Miller ROBOTIC INTERFACE CONTROL Owner's Manual

August 1994 Form: OM-154 145B

OWNER’S

MANUAL

Robotic Interface Control

Gas/Current Sensing Control

Read and follow these instructions and all safety blocks carefully.

Have only trained and qualified persons install, operate, or service this unit.

Call your distributor if you do not understand the directions.

cover 7/93 – Ref. ST-157 095



1994 MILLER Electric Mfg. Co.

Give this manual to the operator.

For help, call your distributor or: MILLER Electric Mfg. Co., P.O. Box 1079,

Appleton, WI 54912 414-734-9821

PRINTED IN USA

ARC WELDING SAFETY PRECAUTIONS

WARNING

ARC WELDING can be hazardous.

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN

AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.

In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The safety information given below is only a summary of the more complete safety information that will be found in the

Safety Standards listed on the next page. Read and follow all Safety Standards.

HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY

QUALIFIED PEOPLE.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

3. Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.

4. Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards).

5. Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

6. Always verify the supply ground – check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

7. When making input connections, attach proper grounding conductor first – double-check connections.

8. Frequently inspect input power cord for damage or bare wiring – replace cord immediately if damaged – bare wiring can kill.

9. Turn off all equipment when not in use.

10. Do not use worn, damaged, undersized, or poorly spliced cables.

11. Do not drape cables over your body.

12. If earth grounding of the workpiece is required, ground it directly with a separate cable – do not use work clamp or work cable.

13. Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

14. Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.

15. Wear a safety harness if working above floor level.

16. Keep all panels and covers securely in place.

17. Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.

ARC RAYS can burn eyes and skin;

NOISE can damage hearing; FLYING

SLAG OR SPARKS can injure eyes.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Noise from some processes can damage hearing. Chipping, grinding, and welds cooling throw off pieces of metal or slag.

NOISE

1. Use approved ear plugs or ear muffs if noise level is high.

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breathe the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, cleaners, and degreasers.

CYLINDERS can explode if damaged.

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.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs.

2. Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

ARC RAYS

2. Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI

Z49.1 and Z87.1 listed in Safety Standards).

3. Wear approved safety glasses with side shields.

4. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

5. Wear protective clothing made from durable, flame-resistant material (wool and leather) and foot protection.

5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

4. Never drape a welding torch over a gas cylinder.

5. Never allow a welding electrode to touch any cylinder.

6. Never weld on a pressurized cylinder – explosion will result.

7. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

8. Turn face away from valve outlet when opening cylinder valve.

9. Keep protective cap in place over valve except when cylinder is in use or connected for use.

10. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety

Standards.

sr1.1.1 2/94

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc.

If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

WARNING

ENGINE EXHAUST GASES can kill.

Engines produce harmful exhaust gases.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS

F4.1 (see Safety Standards).

8. Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

9. Do not use welder to thaw frozen pipes.

10. Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

11. Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

12. Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.

ENGINES can be hazardous.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

ENGINE FUEL can cause fire or explosion.

Engine fuel is highly flammable.

1. Stop engine and let it cool off before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open flames.

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely in place.

2. Stop engine before installing or connecting unit.

SPARKS can cause BATTERY GASES

TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

STEAM AND PRESSURIZED HOT

COOLANT can burn face, eyes, and skin.

It is best to check coolant level when engine is cold to avoid scalding.

3. Do not overfill tank – allow room for fuel to expand.

4. Do not spill fuel. If fuel is spilled, clean up before starting engine.

3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.

4. To prevent accidental starting during servicing, disconnect negative (–) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving parts.

6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

1. If the engine is warm and checking is needed, follow steps 2 and 3.

2. Wear safety glasses and gloves and put a rag over cap.

3. Turn cap slightly and let pressure escape slowly before 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 Superintendent of Documents, U.S. Government Printing Office, Washington,

D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and

Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

sr1.1.1 2/94

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet

P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

S afe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS

1-1.

General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2.

Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1

SECTION 2 – SPECIFICATIONS

2-1.

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 3 – INSTALLATION

3-1.

Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2.

Equipment Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3.

Setting Dip Switches On DVC Board PC8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4.

Burnback Voltage And Wire Stick DIP Switch On Interface Board PC1 . . . . . . . . . . . . . . . . .

3-5.

Yaskawa/Motoman Robot Control Unit – Robot Interface Set Up . . . . . . . . . . . . . . . . . . . . . .

3-6.

Hitachi Robot Control Unit – Robot Interface Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7.

Panasonic Robot Control Unit – Robot Interface Set Up

3-8.

Automatix Robot Control Unit – Robot Interface Set Up

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9.

GMF Robot Control Unit – Robot Interface Set Up

3-10.

ABB Robot Control Unit – Robot Interface Set Up

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11.

Kawasaki Robot Control Unit – Robot Interface Set Up

3-12.

SMIC Robot Control Unit – Robot Interface Set Up

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13.

Gas/Current Sensing Control Interconnections

3-14.

Voltage Sensing Connections

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-15.

Robot Interface – Welding Power Source Connections

3-16.

Connection For Constant Nonpulse Synergic Welding

3-17.

Welding Wire Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

14

14

14

15

9

10

12

12

7

8

5

6

4

4

3

3

SECTION 4 – OPERATOR CONTROLS

4-1.

Power Switch And Pilot Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2.

Jog Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3.

Purge Push Button

4-4.

Voltmeter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5.

Wire Speed Meter

4-6.

Ammeter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7.

Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8.

Preflow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9.

Postflow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10.

Burnback Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-11.

Burnback Voltage Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12.

Selector Switch

4-13.

Manual Controls

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14.

Robotic Interface Command Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

17

17

17

17

18

16

16

17

17

15

15

16

16

SECTION 5 – OPTIONAL RCSP-R OPERATOR CONTROLS

5-1.

Pulse Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2.

Wire Size Select Switch And Standard Mode Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3.

Wire Size Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4.

Wire Type Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5.

Recommended Shielding Gas Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6.

No Program Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

18

19

19

19

19

SECTION 6 – SEQUENCE OF OPERATION

6-1.

Maxtron 450 Control Settings For Welding Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6-2.

Optional RCSP-R Gas Metal Arc Welding-Pulsed (GMAW-P)

6-3.

Shutting Down

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

22

OM-154 145B – 8/94

SECTION 7 – MAINTENANCE & TROUBLESHOOTING

7-1.

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2.

Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3.

Reinstallation Of Hub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4.

Circuit Board Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6.

Use Of Indicator Lights For Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

22

23

23

24

27

SECTION 8 – ELECTRICAL DIAGRAMS

Diagram 8-1.

Circuit Diagram For Robotic Interface Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 8-2.

Circuit Diagram For Analog Channel Board PC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 8-3.

Circuit Diagram For Interface Board PC1

Diagram 8-4.

Circuit Diagram For DVC Board PC8

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 8-5.

Circuit Diagram For Motor Board PC6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 8-6.

Circuit Diagram For Power Supply Board PC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 8-7.

Circuit Diagram For Isolation Board PC2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 8-8.

Circuit Diagram For Display Board PC7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 8-9.

Circuit Diagram For Filter Board PC9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 8-10. Circuit Diagram For Gas/Current Sensing Control . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 8-11.

Circuit Diagram For Optional RCSP-R Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 8-12. Circuit Diagram For Feedback Board PC10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 8-13. Circuit Diagram For Optional RCSP-R Offset/Supply Board PC5 . . . . . . . . . . . . . .

Diagram 8-14. Circuit Diagram For Selector Board PC6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 8-15. Circuit Diagram For Optional RCSP-R Interface Board PC1 . . . . . . . . . . . . . . . . . .

Diagram 8-16. Wiring Diagram For Robotic Interface Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 8-17. Wiring Diagram For Gas/Current Sensing Control . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diagram 8-18. Wiring Diagram For Optional RCSP-R Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

39

40

40

41

41

42

36

37

38

38

28

30

32

34

44

46

47

SECTION 9 – PARTS LIST

Figure 9-1. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 9-2. Control Panel w/Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 9-3. Door Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 9-4. Control Box, Gas Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48

50

52

54

LIST OF CHARTS AND TABLES

Chart 3-1.

Interface Board DIP Switch Settings For Burnback Voltage Control

And Wire Stick Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chart 3-2.

Welding Operation Control By Type Of Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . .

Chart 3-3.

Analog Channel Board DIP Switch Settings For 2 Channel Robot . . . . . . . . . . . . . . . . .

Chart 3-4.

Analog Channel Board DIP Switch Settings For 3 Channel Robot . . . . . . . . . . . . . . . . .

Chart 5-1.

RCSP-R Modes And Weld Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 5-1.

Synergic Pulse Panel Welding Schedules

Table 7-1.

Robot Interface Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table 7-1.

Robot Interface Troubleshooting (Continued)

Table 7-2.

Optional RCSP-R Troubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

19

20

24

25

26

5

5

5

SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS

1-1.

GENERAL INFORMATION AND SAFETY

A. General

Information presented in this manual and on various labels, 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. Safety

The installation, operation, maintenance, and troubleshooting of arc welding equipment requires practices and procedures which ensure personal safety and the safety of others. Therefore, this equipment is to be installed, operated, and maintained only by qualified persons in accordance with this manual and all safety precautions listed in the Arc Welding Safety Precautions.

1-2.

SAFETY ALERT SYMBOL AND SIGNAL

WORDS

The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instructions.

This safety alert symbol is used with the signal words WARNING and CAUTION to call attention to the safety statements.

WARNING statements identify procedures or practices which must be followed to avoid serious personal injury or loss of life.

CAUTION statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment.

IMPORTANT statements identify special instructions necessary for the most efficient operation of this equipment.

SECTION 2 – SPECIFICATIONS

2-1.

DESCRIPTION

The robotic interface control is designed to interface a

Maxtron 450 or Deltaweld welding power source to a welding robot. This unit provides digital display of weld volts,wire feed speed, and amperage.

The gas/current sensing control contains the gas valve, current sensing reed relay, and shunt.

These components function with the robot system when using the Gas Metal Arc Welding (GMAW) and Gas Metal Arc Welding - Pulsed Arc (GMAW-P) processes.

The optional RCSP-R panel is a synergic control designed to be used with the Maxtron 450 welding power source, robot interface, and the robot system. The unit is designed for Gas Metal Arc Welding (GMAW) in both nonpulsed and pulsed dc arc welding modes. The unit is shipped ready for pulsed welding.

The panel is considered a synergic control because welding parameters which determine arc power and arc length are programmed for wire type and size selections to allow adjustment at two controls rather than individual controls for each parameter. If pulse welding, arc power parameters are wire feed speed, background amperage, peak amperage, pulse frequency, and pulse width; arc length is a fine tuning of pulse frequency. If nonpulse welding, arc power parameters are wire feed speed, arc voltage, and inductance; arc length is a fine tuning of arc voltage.

When used with its associated equipment, the optional

RCSP-R panel allows the operator to set welding parameters for optimum welding conditions in a majority of situations using various types and sizes of welding wire and shielding gases.

OM-154 145 Page 1

4 in. (102 mm)

1-1/2 in.

(38 mm)

10-1/2 in.

(267 mm)

9/32 in. (7 mm)

Dia. 4 Holes

22 in.

(599 mm)

19 in.

(482 mm)

9-1/2 in.

(241 mm)

9/32 in.

(7 mm) Dia.

6 Holes

3/8 in.

(10 mm)

5/8 in.

(16 mm)

7-1/2 in.

(191 mm)

8-3/4 in.

(222 mm)

3/8 in.

