface board PCi.
On
Wire Feed Indicator
Wire feeds:
System
normal
(on).
Off
Light
Wire does not feed:
Wire feeds:
Wire does not feed:
Check circuit breaker CB1.
Check input signal from
robot to motor board PC6.
Signal should be 0-8 vdc
between pins K and B
(common) at RC5.
System
Check relay CR1.
Check interface board PCi.
Check motor board P06.
normal
(off).
normal
(off).
Check motor board PC6.
On
Current Indicator
Arc started:
System
On
No
No
normal
(on).
reed
~
arc:
Check weld parameters.
relay.
Page
28
Replace
reed
Arc Failure Indicator
Arc started:
No
Check reed relay
connection inside Gas/
Current Sensing Control.
Normal
Check display board PC7.
OM-154 145
Off
Arc started:
arc:
Replace
Light
No
relay.
Light
arc:
System
Off
Arc started:
arc:
during idling.
Normal while
welding.
NOTES
QM-154 145 Page 29
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OM-154 145
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POI~ER/S~)~ 4(15 F~ CHIPS
#1,82
T
II.COI1,4*ISIJ
U2
8.CYI,16..ISIJ
113
?.C~4,I4.*I5U
U4,LS,1(
7.C~1,I6.*ISU
~f~E~-T
___________
DISABLE
STICK CHECK
~ I J~ J.~ J~
T~ T~T~T~T~T T
9~PR55
Diagram
OM-154 145
Page
34
8-3. CIrcuit
Diagram
For Interface Board PCi
CAPACITORS
C)
C)
8VPRSS CAP~ITORS FOR
P~R~GROU~ ~1S FOP CHIPS
POI(R/GPQ.PC ~TS FOR CHIPS
UI
4.-ISU
I7,I3~ISIJ S.G~
HI
02
I4~IS
?
42
4..~5U
II.154J
03
8~UI
3.GH~6
43
8150
4-ISU
04
8.01
3GH~O
HI
IIS
45
I.U2
4~.ISU 11.-IOU
IIG~C
11.03
______________________________
Diagram
OM-154 145 Page 36
8-4. Circuit
Diagram For DVC Board PC8
C3IMPNO
NCI
9,
~oe
SI
52
Owl TCN
SETTINGS
2
I
23
DELTN.&LD ~
: : :
DELT~LD 451
2
N
0ELT~LD ESI
0
ON
~
ITAXTRON 39~49
-
ON
ON
2~
-
rIRXTRON,SA
~ -~
Xr~T
2AR/300
ON
ON
ON
RRCRRK3SA
ON
ON
ON
S~?~STEA
DIl~NSION
o
A
-
380
400
ON FOR OPTIO#~L
ON FOR OPTIrAR.
A
ON
SOrT
~T
START.
014
TI_004 OF
Sl3
START.
ACI
l3~
rrETER
ACI
Circuit
Diagram
No. SD-148 323
OM-154 145 Page 37
38 -B
SD-083
No.
Diagr m
Circuit
PC6
Board
Motor
For
DJ C
~ sEAS A.~
Diagr m
.c a~
vAS~ sar.I.010 aWwinrd
Circuit
a.t Ass .1.
8-5.
ro
i,a-.crm sins(AWl .01Mg
W.
to
Ar
J.
WdC5
J/~L J
fifl U
fi
0
(n
-o (a
C.)
fiJLfL _i]IMLluh1~
fi
Diagr m
591
SC-146
No.
85-8
.56-B .56-B
Isv-u
185-B
B
ISU-
Isv-B
8
B
580 514)
614)-B 514)-U
8
8
6*4)
680
Isv-B
Diagr m
-*5 -8
-
Circuit
S1Y
INtE8~.
PC5
Board
Sup ly
Power
For
I~J-A
IłU-A l~J-R
ISU-A ISU-A ISU-R ISU-A
Diagram
680-A (10-A 680-fl 1 0-fl 610-A 610-A ISU-fi -ISU-A
Circuit
-
8-6.
DSLl~ftv iagr m
~* l_OG
E8F~48.