(10 mm)

13-1/4 in.

(367 mm)

14 in.

(356 mm)

25-3/4 in.

(654 mm)

26-1/2 in.

(673 mm)

Opening For

Receptacle Kit

Installation

E

F

G

B

C

D

A

Overall Dimensions And

Mounting Hole Locations

Inches Millimeters

21-7/8 556

13-3/4

3

2-1/2

3-1/2

4-1/2

10-11/16

349

76

63.5

88.9

114

275

5/16 in. (7.9 mm)

Dia. 4 Holes

G

F

E

Figure 2-1. Dimensional Views

OM-154 145 Page 2

B

A

D

C

ST-157 095 / ST-080 486-C

SECTION 3 – INSTALLATION

3-1.

SITE SELECTION

Select an installation site which provides the following:

1.

Correct input power supply (see unit rating label)

2.

Shielding gas supply (if applicable)

3.

Water supply (if applicable)

4.

Adequate ventilation and fresh air supply

5.

No flammables

6.

A clean and dry area

7.

Proper temperature that avoids extremes of heat or cold

8.

Proper airflow around unit

9.

Adequate space to open and remove cover and wrapper for installation, maintenance, and repair functions.

Mounting holes provide the capability to install and secure the system components in a permanent location.

3-2.

EQUIPMENT INSTALLATION

A. Supplied Equipment

The following equipment is supplied as standard and requires installation or assembly:

1.

Weld Control with Gas/Current Sensing Control

Cord and Motor Cord

2.

Gas/Current Sensing Control

3.

Hub and Spindle Assembly

4.

Hub Support

5.

10 ft. (3 m) Weld Control – Welding Power Source

Interconnecting Cords

6.

10 ft. (3 m) Gas Hose

7.

Voltage Sensing Cord

B. Equipment Location

When deciding on equipment location, consider the following:

1.

The equipment must be mounted to a structure capable of supporting the weight of the equipment.

2.

The lead lengths of the cords supplied with the equipment will limit the area in which the equipment can be located. Some cords can be extended by using optional extension cords (check with welding equipment distributor).

3.

The interconnecting cords must be routed so that they are not caught, pinched, or strained during welding operations.

4.

Two weld output cables must be routed to the Gas/

Current Sensing control.

5.

Welding wire must be routed so that it does not contact the weld control or any other grounded equipment.

C. Equipment Installation

Obtain appropriate mounting brackets or adapter plates as necessary and mounting hardware. Prepare structure for equipment installation. Secure weld control,

Gas/Current Sensing control, and all other equipment onto structures in the welding area.

D. Hub Installation (Figure 3-1)

The hub assembly is supplied with the robot interface.

Remove the hub assembly from the shipping carton, and install it as follows:

4.

Remove hex nut from end of hub support shaft.

5.

Align keyway and insert hub support shaft through selected hole in hub support. Hole selection in hub support depends on wire spool size. Be sure the brake washers are properly seated in the hub.

6.

Reinstall hex nut onto support shaft. Tighten hex nut until a slight drag is felt while turning hub.

7.

Install welding wire according to Section 3-17.

Hub Support Shaft

Retaining Ring

Hub Assembly

Fiber Washer

Brake Washer

ST-126 870-A

Figure 3-1. Hub Assembly Installation

Hex

Nut

OM-154 145 Page 3

DELTAWELD 300

DVC SWITCH SETTINGS

S2

DELTAWELD 451, 450

S1

1 2 1 2 3 4 5

ON ON ON

O ON ON

DELTAWELD 651, 650

O ON ON

MAXTRON 300, 400

ON ON

MAXTRON 450 ON ON ON

XMT 200/300

ARC PAK 350

SHOPMASTER 300

DIMENSION 400

ON

ON

ON

ON

ON ON

ON

∆ ∆

ON

ON

ON

ON

ON

PULSTAR 450

O – On For Optional Soft Start. Turn Off S1 -3.

∆

– On For Optional Hot Start.

S-150 864-C

Figure 3-2. DVC DIP Switch Setting Label

3-3.

SETTING DIP SWITCHES ON DVC BOARD

PC8 (Figure 3-2)

DIP switches S1 and S2 on DVC Board PC8 allow setting the proper command signal voltage level for controlling voltage output at a welding power source. To change factory set position of DIP switches from a Deltaweld 451 to another welding power source, proceed as follows:

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 setting

DIP switches.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

ELECTROSTATIC DISCHARGE (ESD) can damage circuit boards.

•

Put on properly grounded wrist strap BE-

FORE handling circuit boards.

•

Perform work only at a static-safe work area.

1.

Loosen screws and open control panel door.

2.

Locate DVC Board PC8 in lower left portion on rear panel inside the interface.

3.

Set position of DIP switches S1 and S2 according to label inside interface and Figure 3-2 for appropriate welding power source.

4.

Close and secure door.

OM-154 145 Page 4

CAUTION: INCORRECT DVC BOARD DIP

SWITCH POSITION can cause equipment malfunction.

•

DVC DIP switch is factory set for operation with Deltaweld 451 welding power source.

See Figure 3-2 for DVC DIP switch setting when using another welding power source.

3-4.

BURNBACK VOLTAGE AND WIRE STICK DIP

SWITCH ON INTERFACE BOARD PC1

DIP switch S1 on the Interface Board allows enabling or disabling the burnback voltage front panel control and wire stick circuitry. To change factory set position of switches, proceed as follows:


•


•


DIP switches.



•



•


1.


2.

Locate Interface Board in right center portion on rear panel inside the interface.

3.

Set position of switches according to Chart 3-1 for enabling or disabling the burnback voltage control or wire stick circuitry.

4.


Chart 3-1. Interface Board DIP Switch Settings For

Burnback Voltage Control And Wire Stick Circuitry

FUNCTION

1

DIP SWITCH S1

2

ENABLE DISABLE ENABLE DISABLE

WIRE STICK

CIRCUITRY

BURNBACK

VOLTAGE

CONTROL

OFF ON

ON OFF

3-5.

YASKAWA/MOTOMAN ROBOT CONTROL

UNIT – ROBOT INTERFACE SET UP


•


•


DIP switches or making interconnections.



•



•


A. Setting DIP Switch On Analog Channel Board

(Chart 3-2)

IMPORTANT: Recommended mode selection for 2 channel Yaskawa/Motoman robot is Selector Switch and Manual Inductance; mode selection for 3 channel robot is Selector Switch (see Chart 3-2 and Chart 3-3 or

Chart 3-4). When using the selector switch, the inner settings apply to all robot models except ABB which uses the outer settings.

DIP switch S1 on Analog Channel Board PC4 allows setting 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 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.


2.

Locate Analog Channel Board PC4 in right side portion of base inside the interface.

3.

Set switches No. 1 thru 5 of DIP switch S1 for desired mode selection and the available robot channels (see Chart 3-3 or Chart 3-4).

4.


Chart 3-2. Welding Operation Control By Type Of

Mode Selection

MODE

SELECTION

AUTOMATIC

MANUAL

SELECTOR

SWITCH

PRESET

SELECTOR

SWITCH AND

PRESET

WELDING OPERATION

CONTROL

PROGRAM DATA FROM ROBOT CONTROL

SETS WELDING PARAMETERS.

ROBOT INTERFACE FRONT PANEL CON-

TROLS SET WELDING PARAMETERS.

AUTOMATIC – SAME AS ABOVE.

MANUAL – SAME AS ABOVE.

SET UP – WELDING OPERATION DRY RUN

USING A SIMULATED CURRENT DETECT

SIGNAL.

SIMILAR TO RUN-IN FUNCTION USING

FRONT PANEL CONTROLS TO SET WELD-

ING PARAMETERS UNTIL ROBOT CON-

TROL DETECTS WELD CURRENT AND

SWITCHES TO PROGRAM DATA WELDING

PARAMETERS.

AUTOMATIC – SAME AS ABOVE.

MANUAL – SAME AS ABOVE.

SET UP – SAME AS ABOVE.

Chart 3-3. Analog Channel Board DIP Switch Settings For 2 Channel Robot

MODE

SELECTION 1

DIP SWITCH S1

2 3 4 5

AUTOMATIC

AUTOMATIC

MANUAL INDUCTANCE*

MANUAL

OFF OFF

OFF OFF

OFF OFF

OFF OFF

OFF OFF

ON ON

OFF

ON

ON

SELECTOR SWITCH

MANUAL INDUCTANCE*

ON OFF ON OFF ON

PRESET

MANUAL INDUCTANCE*

OFF ON ON OFF ON

SELECTOR SWITCH

AND PRESET

MANUAL INDUCTANCE*

ON ON ON OFF ON

*Inductance only functions with a Maxtron 450 welding power source.

Chart 3-4. Analog Channel Board DIP Switch Settings For 3 Channel Robot

MODE

SELECTION

AUTOMATIC

MANUAL

SELECTOR SWITCH

PRESET

SELECTOR SWITCH

AND PRESET

DIP SWITCH S1

1 2 3 4 5

OFF OFF OFF OFF OFF

OFF OFF ON ON ON

ON OFF ON ON OFF

OFF ON ON ON OFF

ON ON ON ON OFF

OM-154 145 Page 5

B. Connection To Receptacles On Robot Interface

(Figure 3-3)

1.

Obtain two cords of the proper type and length, and two 17-pin Amphenol plugs (not supplied).

2.

Connect conductors at end of one cord to appropriate pins in one plug.

3.

Align keyway, insert 17-pin plug into matching receptacle on robot interface, and rotate threaded collar fully clockwise.

4.

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

RC100 and RC101 by means of the robot interface control circuitry are as follows:

Receptacle RC100

Socket A: Voltage signal; + 0 to 10 volts = 0 to 50 volts 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 ipm.

Socket E: Inductance signal; +0 to 10 volts.

Socket F: Common for Socket E.

Socket K: Common for Socket L.

Socket L: Weld on signal.

Socket M: Wire stick check signal positive (+).

Socket N: Wire stick check signal negative (–).


Socket A: Current detect contact.

Socket B: Current detect contact.

Socket D: Gas shortage (terminal strip connection provided for customer).

Socket E: Wire shortage (terminal strip connection provided for customer).

Socket F: Circuit common for Sockets G and H.

Socket G: Jog forward command.

Socket H: Jog reverse command.

Socket K: Gas control.

Socket L: Circuit common for Socket K.

IMPORTANT: The remaining sockets in the receptacle are not used.

3-6.

HITACHI ROBOT CONTROL UNIT – ROBOT

INTERFACE SET UP


•


•





•



•



(Chart 3-2)

IMPORTANT: Recommended mode selection for Hitachi robot is Automatic and Manual Inductance (see

Chart 3-2 and Chart 3-3 or Chart 3-4). When using the selector switch, the inner settings apply to all robot models except ABB which uses the outer settings.

DIP switch S1 on Analog Channel Board PC4 allows setting 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 the robot control (Chart 3-2). To change factory set position of the DIP switch from all automatic


1.


2.


3.


4.


B. Connection To Receptacle On Robot Interface

(Figure 3-3)

1.

Obtain a cord of the proper type and length, and a

24-socket Amphenol plug (not supplied).

2.

Connect conductors at end of cord to appropriate sockets in plug.

3.

Align keyway, insert plug into matching receptacle on robot interface, and rotate threaded collar fully clockwise.

4.


OM-154 145 Page 6

The input and output signals at the pins of receptacle

RC100 by means of the robot interface control circuitry are as follows:

Pin A:

Pin B:


Digital common of Pins B, C, D, and E.

Weld Standby signal; contact closure with respect to Pin A.

Pin C:

Pin D:

Pin E:

Pin G:

Pin H:

Pin J:

Pin L:

Pin M:

Current detect signal; contact closure with respect to Pin A.

Arc Failure; normally-open contact.

Wire Stuck signal; contact closure with respect to Pin A.

Cooling Water Shortage; terminal strip connection provided for customer use.

Low Gas; terminal strip connection provided for customer use.

Welding Wire Shortage; terminal strip connection provided for customer use.

Circuit common for Pins M, N, and P.

Arc On signal; starts gas flow and wire feed, and turns on contactor.

Jog FWD. signal.

Pin N:

Pin P:

Pin R:

Pin S:

Pin T:

Pin U:

Jog REV. signal.

Arc Failure; normally-closed contact.

Terminal strip connection provided for customer use.



Pin V:

Pin W:

Pin X:

Wire feed signal positive (+).

Common for Pins V and X.

Arc voltage signal positive (+).

Pin Y: Arc Failure; normally-closed contact.

IMPORTANT: The remaining pins in the receptacle are not used.

3-7.

PANASONIC ROBOT CONTROL UNIT – RO-

BOT INTERFACE SET UP


•


•





•



•



(Chart 3-2)

IMPORTANT: Recommended mode selection for Panasonic robot is Automatic and Manual Inductance (see




1.


2.


3.


4.



(Figure 3-3)

1.


24-pin Amphenol plug (not supplied).

2.

Connect conductors at end of cord to appropriate pins in plug.

3.


4.





Socket A: Digital common of Sockets B, C, and G.

OM-154 145 Page 7

Socket B: Arc Failure; output signal.

Socket C: Touch Sense; output signal.

Socket G: Current Detect; output signal.

Socket H: Weld Start signal; starts gas flow and wire feed, and turns on contactor.

Socket J: Circuit common for Sockets H, K, M, P, and

R; all circuit voltages referenced to this point.

Socket K: Gas Valve; input signal.

Socket L: Circuit common for input signals at Sockets H, K, M, P, and R.

Socket M: Touch Sense; input signal.

Socket N: Circuit common for input signals at Sockets H, K, M, P, and R.

Socket P: Jog FWD.; positive (+) input signal.

Socket Q: Circuit common for input signals at Sockets H, K, M, P, and R.

Socket R: Jog REV.; negative (–) input signal.

Socket S: Circuit common for input signals at Sockets H, K, M, P, and R.

Socket T: Voltage control positive (+) connection.

Socket U: Voltage control command connection; 0 to

10V signal = 0 to 50V output.

Socket V: Voltage control negative (–) connection.

Socket W: Wire feed speed positive (+) connection.

Socket X: Wire feed speed command connection; 0 to 8V signal = 0 to 800 ipm.

Socket Y: Wire feed speed negative (–) connection.


OM-154 145 Page 8

3-8.

AUTOMATIX ROBOT CONTROL UNIT – RO-



•


•





•



•



(Chart 3-2)

IMPORTANT: Recommended mode selection for Automatix robot is Automatic (see Chart 3-2 and Chart 3-3 or




1.


2.


3.


4.


B. Connection To Receptacles On Robot Interface

(Figure 3-3)

1.

Obtain two cords of the proper type and length, and a 10-pin and 24-pin Amphenol plug (not supplied).

2.

Connect conductors at end of one cord to appropriate pins in one plug.

3.


4.


5.

Repeat Steps 2 thru 4 for remaining cord and plug.


RC100 and RC101 by means of the robot interface control circuitry are as follows:


Socket A: Inductance; positive (+) signal.

Socket B: Inductance; signal common.

Socket C: Inductance command signal; 0 to 10 volts for Arc Pak or Maxtron 450 welding power source.

Socket F: Circuit common for Socket G.

Socket G: Jog FWD. signal.

Socket L: Circuit common.

Socket M: Weld Start positive (+) signal.

Socket N: Circuit common for Socket M.

Socket P: Wire Feed Speed; positive (+) signal.

Socket Q: Wire Feed Speed; signal common.

Socket R: Wire Feed Speed command signal; 0 to 8V signal = 0 to 800 ipm.

Socket S: Arc Voltage; positive (+) signal.

Socket T: Arc Voltage; signal common.

Socket U: Arc Voltage command signal; 0 to 10V signal = 0 to 50V output.

Socket V: Arc Failure contact.

Socket W: Arc Failure contact.

Socket X: Current Detect contact.

Socket Y: Current Detect contact.



Socket A: Torch Position signal with respect to Socket D.

Socket D: Torch Position signal with respect to Socket A.

Socket F: Circuit common for Socket G.

Socket G: Torch Position Initiate signal.

Socket I: Circuit common for Socket J.

Socket J: Gas control signal.


3-9.

GMF ROBOT CONTROL UNIT – ROBOT IN-

TERFACE SET UP


•


•





•



•



(Chart 3-2)

IMPORTANT: Recommended mode selection for 2 channel GMF robot is Preset and Manual Inductance; mode selection for 3 channel robot is Preset (see




1.


2.


3.


4.



(Figure 3-3)

1.



2.


3.


4.


OM-154 145 Page 9




Socket A: Arc Volts; positive (+) signal from 0 to 10 volts dc input from robot control unit with respect to Socket A (analog common).

Socket B: Analog common for Socket A.

Socket C: Inductance; positive (+) signal from 0 to 10 volts dc input from robot control unit with respect to Socket D (analog common).

Socket D: Analog common for Socket C.

Socket E: Wire Feed Speed; positive (+) signal from

0 to 10 volts dc input from robot control unit with respect to Socket F (analog common) equals 0 to 1000 IPM from wire drive motor.

Socket F: Analog common for Socket E.

Socket J: Voltage Feedback; 100V (arc voltage) equals 10V (feedback signal) with respect to Socket K.

Socket K: Analog common for Socket J.

Socket L: Current Feedback; 1000A (weld current) equals 10V (feedback signal) with respect to Socket M.

Socket M: Analog common for Socket L.

Socket N: Wire Stuck; return for Socket P.

Socket P: Wire Stuck; output signal to robot control unit with respect to Socket N indicating wire is stuck to work.

Socket R: Contactor Control; contact closure from robot 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

(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; contact closure from robot control unit with respect to Sockets a and b

(circuit common).

Sockets a,b: Circuit common for Sockets R, S, U, and V all circuit voltages referenced to this point.

Socket d: Current Detect; output signal to robot control unit with respect to Socket m.

Socket h: Weld Standby; output signal to robot control unit with respect to Socket m (digital common) indicating the robot interface is in a standby mode. This is a normally-open contact.

OM-154 145 Page 10

Socket m: Digital common for Sockets d and h.

Socket r: +24 volts dc supply (option for Karel Controller). Only plug into this socket if use of the option is desired.

Socket s: Chassis ground.


C. External Jog Connections And Jog Speed Setting

Terminal Strip 3T provides connections for an external jog switch. To make connections to 3T, proceed as follows:

1.


2.

Locate terminal strip 3T in left side portion of base inside the interface.

3.

Remove snap-in blank from right side of interface, and install a customer-supplied strain relief.

4.

Route switch cord through strain relief and to terminal strip 3T.

5.

Strip cord jacket back enough to gain access to switch leads for installing terminals and connecting to terminal strip.

6.

Strip insulation from lead ends, and crimp proper size spade terminals on end of leads.

7.

Connect terminals on end of leads to terminals

3TA and 3TB.

8.

Tighten strain relief clamp. Close and secure door.

The external jog switch provides jog forward operation to feed welding wire from the gun, and places the unit in manual operation. To set the jog speed, make the external jog switch contact closure and set desired jog wire feed speed at the WFS/ARC LENGTH control.

3-10.

ABB ROBOT CONTROL UNIT – ROBOT IN-

TERFACE SET UP


•


•





•



•



(Chart 3-2)

IMPORTANT: Recommended mode selection for ABB robot is Automatic (see Chart 3-2 and Chart 3-3 or




1.


2.


3.


4.



(Figure 3-3)

1.



2.


3.


4.





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.

Socket D: Current Detect; output to robot control unit with respect to Socket B. Isolation relay

CR1 contacts are rated 1A at 120 V.

Socket E: Contactor Control; +24 volts dc input signal from robot control unit with respect to

Socket J (circuit common).

Socket F: Jog Forward; +24 volts dc input signal from robot control unit with respect to Socket J

(circuit common).

Socket G: Gas Control; +24 volts dc input signal from robot control unit with respect to Socket J

(circuit common).

Socket J: Circuit common for Sockets E, F, G, and H; all circuit voltages referenced to this point.

Socket K: Jog Forward; momentary contact closure output signal to robot control unit with respect to Socket Q (digital common).

Socket L: Set-Up; output signal to robot control unit with respect to Socket Q (digital common).

Socket M: Weave Set-Up; output signal to robot control unit with respect to Socket Q (digital common).

Socket N: 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 to robot control unit with respect to Socket Q (digital common) indicating robot interface is in standby mode.

Socket Q: Digital common for output signals at Sockets K, L, M, N, and P.

Socket R: Inductance; positive (+) 0 to 10 volts dc input signal from robot control unit with respect to Socket S (analog common).

Socket S: Analog common for Socket R.

Socket W: Analog common for Socket X.

Socket X: Wire Feed Speed; positive (+) 0 to 10 volts dc input signal from robot control unit with respect to Socket W (analog common) equals 0 to 1000 ipm.

Socket Y: Analog common for Socket Z.

Socket Z: Arc Volts; positive (+) 0 to 10 volts dc input signal from robot control unit with respect to Socket Y (analog common) equals 0 to

50 volts dc output at welding power source.


OM-154 145 Page 11

3-11.

KAWASAKI ROBOT CONTROL UNIT – RO-



•


•





•



•



(Chart 3-2)

IMPORTANT: Recommended mode selection for Kawasaki robot is Selector Switch and Manual Inductance

(see Chart 3-2 and Chart 3-3 or Chart 3-4). When using the selector switch, the inner settings apply to all robot models except ABB which uses the outer settings.



1.


2.


3.


4.



(Figure 3-3)

1.

Locate supplied cord.

2.


3.


The input and output signals at the pins of receptacle


OM-154 145 Page 12


Pin A:

Pin B:

Pin D:

Pin E:

Pin G:

Pin H:

Pin J:

Pin K:

Pin M:

Pin P:

Pin R:

Circuit common for Pins B, C, and L.

Arc On signal; starts gas flow and wire feed, turns on contactor.

Jog FWD. signal.

Current Detect signal; contact closure from robot control unit with respect to

Socket H.

Wire stick check signal; contact closure from robot control unit with respect to

Socket J.

Current Detect signal; contact closure from robot control unit with respect to

Socket E.

Wire stuck signal; contact closure from robot control unit with respect to Socket G.

Circuit common for Pin D.

Wire feed signal; 0 to 8V signal = 0 to 800 ipm.

Analog common for Pins M and R.

Arc voltage signal; 0 to 10V signal = 0 to

50V output.

IMPORTANT: The remaining pins in the receptacle are not used.

3-12.

SMIC ROBOT CONTROL UNIT – ROBOT IN-

TERFACE SET UP


•


•





•



•



(Chart 3-2)

IMPORTANT: Recommended mode selection for SMIC robot is Selector Switch and Manual Inductance (see

Chart 3-2 and Chart 3-3 or Chart 3-4). When using the selector switch, the inner settings apply to all robot models except ABB switch which uses the outer settings.