*215-A 2IU-A 24U-A
-2,0-A
0
(A
(A -u 83 (61 ID (.3 (0
t
POUE~IGROlJND NEIS FOP CNIPS
~
.GNE-8
{~P7
11.-ISO-C
8..
4..ISIJC
Circuit
Diagram
8.7. Circuit
Diagram
Diagram
For Isolation Board PC2
Circuit
Diagram
OM~154 145
Page
40
8-8. Circuit
No. SB-146 599-A
Diagram For Display Board PC7
Diagram
No. SB-146 587
ccl
L.)I
~lL~
Circuit Diagram No. SA-134 562
Diagram
8-9. Circuit
Diagram
For Filter Board PC9
RC5
RC3
/5
A
MOTOR
..
-
/d
B
(
3
MOTOR
8
COMMON
~
FEEDBACK
7
*
5
CHASSIS
85
C
<
/8
--
0
<
/9
E
<
TACH
_J
6~QN
P
<
p
7
IF
I
TI
GPD
r~7
CR4
I5VAC
IN
~
C
8LK
i-J
CURRENT
kHT
T
CURRENT
RELAY
1<
35
*24
(( RC2-2
H
2/
GAS
S
~< PC2-3
<
PC I 0
95
INTERNAL
15
L
(
INTERNAL
-15
M
<
FB
N
I
PCI-S
99
z PCI -7
RC I /PLG I
RC2/PLG2
2
(( PC
I
-
I 0
/7
~NTEPNAL
F8
COMMON
p
((PCI -9
~
SHUNT
Diagram
8-10. CIrcuit
Diagram
For Gas/Current
Circuit
Diagram
No. SB-i 53 758
Sensing Control
OM-154 145
Page
41
ISU-B
L
POLJER,GPOIJNO NETS FO~ CN!PS
4~-(SU-B, 8~)SLI-9
A2
~~GNO, 9~.lS()
A3
~-ISU,
~C2
7~~lSL)
B
L
j~)
~NLP2TUOUT1
-
ISU
Circuit
8-11. Circuit
Diagram
Diagram
Pt.G9/Pl_6I2
_______LLf
For
Optional
No. SB-i 53 762
Diagram
RCSP-R Panel
JO
I
_________________
P1
/L7
I
________________
~I4C
P2 P3 P4 P5
AP
*1
3
CC,Cy
VI
IIOXTAPCE
--
PC3
~E~V
PC2
POAPO
LOGIC
PLG~6<
SI
VOT
~
Sd)~
1-7
V~_T
SENSE
17
>>
POAPO
3
-1,
RCA
PCI
I
INTEPACE
14.0
___________
___________
.1.1.11 1.1.1.1.1.1.
AN
60*00
P1.31/PCI
P1.32/002
P.35/005
CA-CR
PLGA/RCO
*A-AG
PA-OF
((PC3-IA
r>>-.L~<<pc1.7
0-
VPTS
*
OS
OC
AC
>>~<<00I-3
>>~<< PC2-6
>)~<<PC3-5
>>~-~-<< 0C2-7
>)~<< 002-3
A
IT
~
~LGlO/PCI
~LG2O/5C2
c
L
~
cOTAC1~ S2>AL
2)
12)
~7)
~
15>
9
_
I ~
) P
))..
003-9 >>~~
IRVAC
001-2 )>
PCI-S
c~*
>>O~-
1OVAC
PCI-A ~
003-I
>>-....,
003-2
>)~
PC6
SELECTOP BOARO
C3IWSIN)STD(
002-6 )~
002
.J
-~~-~~-
P03-S
005
V0.TS/POWER
IN
ROARO
PLG7/RCI-I.O
PtGR/PCS-I-I4 002-4
WS
OJT
-
--
~
IJ.~_<
Do.~TAlcE
IN
/50
LENGTH
IN
/1/
VQ.TS QJT
/12
-
--
MA1IJAL
-
5
~
C~ 6
-
P02-I
/
<
<I
RCS.IO
Jt~ER FACTOP~ INSTALLED FPOM
11(6) TO (C) FOQ QEI~TE SELECTION
OF NONPU..SE SYNEOGIC WELDING.