DIP switch S1 on Analog Channel Board PC4 allows setting robot interface control function for all automatic, all manual, selector switch, preset, or manual induc-

tance 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


1.


2.


3.


4.



(Figure 3-3)

1.



2.


3.


4.





Socket A: Wire Feed Speed command signal; 0 to 8V signal = 0 to 800 ipm.

Socket B: Wire Feed Speed common.

Socket C: Arc Volts command signal; 0 to 10V signal = 0 to 50V output.

Socket D: Arc Volts common.

Socket E: Jog FWD. signal.

Socket F: Circuit common for Socket E.

Socket G: Arc On signal; starts gas flow and wire feed, and turns on contactor.

Socket H: Circuit common for Socket G.

Socket J: Jog REV. signal.

Socket K: Circuit common for Socket J.

Socket L: Circuit common for Socket M.

Socket M: Arc detect signal.

Socket N: Circuit common for Sockets P and Q.

Socket P: Wire Stuck signal.

Socket Q: Arc Failure signal.

Socket R: Touch Sense signal; contact closure from robot control unit with respect to Socket S.

Socket S: Touch Sense signal; contact closure from robot control unit with respect to Socket R.


3-13.

GAS/CURRENT SENSING CONTROL IN-

TERCONNECTIONS (Figure 3-3)


•


•

Shut down unit, welding power source, and robot, and disconnect input power employing lockout/tagging procedures before making interconnections.


Fuse F1

(See Section 7-2)

Circuit Breaker CB1

(See Section 7-2)

19-Socket Motor/Gas

Control Receptacle

RC2

14-Pin Welding Power

Source Receptacle RC1

17-Pin Receptacle

RC4

4-Pin Arc Sensing

Receptacle RC5

Location Of Receptacle(s)

For Robot Control

Unit Connections

ST-157 096

Figure 3-3. Right Side View

A. Robot Interface – Gas/Current Sensing Control

Connections

1.

Align keyways, insert 19-pin plug into matching receptacle RC2 on robot interface, and rotate threaded collar fully clockwise.

2.

Align keyways, insert 19-pin plug into matching receptacle RC3 on gas/current sensing control, and rotate threaded collar fully clockwise.

B. Weld Cable Connections

For Direct Current Electrode Positive (DCEP), proceed as follows:

1.

Remove wrapper from gas/current sensing control.

2.

Connect a weld cable to positive (+) weld output terminal on welding power source.

3.

Route cable through reed relay, and connect to shunt terminal marked POWER SOURCE +.

4.

Route a weld cable through opening on opposite end of control, and connect to shunt.

OM-154 145 Page 13

5.

Connect remaining end of weld cable to weld cable terminal on wire drive assembly (see Motor/Drive

Assembly Owner’s Manual for location).

6.

Connect a weld cable to negative (–) weld output terminal on welding power source.

7.

Connect remaining end of weld cable to workpiece.

For Direct Current Electrode Negative (DCEN), reverse cable connections at welding power source.

C. Gas Connections

Connect hose from gas regulator/flowmeter (customer supplied) at gas source to IN fitting on gas/current sensing control. Connect gas hose from wire drive assembly to fitting on gas/current sensing control. The gas flow must be accurately controlled by a regulator/flowmeter at the source.

D. Gas/Current Sensing Control – Motor Connections

Align keyways, insert 14-socket plug from motor control cord into matching receptacle RC5 on gas/current sensing control, and rotate threaded collar fully clockwise.

3-14.

VOLTAGE SENSING CONNECTIONS

(Figure 3-4)

IMPORTANT: Voltage sensing connections are polarity sensitive. Connect lead with red band to weld cable terminal on wire drive assembly.

1.

Align keyway, insert 4-socket plug from voltage sensing cord into matching receptacle RC5 on robot interface, and rotate threaded collar fully clockwise.

2.

One lead should be connected to the wire drive assembly, along with the weld cable from the welding power source, as shown in Figure 3-4.

3.

Connect remaining lead to the workpiece.

Nut

Lock Washer

Flat Washer

Voltage Sensing

Lead Ring

Terminal Location

Wire Drive

Assembly

Weld Cable Lug

Location

Figure 3-4. Voltage Sensing Connections

At Wire Drive Assembly

OM-154 145 Page 14

S-0401

3-15.

ROBOT INTERFACE – WELDING POWER

SOURCE CONNECTIONS (Figure 3-3)


•


•

Shut down unit, welding power source, and robot, and disconnect input power employing lockout/tagging procedures before making interconnections.


There are two cords supplied with the receptacle kit for interconnection between the robot interface and welding power source. Examine cords and select the proper cord(s) for the connection.

A. REMOTE 14 Connections

1.

Align keyway, insert 14-socket plug into matching receptacle RC1 on robot interface, and rotate threaded collar fully clockwise.

2.

Align keyway, insert 14-pin plug into matching receptacle on welding power source, and rotate threaded collar fully clockwise.

B. REMOTE 17 Connections For Maxtron 450

IMPORTANT: Place the REMOTE 14/17 selector switch in the REMOTE 14 position, and make connections to both the REMOTE 14 and REMOTE 17 receptacles. For the Maxtron 450 welding power source, place the Arc Force/Inductance And CC/CV Control

Switch in the REMOTE 17 position.

1.

Align keyway, insert 17-socket plug into matching receptacle RC4 on robot interface, and rotate threaded collar fully clockwise.

2.

Align keyway, insert 17-pin plug into matching receptacle on welding power source, and rotate threaded collar fully clockwise.

3-16.

CONNECTION FOR CONSTANT NONPULSE

SYNERGIC WELDING


•


•

Shut down robot and welding power source, and be sure equipment cannot be accidently energized before inspecting or installing.

IMPORTANT: To provide switching capability between pulse/nonpulse synergic welding, connect a set of dry contacts between terminals A and B on terminal strip 1T at the RCSP-R panel. A contact closure will provide nonpulse synergic welding and open contacts will provide pulse synergic welding.

If the RCSP-R panel is installed on this unit, the RCSP-R terminal strip 1T jumper link is across terminals B and C for remote control switching between pulse and nonpulse synergic welding. If constant nonpulse synergic welding is desired, proceed as follows:

1.


2.

Locate terminal strip 1T in upper left corner of

RCSP-R panel on inside of control panel door.

3.

Move jumper link from 1T terminals B and C to terminals A and B.

4.


3-17.

WELDING WIRE INSTALLATION (Figure 3-5)

A. Installation Of Spool-Type Wire

1.

Remove retaining ring.

2.

Slide spool of wire onto hub 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 ring onto hub.

B. Installation Of Optional Wire Reel And Reel-

Type Wire

1.

Remove retaining ring and, if applicable, wire reel assembly from hub.

2.

Lay wire reel assembly flat on a table or floor.

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 reel.

6.

Slide wire reel assembly onto hub, and rotate assembly until hub guide pin is seated in reel.

7.

Reinstall retaining ring onto hub.

C. Adjustment Of Hub Tension (Figure 3-1)

Check the hub tension by slowly rotating the wire spool or reel. The wire should unwind freely, but hub tension should be sufficient to keep wire taut and prevent backlash when the wire feed stops. If adjustment is required, loosen or tighten the hex nut on the end of the hub support shaft accordingly.

Retaining

Ring

Spanner

Nut

Wire Retainer

Hub Support

Wire Reel

Hub

SC-127 308

Figure 3-5. Optional Wire Reel And Reel-Type Wire

Installation

SECTION 4 – OPERATOR CONTROLS

4-1.

POWER SWITCH AND PILOT LIGHT

(Figure 4-1) to weld. Placing the POWER switch in the OFF position shuts down the interface and turns off the pilot light.

4-2.

JOG PUSH BUTTONS (Figure 4-1)

ON

OFF

POWER

V

Placing the POWER switch in the ON position energizes the robot interface. The pilot light comes on when the

POWER switch is in the ON position, indicating that the unit is energized. The interface must be on for the robot

JOG

FORWARD

JOG

REVERSE

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 15

Voltmeter

Wire Speed

IPM Meter Ammeter

Purge

Push Button

Pilot

Light

Power

Switch

Wire Feed

Indicator Light

Gas

Indicator Light

Contactor

Indicator Light

Current

Indicator Light

Arc Failure

Indicator Light

Preflow

Control

Postflow

Control

Burnback Time

Burnback

Voltage

Voltage/Arc

Power Manual

Control

Jog Reverse

Push Button

Jog Forward

Push Button

♦

RCSP-R Panel

(See Figure 5-1)

♦

OPTIONAL

WFS/Arc Length

Manual Control

Selector

Switch

Inductance

Manual Control

Figure 4-1. Front Panel Controls

4-3.

PURGE PUSH BUTTON (Figure 4-1) 4-5.

WIRE SPEED METER (Figure 4-1)

WIRE SPEED IPM

ST-157 097

PURGE

The PURGE push button is a momentary-contact switch. This switch energizes the gas solenoid and purges the shielding gas line of the gun. The PURGE push button allows the flow meter to be adjusted without energizing the welding circuit.

4-4.

VOLTMETER (Figure 4-1)

VOLTS

V

The voltmeter displays weld voltage to the nearest tenth of a volt while welding and preset voltage while idling.

OM-154 145 Page 16

The wire speed meter displays preset wire feed speed to the nearest inch per minute while welding and idling. Actual and preset wire feed speed are the same due to the wire feed speed feedback circuit.

4-6.

AMMETER (Figure 4-1)

AMPS

A

The ammeter indicates amperage draw through the shunt in the gas/current sensing control during welding; however, the amperage value may not necessarily be actual welding amperage.

4-7.

INDICATOR LIGHTS (Figure 4-1)

There are five indicator lights on the interface. These are visual indications of various process functions.

The GAS light turns on when the gas valve is energized to indicate shielding gas flow.

The CONTACTOR light turns on when the welding power source contactor is energized to indicate that weld output is available.

The WIRE FEED light turns on when the wire drive motor is energized to indicate that wire is feeding.

The CURRENT light turns on when the current detect relay is energized to indicate that an arc is established.

The ARC FAILURE light turns on when there is an arc outage while welding.

4-8.

PREFLOW CONTROL

PREFLOW

IMPORTANT: PREFLOW is used by all robot models except ABB.

The PREFLOW control is located on the front panel to allow setting the time that shielding gas flows before the arc is started. Preflow time can be varied from approximately 0 to 6 seconds.

4-9.

POSTFLOW CONTROL

IMPORTANT: POSTFLOW is used by all robot models except ABB.

POSTFLOW

The POSTFLOW control is located on the front panel to allow setting the time that shielding gas flows after burnback. Postflow time can be varied from approximately 0 to 6 seconds. Postflow time starts after burnback time ends.

4-10.

BURNBACK TIME CONTROL t

BURNBACK

The BURNBACK time control is located on the front panel. Burnback time can be varied from approximately 25 to 250 milliseconds.

4-11.

BURNBACK VOLTAGE CONTROL v

BURNBACK

The BURNBACK voltage control is located on the front panel. Burnback voltage is the voltage on the welding wire after the drive motor stops at the end of a welding operation. The welding wire remains electrically energized 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.

SELECTOR SWITCH

IMPORTANT: The Analog Channel Board DIP switch

S1 must be set correctly to allow use of the front panel

Selector switch (see Chart 3-2, Chart 3-3 and

Chart 3-4).

The Selector switch has three positions: MANUAL,

AUTO, and SETUP.

In MANUAL mode, the robot interface front panel controls provide the weld parameters (see Section 4-13).

The label by each control identifies its function when the

Selector switch is in the MANUAL position. The MANU-

AL mode only affects the channels for signals that control voltage/arc power, WFS/arc length, and inductance.

Control of gas valve, wire feed, and contactor signals stays with the robot control.

In AUTO mode, the robot control provides the weld parameters.

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

S1 must be set correctly to allow use of the front panel controls (see Section 3-5).

There are three controls on the front panel that are activated when Analog Channel Board DIP switch S1 is set to provide all manual operation or Selector switch operation using the MANUAL position: VOLTAGE/ARC

POWER, WFS/ARC LENGTH, and INDUCTANCE.

A. VOLTAGE/ARC POWER Control

V

VOLTAGE/

ARC POWER

The VOLTAGE/ARC POWER control provides selection of the arc voltage when the RCSP-R panel is not operational. Rotating the control clockwise increases voltage.

Preset voltage will be displayed on the voltmeter.

When the RCSP-R panel is operational and set for pulsing, arc power parameters are wire feed speed, background amperes, peak amperes, pulse frequency, and pulse width (see Sections 5-1 and 5-3).

If the unit is set for nonpulsing, arc power parameters are wire feed speed, arc voltage, and inductance (see

Sections 5-1 and 5-3).

OM-154 145 Page 17

B. WFS/ARC LENGTH Control

WFS/

ARC LENGTH

The WFS/ARC LENGTH control provides selection of the wire feed speed when the RCSP-R panel is not operational. Rotating the control clockwise increases wire feed speed. The wire feed speed will be displayed on the wire speed meter.

When the RCSP-R panel is operational and set for pulsing, arc length is a fine tuning of pulse frequency (see

Sections 5-1 and 5-3).

If the unit is set for nonpulsing, arc length is a fine tuning of arc voltage (see Sections 5-1 and 5-3).

C. INDUCTANCE Control

IMPORTANT: The INDUCTANCE control only functions with a Maxtron 450 welding power source and the

Analog Channel Board DIP switch S1 setting provides manual inductance control (see Chart 3-2, Chart 3-3 and Chart 3-4).

INDUCTANCE

The INDUCTANCE control allows manual adjustment of inductance at the robot interface front panel.

4-14. ROBOTIC INTERFACE COMMAND SIGNALS

The robotic interface command signal range is 0 to +10 volts dc for voltage/arc power and WFS/arc length.

The scaling of programmable values to command signal range can vary for different robot control models. For example, a programmable range of wire feed speed for a robot control model may be 0 to 1000 ipm and the command signal range is 0 to 10 volts dc. In this case, the scale for wire feed speed is 100 ipm programmable value equals 1 volt dc command signal at the robotic interface. Another example is a programmable range of arc voltage at the robot control may be 0 to 50 volts and the command signal range is 0 to 15 volts. In this case, the scale for arc voltage is 3.3 volts programmable value equals 1 volt dc command signal at the robotic interface.

In addition, a programmable arc voltage value of 33 volts is the maximum 10 volts command signal accepted by the robotic interface and any programmable value that results in a command signal greater than the maximum is ignored by the robotic interface.

SECTION 5 – OPTIONAL RCSP-R OPERATOR CONTROLS

5-1. PULSE PARAMETERS

IMPORTANT: See IMPORTANT block at beginning of

Section 3-16 for instructions to provide switching capability between pulse/nonpulse synergic welding.

The arc voltage channel from the robot control is the voltage/arc power parameter at the robotic interface.

When using the unit in a pulse welding operation, arc power changes the wire feed speed as well as other pulse parameters (see Section 5-2 and 5-4). The wire feed speed channel from the robot control is the WFS/ arc length parameter at the robotic interface. When using the unit in a pulse welding operation, arc length is the fine adjustment to the pulse frequency. The arc length command signal is a nominal value of 5 volts dc (see

Section 4-14). This means the midrange of programmable wire feed speed, depending on scaling of the robot control channels, will be at the pulse frequency set by arc power. Changing arc length will result in slight changes to the pulse frequency set by the arc power value.

5-2.

WIRE SIZE SELECT SWITCH AND STAN-

DARD MODE INDICATOR LIGHT

The WIRE SIZE SELECT Switch and the WIRE TYPE

SELECT Switch set the output range of the welding

OM-154 145 Page 18 power source and robot wire drive for the specific type and size of wire chosen. Together, the switches determine the relationship of the various arc power parameters.

If the unit is operated in a pulse condition, arc power parameters are wire feed speed, background amperes, peak amperes, pulse frequency, and pulse width. Arc length is a fine tuning of pulse frequency (see

Chart 5-1).

If the unit is operated in a nonpulse condition, arc power parameters are wire feed speed, arc voltage, and inductance. Arc length is a fine tuning of arc voltage (see

Chart 5-1).

When the WIRE SIZE SELECT Switch is placed in the

STD position, the STANDARD MODE Indicator Light will come on, indicating that the Synergic Pulse panel is in standard mode and cannot be used to set the output parameters for the welding power source or robot wire drive (see Chart 5-1).

IMPORTANT: Position the WIRE SIZE SELECT Switch in the .045 position when welding with .047 in. diameter welding wire.

Standard Mode

Indicator Light

Wire Type

Selector Switch

Wire Size

Indicator Lights

Wire Size

Selector Switch

No Program

Indicator Light

Recommended

Shielding Gas

Indicator Lights

Figure 5-1. Operator Controls

Chart 5-1. RCSP-R Modes And Weld Parameters

RCSP-R

MODES

ROBOT OUTPUT SIGNALS

WFS/CURRENT

CONTROL

(0 To 10 VDC)

VOLTAGE

CONTROL

(0 To 10 VDC)

Arc

Length

Arc

Power

SYNERGIC

PULSE MODE

SYNERGIC

NONPULSE

MODE*

STANDARD**

Arc

Length

Arc

Power

WFS Volts

* Select by robot I/O or moving jumper link (see Section 3-16).

** Select by Wire Size Selector switch (see Section 5-2).

5-3.

WIRE SIZE INDICATOR LIGHTS (Figure 5-1)

The top light indicates whether the unit is set to pulse

(light on) or is in STD (light off). The remaining lights turn on when the corresponding wire size is selected by the

WIRE SIZE SELECT switch.

5-4.

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, the switches determine the relationship of the various arc power parameters.

If the unit is operated in a pulse condition, arc power parameters are wire feed speed, background amperes, peak amperes, pulse frequency, and pulse width. Arc length is a fine tuning of pulse frequency.

ST-157 098

If the unit is operated in a nonpulse condition, arc power parameters are wire feed speed, arc voltage, and inductance. Arc length is a fine tuning of arc voltage.

5-5.

RECOMMENDED SHIELDING GAS INDICA-

TOR LIGHTS (Figure 5-1)

The RECOMMENDED SHIELDING GAS Indicator

Lights represent the types of shielding gases recommended for use with the Synergic Pulse panel. The panel is programmed to select the shielding gas that will provide optimum welding conditions in a majority of situations for the type and size of wire selected on the WIRE

SIZE SELECT and WIRE TYPE SELECT switches.

After selecting the wire size and type, the indicator light for the recommended shielding gas will come on. If a light does not come on, and the NO PROGRAM Indicator light does not come on, refer to Table 5-1 for the recommended shielding gas.

If the NO PROGRAM Indicator Light comes on with or without a RECOMMENDED SHIELDING GAS Indicator

Light, reselect the wire type and size to be used (see

Section 5-6).

5-6.

NO PROGRAM INDICATOR LIGHT

(Figure 5-1)

The Synergic Pulse panel has been programmed to provide optimum welding conditions in a majority of situations using various types and sizes of welding wire and various shielding gases. The NO PROGRAM Indicator

Light allows the operator to determine if the unit has been programmed for the conditions set by the WIRE

TYPE SELECT and WIRE SIZE SELECT switches. If the NO PROGRAM Indicator light comes on, the control is not 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.

IMPORTANT: Use of a nonrecommended shielding gas could change weld characteristics.

OM-154 145 Page 19

Wire

Size

.030

.035

.045

.062

STL1

*

*

*

*

STL2

*

98Ar/2 0

2

98Ar/2 0

2

*

Table 5-1. Synergic Pulse Panel Welding Schedules

NI

PULSE WELDING

Wire Type

SS1 SS2 AL1 AL2

*

75Ar/25 HE

75Ar/25 HE

*

*

98Ar/2 0

2

98Ar/2 0

2

*

*

*

*

*

*

Ar

Ar

Ar

*

Ar

Ar

Ar

SI BR

*

Ar

Ar

*

CUST.

*

*

*

*

Wire

Size

.030

.035

.045

.062

STL1

CO

2

CO

2

CO

2

*

STL2

75Ar/25 CO

75Ar/25 CO

75Ar/25 CO

*

2

2

2

NI

*

*

*

*

NONPULSE WELDING

Wire Type

SS1

SPCL

SPCL

SPCL

*

SS2

98Ar/2 O

98Ar/2 O

98Ar/2 O

*

2

2

2

*The Synergic Pulse panel is not programmed for type and size of welding wire indicated.

AL1

*

Ar

Ar

Ar

AL2

*

Ar

Ar

Ar

SI BR

*

*

*

Ar

CUST.

*

*

*

*

DEFINITION OF TABLE 5-1 DATA

Wire Type:

STL1 =

STL2 =

NI

SS1

SS2

AL1

AL2

SI BR

*CUST.

=

=

=

=

=

=

=

Mild Steel (Used with C0

2

shielding gas for short circuit welding from minimum to maximum wire feed speed.)

Mild Steel (In PULSE mode, STL2 is used with 98 Ar/2 0

2 shielding gas for pulse spray welding from minimum to maximum wire feed speed. In NONPULSE mode, STL2 is used with 75 Ar/25 CO

2

shielding gas for short circuit welding from minimum to maximum wire feed speed.)

High Nickel Alloy

Stainless Steel (In PULSE mode, SS1 is used with 98 Ar/2 0

2

shielding gas for spray transfer welding from minimum to maximum wire feed speed. In NONPULSE mode, SS1 is used with Tri-Mix shielding gas for short circuit transfer welding from minimum to maximum wire feed speed.)

Stainless Steel (SS2 is used with 98 Ar/2 0

2

shielding gas for spray transfer welding from minimum to maximum wire feed speed.)

4043 Aluminum

5356 Aluminum

Silicon-Bronze

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 = .045 409 flux-cored stainless steel welding wire

*NONPULSE Welding = .045 AWS class E71T-1 flux-cored welding wire

Shielding Gas:

CO

2

75 Ar/25 CO

2

SPCL

AR

98 Ar/2 0

2

**75 Ar/25 HE

=

=

=

=

=

=

Carbon Dioxide

75% Argon

25% Carbon Dioxide

Tri-Mix: 90% Helium, 7.5% Argon, 2.5% Carbon Dioxide

Argon

98% Argon, 2% Oxygen

75% Argon, 25% Helium

**This shielding gas is not included on nameplate of the Synergic Pulse panel.

OM-154 145 Page 20

SECTION 6 – SEQUENCE OF OPERATION

6-1. MAXTRON 450 CONTROL SETTINGS FOR

WELDING PROCESSES (Figure 6-1)

Switch Settings

Gas Metal Arc Welding (GMAW) And

Gas Metal Arc Welding-Pulsed (GMAW-P)

Ref. SC-154 197

Figure 6-1. Control Settings For Welding Processes

IMPORTANT: All control settings and connections must be correct for the welding power source to operate with the robotic interface.