INSTALL
7
~F5ET/~.PPtT
orb
PLG3/RC3-I-2
105
6
1)6) TO (6)
JJ14P56 FPOl4
NGNLP.SE SYNERGIC WELDING.
Circuit
Diagram
OM-154 145
Page
42
8-12. Circuit
Diagram
Diagram For Feedback Board PCIO
No. SB-i 54 743
OUT
TO NOTOP 00880
~FS
F80f1 8CSP~ I~C
~
TO
~D~C~CE
LE~G
~cs~
~:
INOUCU~C0
~TS
TQ
80.
o~
OUT
COTT8~~O
~CSP
UFS/81.
OUTPUT
I~C
SO
VOLTS :~~NO
~POS ~CSP
Oct.15
20
000rPNO
~C 50
toun
ITO
DUCt
C OPT PC I OR
Pt
BYPPSS CPPS
#OUEP
I I
UOLTS
o~o
POLJEP/GPOUND METS ~OR
RI
I
~-
ISO
UCLIS COTINPPO
-iso
tsu
isU
~
CI.~PS
CU/CC
SOLOCT
CR~
~ ISO
Circuit
Diagram
~O
SOUPCE
8-13. Circuit
Diagram
For
8-14. CIrcuit
No. SB-153 897
Optional RCSP-R Offset/Supply Board PC5
Circuit
Diagram
Diagram
Diagram
Diagram
No. SA-143 978
For Selector Board PC6
OM-154 145
Page
43
/
8
OUT
II
I
C4!
c~I
UI~HH~
-HH~
csa
C21
-HF -HF
_
~k1~
C33
-HF H
C48
-
C34
~~~1
-HF -HF-
~l ~
l1-ISU
~.1bU
______
84.85
UI
C32
u~
C47
HE
HF--
T+U US
II.G#C 4..I5&J
4.154J S.G8C
US
I.9C8..ISIJ
U?
5.-I5~J 8..184i
12.SU
3~I5~J
_____________
V
DIagram
OM-154 145
Page~
8-15. Circuit
Diagram
For
Optional RCSP-R
Interface Board PCi
C)
- 0C
0
(0 -I
3
z 0 U) 9 C.)
0
P.) -1
0~
cD
(ii
SECTION 9
PARTS LIST
~1
C,
U,
U-
E
~4)
U,
4
CD
a,
a,
14,
c..J
(0
C)
OM-136 849
Page
46
C~i
Item
No.
Part
No.
Dia.
Mkgs.
Quantity
Description
Figure
057 084
.
9-1. Main
Assembly
BUSHING, snap-in nyl .250 ID
x
.375
.1
.2
084184
BRACKET, mtg res~stor
.1
.3
010199
TUBING, stl .275 Id x .048 wall x 1
HEAT SINK, rectifier
RESISTOR, WW fxd 100W 5 ohm
CABINET, control
BLANK, snap-in nyl 1. mtg hole
CIRCUIT BREAKER, man reset 1 P 1 .5A 250V..
LABEL, warning general precautionary
.2
HOLDER, fuse mintr
FUSE, mintr cer 1 OA 250V
CABLE, interconnecting
CONNECTOR, circ l9skt MS-3106A-22-14S
CONNECTOR, circ clamp str rh AN-3057-1 2
CABLE, pwr No. 1 8ga 18/c 600V (order by ft)
CONNECTOR, circ 19 pin MS-3106A-22-14P
.1
030 949
030941
.4
R2
.5
.
.6
+153 753
.7
047 838
CB1
.8
011 991
134327
.9
046 432
10
*012655
153885
.11...F1
12
13
153887
14
16
039 734
090 263
153 886
17
RC5,PC9. 152 899
15
.19..
039 828
RC4... 097 867
097 868
039 734
RC1... 152 492
134 731
143 426
079 534
079 739
143 922
22
.