6-2.

OPTIONAL RCSP-R GAS METAL ARC WELD-

ING-PULSED (GMAW-P)

WARNING: ELECTRIC SHOCK can kill;

MOVING PARTS can cause serious injury;

IMPROPER AIRFLOW AND EXPOSURE TO

ENVIRONMENT can damage internal parts.

•


•

Keep all covers and panels in place while operating.

•

Do not touch welding wire or any metal part in contact with it while welding.

The welding wire and all metal parts in contact with it carry weld output when the welding power source contactor is energized.

Warranty is void if any of the equipment is operated with any portion of the outer enclosure removed.

WARNING: ELECTRIC SHOCK can kill;

MOVING PARTS can cause serious injury;

IMPROPER AIRFLOW AND EXPOSURE TO

ENVIRONMENT can damage internal parts.

•


•

Keep all covers and panels in place while operating.

•

Do not touch welding wire or any metal part in contact with it while welding.

The welding wire and all metal parts in contact with it carry weld output when the welding power source contactor is energized.

Warranty is void if any of the equipment is operated with any portion of the outer enclosure removed.

ARC RAYS, SPARKS, AND HOT SURFACES can burn eyes and skin; NOISE can damage hearing.

•

Wear correct eye, ear, and body protection.

FUMES AND GASES can seriously harm your health.

•

Keep your head out of the fumes.

•

Ventilate to keep from breathing fumes and gases.

•

If ventilation is inadequate, use approved breathing device.

WELDING WIRE can cause puncture wounds.

•

Do not point gun toward any part of the body, any conductive surface, or other personnel.

MAGNETIC FIELDS FROM HIGH CURRENTS can affect pacemaker operation.

•

Wearers should consult their doctor before going near arc welding, gouging, or spot welding operations.

HOT METAL, SPATTER, AND SLAG can cause fire and burns.

•

Watch for fire.

•

Keep a fire extinguisher nearby, and know how to use it.

•

Do not use near flammable material.

•

Allow work and equipment to cool before handling.

See Arc Welding Safety Precautions in the welding power source Owner’s Manual for basic welding safety information.

1.

Install and connect robot system according to its

Owner’s Manuals.

2.

Connect robot interface according to Section 3.

OM-154 145 Page 21

3.

Position WIRE SIZE SELECT Switch for size wire used (see Section 5-2).

4.

Position WIRE TYPE SELECT Switch for type wire used (see Section 5-4).

5.

Turn on shielding gas at its source.

WARNING: HIGH CONCENTRATION OF

SHIELDING GAS can harm health or kill.

•

Shut off gas supply when not in use.

6.

Energize robot system.

7.

Begin welding.

6-3.

SHUTTING DOWN

1.

Stop welding.

2.

Shut down robot system.

3.

Turn off shielding gas at the source.

7-1.

ROUTINE MAINTENANCE

IMPORTANT: Every six months inspect the labels on this unit for legibility. All precautionary labels must be maintained in a clearly readable state and replaced when necessary. See Parts List for part number of precautionary labels.

Usage and shop conditions determine the frequency and type of maintenance. At minimum, inspect equipment every three months as follows:


•


•

Shut down unit, welding power source, and robot, and disconnect input power employing lockout/tagging procedures before inspecting, maintaining, or servicing.


MOVING PARTS can cause serious injury.

•

Keep away from moving parts.

HOT SURFACES can cause severe burns.

•

Allow cooling period before servicing.

Maintenance to be performed only by qualified persons.

1.

Repair or replace, as required, all hose and cable; give particular attention to frayed and cracked insulation and areas where it enters equipment.

2.

Remove grease and grime from components; moisture from electrical parts and cable.

7-2.

OVERLOAD PROTECTION


•


•

Shut down unit, welding power source, and robot, and disconnect input power employing lockout/tagging procedures before inspecting, maintaining, or servicing.

OM-154 145 Page 22

SECTION 7 – MAINTENANCE & TROUBLESHOOTING


INCORRECT FUSE can damage unit.

•

Use only replacement fuse of same size, type, and rating (see Parts List).

A. Wire Drive Motor Circuit Breaker CB1

(Figure 3-3)

WARNING: Read and follow safety information at beginning of Section 7-2 before proceeding.

Circuit breaker CB1 protects the wire drive motor from overload . If CB1 opens, the wire feed motor would stop.

Should a motor overload occur and CB1 open, proceed as follows:

1.

Check for jammed wire or clogged gun liner, and correct problem. If wire jams often, replace gun liner.

2.

If motor overload occurs often, repair or replace wire drive motor.

3.

Check for binding drive gear or misaligned drive rolls, and correct problem.

4.

Reset circuit breaker by depressing the button. A cooling period may be necessary before the circuit breaker can be reset.

5.

Resume operation.

B. Main Fuse F1 (Figure 3-3)

WARNING: Read and follow safety information at beginning of Section 7-2 before proceeding.

Fuse F1 protects the robot interface and RCSP-R panel from an internal short or excessive overload . If fuse F1 opens, the robot interface and RCSP-R shuts down. If the fuse opens, correct the problem and replace F1 as follows:

1.

Depress and rotate fuse holder cover counterclockwise.

2.

Pull out fuse with cover when fuse holder cover is free.

3.

Insert new fuse into fuse holder cover.

4.

Install fuse with fuse holder cover back into unit.

5.

Depress and rotate fuse holder cover clockwise until cover is secure.

7-3.

REINSTALLATION OF HUB ASSEMBLY

(Figure 7-1)

If it becomes necessary to replace part or all of the hub assembly, reinstall the new hub assembly as follows:

1.

Remove hub assembly from hub support, and disassemble discarding worn or broken parts.

2.

Slide the following items onto the hub support shaft in order given.

a.

Spring b.

Keyed Washer c.

Fiber Washer d.

Brake Washer e.

Hub f.

Brake Washer g.

Fiber Washer

3.

Align keyway, and insert hub support shaft through selected hole in hub support.

4.

Install hex nut onto hub support shaft. Tighten hex nut until a slight drag is felt while turning hub.

5.

Install welding wire according to Section 3-17.

Retaining Ring

7-4.

CIRCUIT BOARD HANDLING PRECAUTIONS


•


•

Shut down unit , welding power source, and robot, and disconnect input power employing lockout/tagging procedures before inspecting, maintaining, or servicing.



•



•

Transport circuit boards in proper staticshielding carriers or packages.

•


INCORRECT INSTALLATION or misaligned plugs can damage circuit board.

•

Be sure that plugs are properly installed and aligned.

EXCESSIVE PRESSURE can break circuit board.

•

Use only minimal pressure and gentle movement when disconnecting or connecting board plugs and removing or installing board.

IMPORTANT: The circuit boards in the RCSP-R panel –

Interface Circuit Board PC1, Logic Circuit Board PC2, and Memory Circuit Board PC3-–are installed stacked on top of each other on the inside of the operator control panel. PC2 is at the bottom of the stack (closest to the operator control panel), PC3 is in the middle, and PC1 is at the top of the stack.

Spanner Nut

Wire Retainer

Wire Reel

Hub Support

Shaft

Spring

Keyed

Washer

Fiber

Washer

Brake

Washers

Fiber

Washer

Hub

Hex Nut

Hub Support

Ref. SD-045 317-J

Figure 7-1. Hub And Reel Assemblies

OM-154 145 Page 23

7-5.

TROUBLESHOOTING


•


•

Shut down unit, welding power source, and robot, and disconnect input power employing lockout/tagging procedures before inspecting or servicing.


MOVING PARTS can cause serious injury.

•

Keep away from moving parts.

HOT SURFACES can cause severe burns.

•

Allow cooling period before servicing.

Troubleshooting to be performed only by qualified persons.

It is assumed that the unit was properly installed according to Section 3 of this manual, the operator is familiar with the function of controls, the robot interface was working properly, and that the trouble is not related to the welding process.

The following table is designed to diagnose and provide remedies for some of the troubles that may develop in this robot interface. Use this table in conjunction with the circuit diagram while performing troubleshooting procedures. If the trouble is not remedied after performing these procedures, contact the nearest Factory Authorized Service Station/Service Distributor. In all cases of equipment malfunction, strictly follow the manufacturer’s procedures and instructions.

Table 7-1. Robot Interface Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

Unit does not operate.

Welding power source off.

14-pin receptacle on interface or 14-socket receptacle on welding power source.

Circuit breaker CB1 tripped.

Fuse F1 open.

Turn welding power source on (see welding power source Owner’s Manual.

Check and secure connections (see Section

3-15 and welding power source Owner’s Manual).

Check CB1, and reset if necessary (see Section

7-2). Correct overload problem before continuing operation.

Check F1, and replace if necessary (see Section


No weld output.

Power switch on welding power source in OFF position.

Fuse F1 open.

Place POWER switch in ON position.

Improper regulation of arc voltage.

Work connection loose or incomplete due to rust, paint, etc.

on surface of workpiece.

Check F1, and replace if necessary (see Section


Check work connection for good metal-to-metal contact.

AMPERAGE/VOLTAGE control switch on welding power source front panel in PANEL position.

14-pin receptacle on interface or 14-socket receptacle on welding power source.

Place AMPERAGE/VOLTAGE control switch in the REMOTE 14 position (see welding power source Owner’s Manual).


3-15 and welding power source Owner’s Manual).

Receptacle connections inside interface.

Check and secure connections.

Incorrect DIP switch settings.

Check DIP switch settings on Analog Channel

Board PC4 (see Charts 3-2, 3-3, and 3-4, and appropriate set up section for correct robot model).

OM-154 145 Page 24

Table 7-1. Robot Interface Troubleshooting (Continued)


Improper regulation of arc voltage. (Continued)

Incorrect robot command voltage.

Wire feeds at maximum only.

Tach Board at wire drive motor

Wire speed (IPM) meter goes to zero or no wire feed operation.

Not meter display.

No wire stick check.

Analog Channel Board PC4 not working.

Voltage Board PC1 not working.

not working.

Incorrect robot command voltage.

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 terminal strip 1T.

Replace PC4 (see Section 7-4 and contact nearest Factory Authorized Service Station).

Replace PC1 (see Section 7-4 and contact nearest Factory Authorized Service Station).

Replace Tach Board (see motor/drive assembly

Owner’s Manual).

Check robot command voltage at Analog Channel Board PC4. Signal should be 0-8 vdc between RC4-13 and lead 85 (common) at terminal

B on terminal strip 2T.

Display Board PC4 not working. Replace PC4 (see Section 7-4 and contact nearest Factory Authorized Service Station).

Wire stick connection.

Be sure that leads from robot are connected to correct receptacle at interface.


Check DIP switch settings on Interface Board

PC1 (see Chart 3-1 and appropriate set up section for correct robot model).

OM-154 145 Page 25

Table 7-2. Optional RCSP-R Troubleshooting


Synergic pulse panel not operational.

Erratic weld: incorrect weld characteristics.

Panel connections inside Interface.

Interface Circuit Board PC1.

Check and secure connections.

Memory Circuit Board PC3.

See Section 7-4 and contact nearest Factory Authorized Service Station.


Logic Circuit Board PC2.



Check DIP switch settings on DVC Board PC8

(see Section 3-3).

Reselect wire type and wire size to be used.

Synergic pulse panel not programmed for weld conditions set by WIRE SIZE SELECT and

WIRE TYPE SELECT switches

(NO PROGRAM indicator light will be on).