RC2... 153 884
Fig 9-2
130 203
PLG31
23
.
PLG33..
24
.
PLG32..
25
.
.20..
21
CONNECTOR,
CONNECTOR,
CONNECTOR,
CONNECTOR,
Fig 9-3
.27
000364
.083641
.28
+When
ordering
*Recommended
a
.1
.1
.1
.2
1 Oft
clamp str rlf AN-3057-6
circ 17 pin MS-3102A-20-29P
circ l7skt MS-3106-20-29S
circ clamp str rlf AN-3057-12
circ
circ skt
..
1
14
pin pushin 18-l4ga
CONNECTOR,
rect
12
pin 24-l8ga
.4
HOUSING PLUG & SOCKETS,
..
(consisting of)
CONNECTOR, circ skt 24-l8ga
HOUSING RECEPTACLE & SOCKETS, (consisting of)
CONNECTOR, circ skt 24-l8ga
.4
.2
DOOR ASSEMBLY
RING, retainer ext .188 shaft
SCREW, closure door
component originally displaying
Spare
.1
CONNECTOR, circ skt 24-l8ga
HOUSING PLUG & PINS, (consisting of)
115 094
113 746
PLG99.. 131 054
113746
.2
.1
circ clamp str rlf Amp 206322-2
circ clamp str rlf Amp 206070-3
circ l9skt MS-3102A-22-14S
CONTROL PANEL w/COMPONENTS
HOUSING PLUG & SOCKETS, (consisting of)
113 746
.26
.1
RECEPTACLE w/PINS, (consisting of)
CONNECTOR, circ pin pushin 18-l4ga
CONNECTOR, circ l4skt Amp 213652-1
115 090
114 656
.1
RECEPTACLE w/COMPONENTS
circ 4skt MS-3106A-14S-2S
CONNECTOR,
CONNECTOR,
CONNECTOR,
CONNECTOR,
CONNECTOR,
073 686
.18..
.1
a
x
.O25thk
precautionary label,
.2
.2
the label should also be ordered.
Parts.
BE SURE TO PROVIDE MODEL AND NSPR NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-154 145 Page
47
1569 7
ST
11
.9
a
12
15
13
8
7
6.
16
w/Compnets
Panel
Control
18
9-2.
Figure
26
25
I
21
24
28
23
0
C.)
(0 -u (0
19
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
.1.. SRi... 035 704
.2...R3... 079 497
.3...R1
030 651
605 741
.4
153 007
PC6... 071 642
.5
.6
..
.7
083 147
.8
009 335
117 865
HOUSING. term hdr l4skt
113 746
CONNECTOR, rect skt 24-18 ga
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-18 ga
HOUSING PLUG & SOCKETS, (consisting of)
026 202
.13...FL1... 084 171
.14.. P02... .146 596
PLG15.. 130 203
113 746
.15..
Pci...
148 421
PLG1..
130 203
PLG2..
PLG3..
115 094
113 746
PLG4,5
115 092
113 746
PLG9.. 131 055
113 746
115 093
113 746
.16.. PC4... 148 761
PLG24.. 115 092
PLG12..
113 746
PLG25.. 131 052
113 746
PLG27.. 131 204
113 746
PLG28..
115 093
113 746
134 201
17
18
.
iT,2T
.
T4
19
.20...T5
.21...T3...
.22...T2
...
.23...T1
.24...3T
.25.. PC8...
PLG16..
038 856
154 781
156 267
154 780
154 782
153 883
038 832
148 320
131 054
113 746
PLG8.. 079
079
.26.. P05... 146
PLG17.. 131
748
747
588
052
113 746
PLG18.. 152 249
147 995
PLG19.. 150 315
147 995
9-1 Item
21)
RECTIFIER, integ 40A 800V
RESISTOR, WW fxd 25W 2K ohm
RESISTOR, WW fxd 25W 10 ohm
CLIP, mtg resistor .312 ID
PANEL. mtg components
CIRCUIT CARD, motor speed control
GROMMET, scr No. 8/10
113 746
.
.12... Dl
w/Components (Fig
STAND-OFF, No. 4-40 x .625 19
HOUSING, term conn 22 posn panel mtg
RELAY, end 24VAC DPDT
RELAY, end 24VDC DPDT
DIODE, rect 1A 400V
FILTER, line pwr 115/250V
CIRCUIT CARD, isolation
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-i 8 ga
CIRCUIT CARD, interface
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-18 ga
PLG1O.. 117 374
.10.. CR1... 109 006
.11.. CR2... 052 964
9
9-2. Control Panel
Quantity
1
1
I
.4
.2
.2
.1
.1
.1
.1
.1
12
12
14
.1
.4
.1
CONNECTOR, rectskt24-l8ga
16
HOUSING RECEPTACLE & SOCKETS, (consisting of)
.1
CONNECTOR, rectskt24-l8ga
5
HOUSING PLUG & SOCKETS,
(consisting of)
CONNECTOR, rectskt24-l8ga
CIRCUIT CARD, analog channel
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rectskt24-l8ga
HOUSING RECEPTACLE & SOCKETS, (consisting of)
CONNECTOR,
.6
.8
rect skt 24-18 ga
HOUSING PLUG & SOCKETS,
16
(consisting of)
CONNECTOR, rect skt 24-18 ga
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-18 ga
STAND-OFF, support pc card
.6
20
BLOCK, term 20A i4P
TRANSFORMER, control
TRANSFORMER, control
TRANSFORMER, control
TRANSFORMER, control
TRANSFORMER, signal 115V 36VCT 2A
BLOCK, term 20A 9P
CIRCUIT CARD, voltage control
HOUSING RECEPTACLE & SOCKETS, (consisting of)
CONNECTOR, rect skt 24-18 ga
HOUSING, term hdr 18 pin
TERMINAL, cont hdr 24-18 wire
CIRCUIT CARD, power supply
HOUSING RECEPTACLE & SOCKETS, (consisting of)
CONNECTOR, rectskt24-l8ga
HOUSING RECEPTACLE & SOCKETS, (consisting of)
.2
2
.
18
.6
TERMINAL, female lskt 22-18 wire
15
HOUSING, term plug nyl 9
TERMINAL, hdr 9 pin
.9
OM-154 145
Page
49
Item
No.
Dia.
Mkgs.
Part
No.
Description
Figure
PLG19..
130 203
27
9-1 Item
21) (Continued)
1
6
1
CONNECTOR, rectskt24-l8ga
CLAMP, capacitor 2.000dia
CAPACITOR, elctlt 750uf 200VDC
113 746
006 426
.28...C1
w/Components (Fig
HOUSING PLUG & SOCKETS, (consisting of)
CONNECTOR, rectskt24-l8ga
HOUSING PLUG & SOCKETS, (consisting of)
150 315
113 746
PLG23
9-2. Control Panel
Quantity
031 692
6
1
BE SURE TO PROVIDE MODEL AND NSPR NUMBER WHEN ORDERING REPLACEMENT PARTS.
4
S
5
2
3
L
6
~
19
~
11
15
12
14
13
SIT 56 955
Figure
OM-136 849 Page 50
9-3. Door
Assembly
Item
No.
Part
No.
Dia.
Mkgs.
Figure
.1
.2
.3
.4
.5
.8
9
.10
.11
.12
.13
.14
079798
..
079797
.
131055
.
.
.7
PL1.
HOUSING,
HOUSING,
26)
.
term hdr 13 pin
term hdr 4 pin
HOUSING RECEPTACLE & SOCKETS,
..
.
.
1
.
13
(consisting of)
.
.
.
.
.
.
.1
.3
.
.
.2
..
..
.16
.000364..
.17
..
.19
058420
..
..
...
.20
..
.21
...
S2
...
ordering
..
+153755
...
.18
..
..
154474
a
084034..
097922..
089032..
086895..
PLATE, control lower
RING, retainer ext .188 shaft x .O25thk
THUMB SCREW, knurled .250-20
DOOR, tray front
BAR, trim horizontal
KNOB, pointer
LENS, LED 4341 red
SWITCH, relay 3 posn
component originally displaying
a
precautionary label,
1
1
...