Incorrect arc length.

Adjust ARC LENGTH control on the robot interface.

Check routing of voltage sensing cable and secure connections.

Weld voltage goes to maximum in pulse mode.

Work connection loose or incomplete due to rust, paint, etc., on surface of workpiece.

Welding power source and robotic interface connections.

Check work connection for good metal-to-metal contact.

No pulsing; pulse light off.

Arc sensing connections.

Welding power source and robotic interface connections.

Incorrect jumper link position at terminal strip 2T.

Check REMOTE 17 connection and welding power source switch settings (see Section 3-15 and 6-1)*.


3-14).

Check REMOTE 17 connection and welding power source switch settings (see Section 3-15 and 6-1)*.

Move jumper link across terminals M and N for pulsing.

*Maxtron 450 must have 17-socket receptacle connection, and the CV/CC front panel switch must be in the REMOTE position.

OM-154 145 Page 26

7-6.

USE OF INDICATOR LIGHTS FOR TROUBLE-

SHOOTING

On Gas Indicator Light Off

Gas flows:

System normal (on.)

On

Gas does not flow Gas flows:

Check gas valve operation.

Check gas valve operation and gas line for leaks.

Check interface board PC1.

Contactor Indicator Light

Gas does not flow

System normal (off).

Off

Contactor open:


Contactor closed:

System normal (on).

Contactor open:

Check interconnecting cords.


Contactor closed:

Check display board PC7.

On Wire Feed Indicator Light Off

Wire feeds:

System normal (on).

Wire does not feed:

Check circuit breaker CB1.

Check relay CR1.


Check motor board PC6.

Wire feeds:

Check input signal from robot to motor board PC6.

Signal should be 0-8 vdc between pins K and B

(common) at RC5 on circuit board.

Check motor board PC6.

On Current Indicator Light

Wire does not feed:


Off

Arc started:

System normal (on).

No arc:

Replace reed relay.

Arc started:

Replace reed relay.

No arc:


On Arc Failure Indicator Light

No arc:

Check weld parameters.

Arc started:

Check reed relay connection inside Gas/

Current Sensing Control.

Check display board PC7.

No arc:

Normal during idling.

Off

Arc started:

Normal while welding.

OM-154 145 Page 27

SECTION 8 – ELECTRICAL DIAGRAMS

OM-154 145 Page 28

Diagram 8-1. Circuit Diagram For Robotic Interface Control

Circuit Diagram No. SD-165 997

OM-154 145 Page 29

OM-154 145 Page 30

Diagram 8-2. Circuit Diagram For Analog Channel Board PC4


OM-154 145 Page 31

OM-154 145 Page 32

Diagram 8-3. Circuit Diagram For Interface Board PC1

Circuit Diagram No. SD-146 306-A

OM-154 145 Page 33

OM-154 145 Page 34

Diagram 8-4. Circuit Diagram For DVC Board PC8


OM-154 145 Page 35

Diagram 8-5. Circuit Diagram For Motor Board PC6

Circuit Diagram No. SD-083 388-B

Diagram 8-6. Circuit Diagram For Power Supply Board PC5

Circuit Diagram No. SC-146 591

Circuit Diagram No. SB-146 599-A

Diagram 8-7. Circuit Diagram For Isolation Board PC2

OM-154 145 Page 38

Circuit Diagram No. SB-146 587

Diagram 8-8. Circuit Diagram For Display Board PC7

Circuit Diagram No. SA-134 562

Diagram 8-9. Circuit Diagram For Filter Board PC9


Diagram 8-10. Circuit Diagram For Gas/Current Sensing Control

OM-154 145 Page 39


Diagram 8-11. Circuit Diagram For Optional RCSP-R Panel

OM-154 145 Page 40

Circuit Diagram No. SB-154 743-A

Diagram 8-12. Circuit Diagram For Feedback Board PC10


Diagram 8-13. Circuit Diagram For Optional RCSP-R Offset/Supply Board PC5

Circuit Diagram No. SA-143 978

Diagram 8-14. Circuit Diagram For Selector Board PC6

OM-154 145 Page 41

OM-154 145 Page 42

Diagram 8-15. Circuit Diagram For Optional RCSP-R Interface Board PC1


OM-154 145 Page 43

OM-154 145 Page 44

Diagram 8-16. Wiring Diagram For Robotic Interface Control

Wiring Diagram No. SD-165 998

OM-154 145 Page 45

Diagram 8-17. Wiring Diagram For Gas/Current Sensing Control

Wiring Diagram No. SC-158 007

Diagram 8-18. Wiring Diagram For Optional RCSP-R Panel

Wiring Diagram No. SC-158 008-A

29

28

Fig 9-3

27

26

25

24

23

2

1

3 4

5

6

7

8

9

10

11

17 16 15 14 13

12

22

Fig 9-2

21

20

19

18

ST-156 956

Figure 9-1. Main Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description Quantity

Figure 9-1. Main Assembly

. .

.

.

1 . . . . . . . . . . . .

. . 2 . . . . . . . . . . . .

. . 3 . . . . . . . . . . . .

. . 4 . . . . . . . . . . . .

. . 5 . . . . R2 . . . .

057 084 . . BUSHING, snap-in nyl .250 ID x .375

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

084 184

010 199

. .

. .

BRACKET, mtg resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TUBING, stl .275 Id x .048 wall x 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

030 949

030 941

. .

. .

HEAT SINK, rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RESISTOR, WW fxd 100W 5 ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 6 . . . . . . . . . . .

. . 7 . . . . . . . . . . . .

. . 8 . . . . CB1 . . .

+153 753 . . CABINET, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

070 371

011 991

. .

. .

BLANK, snap-in nyl 1.093/1.125mtg hole blk . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT BREAKER, man reset 1P 1.5A 250V . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

.

9

10

11

12

. . . . . . . . . . . .

. . . . . . . . . . .

134 327

046 432

. .

. .

LABEL, warning general precautionary

HOLDER, fuse mintr

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . F1 . . .

. . . . . . . . . . .

*012 655 . . FUSE, mintr cer 10A 250V

153 885 . . CABLE, interconnecting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

.

.

.

.

.

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

.

13

14

15

16

17

19

. . . . . . . . . . .

. . . RC4 . . .

. . . . . . . . . . . . . . . .

153 887

039 734

090 263

153 886

047 838

073 686

039 828

097 867

. . . .

. . . .

CONNECTOR, circ 19skt plug Amphenol MS-3106A-22-14S . . . . . . . . . . . .

CONNECTOR, circ clamp str rlf sz 20-22S Amphenol AN-3057-12 . . . . . . .

. . . .

. . . .

CABLE, pwr No. 18ga 18/c 600V (order by ft) . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR, circ 19 pin plug Amphenol MS-3106A-22-14P . . . . . . . . . . .

10ft

1

. . BLANK, snap-in nyl 1. mtg hole

18 PC9,RC5 . 152 899 . . CONNECTOR w/COMPONENTS

. .

. .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR, circ 4skt plug Amphenol MS-3106A-14S-2S

CONNECTOR, circ clamp str rlf sz 14-14S Amphenol AN-3057-6

CONNECTOR, circ 17 pin rcpt Amphenol MS-3102A-20-29P

097 868 . . CONNECTOR, circ 17skt plug Amphenol MS-3106A-20-29S

. . . . . . . . . . . . . .

1

2

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

.

.

.

. . . . . . . . . . . . . . . .

. 20 . . . RC1 . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

21 . . . RC2 . . .

039 734 . . CONNECTOR, circ clamp str rlf sz 20-22S Amphenol AN-3057-12

152 492

134 731

143 426 . . CONNECTOR, circ 14skt plug Amp 213652-1

079 534 . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6

079 739 . . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2

143 922

153 884

. .

. . . .

. .

. .

CONNECTOR w/PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR, circ pin push-in 18-14ga Amp 213603-1

CONNECTOR, circ clamp str rlf sz 17-20 Amp 206070-3

. . . . . . . . . . . . . . . .

CONNECTOR, circ 19skt rcpt Amphenol MS-3102A-22-14S . . . . . . . . . . . . . .

22

23

. . . . . . . . . . . .

. PLG31 . .

Fig 9-2

130 203

. .

. .

CONTROL PANEL w/COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

14

. . . . . . . . . . . . . . . .

. 24 . PLG33 . .

113 746

115 090

. . . .

. .

CONNECTOR, rect skt 24-18ga Molex 39-00-0038

CONNECTOR & PINS, (consisting of)

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

1

. . . . . . . . . . . . . . . .

. 25 . PLG32 . .

114 656

115 094

. . . .

. .

CONNECTOR, rect pin 24-18ga Molex 39-00-0040

CONNECTOR & SOCKETS, (consisting of)

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

1

1

1

1

. . . . . . . . . . . . . . . .

.

.

.

26

28

29

. PLG99 . .

. . . . . . . . . . . . . . . .

. 27 . . . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

113 746

131 054

113 746

Fig 9-3

000 364

083 641

. . . .

. .

. . . .

. .

. .

. .




DOOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RING, retainer ext .188 shaft x .025thk

SCREW, closure door

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

1

2

1

2

2

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

*Recommended Spare Parts.

BE SURE TO PROVIDE MODEL AND NSPR NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-154 145 Page 49

29

28

27

26

1

2

3

4

5 6

7

31

34

33

32

30

25

24

23

22

21

19

18

20

Figure 9-2. Control Panel w/Components

8

9

14

15

16

17

10

11

12

13

ST-156 957-A

OM-154 145 Page 50

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 9-2. Control Panel w/Components (Fig 9-1 Item 22)

Quantity

. . 1 . . . . C1 . . . .

. . 2 . . . . . . . . . . . .

. . 3 . . . .

. . 5 . . . .

R1 . . . .

. . 4 . . . . . . . . . . . .

R3 . . . .

031 692

006 426

. .

. .

CAPACITOR, elctlt 750uf 200VDC

CLAMP, capacitor 2.000dia

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

030 651

605 741

. .

. .

RESISTOR, WW fxd 25W 10 ohm

CLIP, mtg resistor .312 ID

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

079 497 . . RESISTOR, WW fxd 25W 2K ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

.

.

.

. .

. .

. .

6

8

9

. . . .

. . . .

SR1 . . .

. . 7 . . . . . . . . . . . .

PC6 . . .

. . . . . . . . . . . .

035 704

153 007

. .

. .

RECTIFIER, integ 40A 800V

PANEL, mtg components

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

071 642

083 147

. .

. .

CIRCUIT CARD, motor speed control

GROMMET, scr No. 8/10

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

11

. . . . . . . . . . .

. PLG10 . .

009 335

117 374

. .

. .

STAND-OFF, 4-40 x .625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR, edge 22skt plug Amp 583282-1 . . . . . . . . . . . . . . . . . . . . . . . . .

12

13

. . .

. . .

CR1

CR2

. . .

. . .

109 006

052 964

. .

. .

RELAY, encl 24VAC DPDT

RELAY, encl 24VDC DPDT

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

.

.

14

15

16

. . .

. . .

. . .

D1

FL1

. . . .

. . .

PC2 . . .

152 898

084 171

. .

. .

DIODE, w/leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FILTER, line pwr 115/250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

146 596 . . CIRCUIT CARD, isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . PLG15 . .

. . . . . . . . . . . . . . . .

130 203

113 746

. . CONNECTOR & SOCKETS, (consisting of)

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . . . . . . .

. 17 . . .

. . . . . . .

PC1

PLG1

. . .

. .

148 421

130 203

. .

. .

CIRCUIT CARD, interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


1

12

1

1

1

1

1

1

1

2

1

1

2

1

1

1

4

1

1

1

. . . . . . . . . . . . . . . .

. . . . . . . PLG2 . .

. . . . . . . . . . . . . . . .

. . . . . . . PLG3 . .

113 746

131 056

113 746

115 094

. . . .

. .

. . . .

. .





. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . PLG4,5 . .

113 746

115 092

. . . .

. .



. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga Molex 39-00-0038 . . . . . . . . . . . . . . . . . . . .

12

1

14

1

4

2

8

. . . . . . .

. . . . . . . . . . . . . . . .

. . . . . .

. 18

. . . . . .

. . . . . .

PLG9

PLG12

. . . PC4

PLG24

PLG25

. .

. .

. . . . . . . . . . . . . . . .

. . .

. .

. . . . . . . . . . . . . . . .

. .

131 055

113 746

115 093

113 746

148 761

115 092

113 746

131 052

. .

. .

. .

. .

. .


. . . .


. . . .

CIRCUIT CARD, analog channel

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .


. . . . . . . . . . . . . . . . . . . . . . . . . . . . .


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .




. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8

1

1

1

1

6

1

5

. . . . . . . . . . . . . . . .

. . . . . . PLG27 . .

113 746

131 204

. . . .

. .



. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .


16

1

3

.

.

. . . . . . PLG28 . .

. . . . . . . . . . . . . . . .

115 093

113 746


. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .


19

20

. . . . . . . . . . .

. . 1T,2T . .

134 201

038 856

. .

. .

STAND-OFF, support pc card .312/.375

BLOCK, term 20A 14P

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

6

20

2

21

22

23

24

25

26

27

.

.

.

.

.

.

.

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . CR3 . . .

. . . . . . . . . . .

. . . T4 . . . .

. . . T5 . . . .

.

.

.

.

28

29

30

31

. . .

. . .

. . .

. . .

T3

T2

D2

T1

. . . .

. . . .

. . . .

. . . .

.

.

32

33

. . .

. . .

3T

PC8

. . . .

. . .

. . . . . . . PLG6 . .

. . . . . . . . . . . . . . . .

. . . . . . . PLG8 . .

. . . . . . . . . . . . . . . .

048 029

049 970

. .

. .

CLIP, retaining socket relay

BRACKET, mtg relay

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

027 811

095 521

. .

. .

SOCKET, relay 14 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RELAY, encl 24VDC 4PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

079 844

154 781

. .

. .

SPRING, holddown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

156 267 . . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

154 780

154 782

. .

. .

TRANSFORMER, control


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

026 202

166 003

. .

. .

DIODE, rect 1A 400V SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSFORMER, control 115V 36VCT 2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

038 832

152 371

. .

. .

BLOCK, term 20A 9P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT CARD, voltage control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

131 054

113 746


. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR, rect skt 24-18 ga Molex 39-00-0038 . . . . . . . . . . . . . . . . . . . .

079 748 . . CONNECTOR, rect 18skt plug Amp 1-640251-8

079 747 . . CONNECTOR, rect skt 24-18ga Amp 350980-1

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

1

18

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

OM-154 145 Page 51

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 9-2. Control Panel w/Components (Fig 9-1 Item 22) (Continued)

Quantity

. 34 . . .

. . . . . .

PC5

PLG17

. . .

. .

146 588

131 052

. .

. .

CIRCUIT CARD, power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


1

1

. . . . . . . . . . . . . . . .

. . . . . . PLG18 . .

113 746

152 249

. . . .

. .

CONNECTOR, rect skt 24-18 ga Molex 39-00-0038


. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

1

. . . . . . . . . . . . . . . .

. . . . . . PLG19 . .

147 995

150 315

. . . .

. .

CONNECTOR, rect skt 22-18ga Amp 170362-3

CONNECTOR, rect 9P/S plug Amp 172169-1

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

15

1

. . . . . . . . . . . . . . . .

. . . . . . PLG20 . .

147 995

115 093

. .

. .



. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

1

. . . . . . . . . . . . . . . .

. . . . . . PLG23 . .

113 746

130 203

. . . .

. .



. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .


6

1

12


4

5

1 2 3

6

7

8

OM-154 145 Page 52

19

18

9

22 21

20

17 16

15

14

13

Figure 9-3. Door Assembly

12

10

11

ST-156 955

Item

No.

Dia.

Mkgs.

Part

No.


Figure 9-3. Door Assembly (Fig 9-1 Item 27)

. . 1 . . . R4-6 . . . 082 708 . . POTENTIOMETER, C sltd sft 1/T 1W 1M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

. .

2

3

. . . R7-10 . . 035 897 . .

. . . . . . . . . . . . . . . . . . . . . . .

POTENTIOMETER, C std slot 1T 2W 1K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . .

. . 4 . . . . . . . . . . . .

. . 5 . . . . PC7 . . .

115 443

146 584

. .

. .

STAND-OFF, 6-32 x .750 lg

CIRCUIT CARD, meter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . PLG14 . . 079 798 . . CONNECTOR, rect 13skt plug Amp 1-640250-3 . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . PLG21 . .

079 797

131 055

. .

. .

CONNECTOR, rect 4skt plug Amp 640250-4


. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

13

1

3

4

1

7

1

.

.

.

.

.

.

.

.

.

.

.

.

. . . . . . . . . . . . . . . .

. . 6 . . . . PL1 . . .

113 746

027 645

. . . .

. .


LIGHT, ind red lens 125VAC

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

. .

7

8

. . . . . . . . . . . .

. . . PB1-3 . .

083 670

021 105

. .

. .

DOOR, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWITCH, PB licon 76-2351 SPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 9 . . . . . . . . . . . .

. 10 . . . S1 . . . .

11

12

13

14

15

16

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

153 754

153 699

084 040

153 076

. .

. .

STAND-OFF, .250-20 x .750 lg .437 hex brs

PANEL, door

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150 866

107 551

154 474

000 364

. .

. .

. .

. .

. .

. .

COVER, blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWITCH, rocker SPDT 16A 125VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LABEL, caution incorrect DVC board DIP switch

STRAIN RELIEF, cover

PLATE, control lower

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RING, retainer ext .188 shaft x .025thk

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

18

19

20

21

22

. . . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . S2 . . . .

058 420

+153 755 . . DOOR, tray front

084 034

097 922

089 032

. .

. .

. .

. .

THUMB SCREW, knurled .250-20

KNOB, pointer

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BAR, trim horizontal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LENS, LED 4341 red

086 895 . . SWITCH, relay 3 posn

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

1

1

8

5

1

1

2

1

2

1

1

2

1

5

1

1

3



OM-154 145 Page 53

1

2

3 4 5

6 7

21

20

8 9

10

11

12

13

14

15

10

9

14

19

18

Figure 9-4. Control Box, Gas Current

17

16

ST-157 025

OM-154 145 Page 54

Item

No.

Dia.

Mkgs.

Part

No.


Figure 9-4. Control Box, Gas Current

.

.

.

.

.

.

. . 1 . . . . . . . . . . .

. . 2 . . . . . . . . . . . .

+083 086

134 327

. .

. .

WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LABEL, warning precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 3 . . . . . . . . . . . .

. . 4 . . . . . . . . . . . .

. . 5 . . . . . . . . . . . .

. .

. .

6

7

. . . . . . . . . . . .

. . . . . . . . . . . .

154 281 . . BLOCK, shunt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

072 426

154 286

. .

. .

SHUNT, meter 50 MV 1000A

INSULATOR, shunt

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 493

154 279

. .

. .

BUSHING, snap-in nyl .625 ID x .875mtg hole

SHIELD, heat

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .

. .

.

.

.

.

.

.

8

9

10

11

12

13

. . . . RC5 . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . .

14

15

. . . . . . . . . . .

. . PC10 . .

. . . . . . . PLG1 . .

. . . . . . . . . . . . . . . .

. . . . . . . PLG2 . .

. . . . . . . . . . . . . . . .

047 637

079 534


. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTOR, circ skt pushin 18-14ga Amp 66358-6 . . . . . . . . . . . . . . . . . .

1

14

048 287 . . CONNECTOR, circ 14 pin plug Amp 206044-1

079 739 . . CONNECTOR, circ clamp str rlf sz 17-20 Amp 206322-2

010 494 . . BUSHING, snap-in nyl 1.375 ID x 1.750mtg hole . . . . . . . . . . . . . . . . . . . . . . . .

057 358

153 004

. .

. .

BUSHING, snap-in nyl 1. OD x 1.375mtg hole

CONTROL BOX

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 190

602 934

. .

. .

FITTING, pipe nipple L .250NPT x 10

FITTING, pipe coupling .250NPSC

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

010 604

153 759

. .

. .

FITTING, hose brs bushing .250NPT x .625-18R

CIRCUIT CARD, feedback

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

2

1

1

1

2

1

158 720

147 995

150 317

147 995

. .

. .

. .

. .



CONNECTOR, rect 4P/S plug Amp 172167-1


. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

1

12

1

4

2

1

2

1

1

1

1

16

17

18

19

20

21

. . . . . . . . . . .

. . . T1 . . . .

. . . GS1 . . .

. . . . . . . . . . .

. . . RC3 . . .

. . . . . . . . . . .

094 484

154 280

. .

. .

STAND-OFF, 6-32 x 1.000 lg


. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109 293

083 083

. .

. .

VALVE, 24VDC 2way 1/4 IPS

BRACKET, mtg control

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

144 982

169 857

. .

. .

CONNECTOR, circ 19 pin plug Amphenol MS-3102A-22-14P-639

SWITCH, reed

. . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

1

1

2

1

1



OM-154 145 Page 55

Miller ROBOTIC INTERFACE CONTROL Owner's Manual

August 1994 Form: OM-154 145B

OWNER’S

MANUAL

Robotic Interface Control

Gas/Current Sensing Control

ARC WELDING SAFETY PRECAUTIONS

WARNING

WARNING

PRINCIPAL SAFETY STANDARDS

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS

SECTION 2 – SPECIFICATIONS

SECTION 3 – INSTALLATION

SECTION 4 – OPERATOR CONTROLS

ON

OFF

POWER

JOG

FORWARD

JOG

REVERSE

WIRE SPEED IPM

PURGE

VOLTS

V

AMPS

A

PREFLOW

POSTFLOW

BURNBACK

BURNBACK

V

VOLTAGE/

ARC POWER

WFS/

ARC LENGTH

INDUCTANCE

SECTION 5 – OPTIONAL RCSP-R OPERATOR CONTROLS

SECTION 6 – SEQUENCE OF OPERATION

SECTION 7 – MAINTENANCE & TROUBLESHOOTING

SECTION 8 – ELECTRICAL DIAGRAMS

Related manuals

Miller

ROBOTIC INTERFACE CONTROL

Miller

Robotic Interface II

Miller

Robotic Interface II

Miller

Robotic Interface II

Miller

COMPUTER INTERFACE MR-5

ESAB

HC-6 Hand Control

Miller

ROBOT INTERFACE NSPR 8933 AND 9184

Miller

ROBOT INTERFACE NSPR 8933

Miller

ROBOT INTERFACE NSPR 9138

Miller

ROBOT INTERFACE NSPR 8945

Miller

COMPUTER INTERFACE MR-5

Miller

ROBOT INTERFACE NSPR 8933 AND 9184