...
1
.1
..
...
1
5
.1
..
.083670.. DOOR, control
.021105.. SWITCH, PB licon 76-2351 SPOT
PB1-3
153754.
COVER, blank
Si
153699.. SWITCH, rocker SPDT 16A 125VAC
.084040.. STAND-OFF, .250-20 x .750 Ig .437 hex brs
153076
PANEL, door
150866.. LABEL, caution incorrect DVC board DIP switch
STRAIN RELIEF, cover
107551
...
+When
9-1 Item
CONNECTOR, rect skt 24-lBga
.027645.. LIGHT, md red lens 125VAC
113746
.
.15
.22
Assembly (Fig
..
PLG21
.
9-3. Door
R4-6 .082708.. POTENTIOMETER, C sltd sft lIT 1W 1M
R7-10 .035897.. POTENTIOMETER, C std slot iT 2W 1K
NAMEPLATE, (order by model and serial number)
115443.. STAND-OFF, No. 6-32 x .750 Ig
FC7. .146584.. CIRCUIT CARD, meter
PLO 14
.6
Quantity
Description
..
2
1
..
..
..
2
2
1
..
..
..
1
..
8
..
5
..
1
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND NSPR NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-154
145
Page
51
+0
-.4
(p
1
0
C.) 0) 0) (0
p) (a
U) 1(3
C -I 0
CD
C) 0 .4.
0
U, 0
C) 0) 0 C) C
-I 0
.4.
to
Part
No.
Dia.
Item
No.
Mkgs.
Figure
1
083
.2...
.3...
154 281
.4...
072 426
.5...
154 286
.6...
010 493
154279
.7
.8..
RC5
.9
.
.
..
079 739
..
010 494
..
010 604
.
.
..
.
.
.
.
.
.
PC1O
153 759
..
PLG1..
147 993
.
147 995
..
PLG2.. 150 317
147995
16
094 484
.17... Ti
154 280
.18.. GS1... 109 293
19
083 083
.20.. RC3... 144 982
21
154 283
+When
.
..
010 190
602 934
.
.
.
048 287
12
.
.
.
...
153 004
14
.
079 534
11
15
.
..
057 358
13
.
047 637
10
ordering
a
9-4. Control Box, Gas Current
WRAPPER
086
134 327
Quantity
Description
.
.
.
..
..
..
..
..
..
..
1
LABEL, warning precautionary
BLOCK, shunt
SHUNT, meter 50 MV 1000A
INSULATOR, shunt
BUSHING, snap-in nyl .625 ID
.2
x
.875mtg hole
SHIELD,heat
HOUSING RECEPTACLE & SOCKETS, (consisting of)
CONNECTOR, circ skt pushin 18-i 4ga
CONNECTOR, circ 14 pin 206044-i
CONNECTOR, circ clamp str rlf 206322-2
BUSHING, snap-in nyl 1.375 ID x 1 .75Omtg hole
BUSHING, snap-in nyl 1. OD x 1 .375mtg hole
14
.2
.2
.
CONTROL BOX
.1
FITTING, pipe nipple L .25ONPT x 10
FITTING, pipe coupling .25ONPSC
FITTING, hose brs bushing .25ONPT x .625-18R
CIRCUIT CARD, feedback
HOUSING, term plug nyl 12 cont
.2
CONNECTOR, rect skt 22-i 8ga
HOUSING, term plug nyl 4 cont
CONNECTOR, rectskt22-i8ga
STAND-OFF, No. 6-32 x 1. 19
TRANSFORMER, control
VALVE, 24VDC 2way 1/4 IPS
BRACKET, mtg control
CONNECTOR, circ 19 pin MS-3102A-22-i4P-639
SWITCH, reed
component originally displaying
a
precautionary label,
12
.4
.4
.2
the label should also be ordered.
BE SURE TO PROVIDE MODEL AND NSPR NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-154 145 Page 53