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OWNERS MANUAL
IMPORTANT: Read and understand the entire contents of both this manual
MILLER ELECTRIC Mfg. Co.
and the power source manual used with this unit, with special emphasis on A Miller Group Ltd.. Compeny
the safety material throughout both manuals, before Installing, operating, or P.O. Box 1079
maintaining this equipment. This unit and these instructions are for use only Appleton, WI 54912 USA
by persons trained and experienced in the safe operation of welding equip Tel. 414-734-9821
ment. Do not allow untrained persons to install, operate, or maintain this unit.
Contact your distributor if you do not fully understand these instructions.
PflINTED IN U.S.A
K!>
:1~.
MILLERS TRUE BLUETM LIMITED WARRANTY
Effective January 1, 1992
(Equipment with a serial number preface of KC or newer)
This limited warranty supersedes atl previous MILLER warranties and is eeclusive with no other guarantees or warranties eepressed or implied.
*
LIMITED WARRANTY Subject to the terms and conditions below. MILLER Electric Accessory Kits
Mfg. Co-. Appleton, Wisconsin, warrants to its original retail purchaser that new *
Replacement Parts
MILLER equipment sold aher the effective dale of this limited warranty is free of de
fects in material and workmanship at the time it is shipped by MILLER. THIS WAR
MILLERS True BIuerM Limited Warranty shall not apply to:
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
NESS. Items furnished by MILLER, but manufactured by others, such as engines or
any.
Within the warranty periods listed below, MILLER will repair or replace any war
ranted parts or components that fail duets such defects in material or workmanship.
MILLER must be notilied in writing within thirty (30) days of such defect or failure, at 2. Consumable components: such as contact tips, cutting nozzles, csnt actors
which time MILLER will provide instructions on the warranty claim procedures to be and relays.
tollowed.
3 Equipment that has been modified by any party other than MILLER, or equip
MILLER shall honor warranty claims on warranted equipment listed below in the ment that has been improperly installed, improperly operated or misused
event of sucha failure within the warranty time periods. All warranty time periods
based upon industry standards, or equipment which has not had reasonable
start on the date that the w55 delivered to the original retail purchaser. and necessary maintenance, or equipment which has been used for operation
equipment
and are as follows: outside of the specifications for the equipment.
t. 5 Years Parts 3 Years Labor MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
*
Original main power rectifiers THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
(NOTE: Field options are covered under True Blue~M for the remaining
installed in, tsr minimum of Some states in the U.S.A. do not allow limitations of how long an implied warranty
warranty period of the product they are or a
lasts. or the soctusion of incidental, indirect, special or consequential damages, so
one year whichever is greater)
the above limitation or eeclusion may not apply to you. This warranty provides spe
5. 6 Months Batteries cific legal rights, and ofher rights may be available, but may vary from state fo stale.
< I
RECEIVING-HANDLING
Before unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for loss or damage
with the delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
When requesting information about this equipment, always provide Model Designation and Serial or Style Number,
Use the following spaces to record Model Designation and Serial or Style Number of your unit. The information is located on the rating label
or nameplate.
Model _________
Date of Purchase
miller 5/92
ERRATA SHEET
Amend Section 3-4B. ROBOT INTERFACE WELDING POWER SOURCE CONNECTIONS: Output Control Con
nections To PULSTAR
CAUTION; WELDING POWER SOURCE will not respond with output corresponding to set value.
a Be sure welding power source main control board is modified to use a 0 to + 10 volt command.
Amend Figure 3-9. Voltage Control Board DIP Switch Setting Label
1 2 1 2 3 4 5
DELTAWELD 300 ON ON ON
DELTAWELD 451 0 ON ON
DELTAWELD 651 0 ON ON
MAXTRON 450 ON ON ON
XMT 200/300 ON ON ON
ARC PAK35O ON ON ON
SHOPMASTER 300 ON ON ON
DIMENSION 400 ON L\ t~ ON
PULSTAR 450 ON
Amend Diagram 7-1. Circuit Diagram For Robot Interface (See Page 2 on this Errata Sheet)
242-B
SC-15
1
Interfac
.1
IC
Rob t
For
U 0 /07
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CD L
K
0
0
52
69
2
WITH Circuit
J ~p
POSITU liVE
H
C
Q~J~JT 70
7/
IN
FTP?
I
30 .
7-1.
F
D
0
0
Ca4~TE0 PCLSTAP. POSIT1~ MAXTPA
ro
A
0
0
~ USE
AiPE FcAC I-CVE F~LTAWED.
21
U 0
6/271J8450
L
K 0
J 0
CI 0
C 0
E
0
Z
0 0
C0
V
C 0
PS .~ B 0 4
A 0 /
IT
C P 0 H F S C
AMENDMENT TO SECTION 8 PARTS LIST
OM-884B Page 3
OM.8849 -
4 92
TABLE OF CONTENTS
SECTION 2 SPECIFICATIONS
2-1. Description 1
SECTION 3 INSTALLATION
1-1. GENERAL INFORMATION AND SAFETY 1-2. SAFETY ALERT SYMBOL AND SIGNAL
WORDS
A. General
The following safety alert symbol and signal words are
Information presented in this manual and on various Ia- used throughout this manual to call attention to and den
bels, tags, and plates on the unit pertains to equipment tify different levels of hazard and special instructions.
design, installation, operation, maintenance, and /%~ This safety alert symbol is used with the signal
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equipment.
4~ words WARNING and CAUTION to call atten
tion to the safety statements.
B. Safety
WARNING statements identify procedures or
The installation, operation, maintenance, and trouble- practices which must be followed to avoid seri
ous personal injury or loss of life.
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in- CAUTION statements identify procedures or
stalled, operated, and maintained only by qualified per- practices which must be followed to avoid minor
sons in accordance with this manual and all applicable personal injury or damage to this equipment.
codes such as, but not limited to, those listed at the end
of Section 1 Safety Rules For Operation Of Arc Weld- IMPORTANT statements identify special instructions
ing Power Source in the welding power source Owners necessary for the most efficient operation of this equip
Manual. ment.
SECTION 2 SPECIFICATIONS
Dimensions Weight
Component Height Width Depth Net Ship
22-1/2in. 16-1/2in. 6~l/4in.* 38lbs.
Robot Interface
(572 mm) (419 mm) (159 mm) (17 kg)
Gas/Current 4-1/2 in. 5-1/2 in. 10-1/2 in. 5 lbs. Total 61 lbs.
Sensing Control (108 mm) (140 mm) (267 mm) (2.3 kg) (27.7 kg)
SpoolSupport 13-3/4in. 8-3/4in. 8-1/2in. 6Ibs.
Assembly+ (349 mm) (222 mm) (216 mm) (2.7 kg)
Add 2-1/4 in. (57 mm) for brake resistor. +Spool Support without optional wire reel.
OM-884 Page 1
5-1/2 in.
(140 mm)
7-3/4 in.
(197 mm)
in.
(89 mm)
19-1/8 in.
(486 mm)
K 16-1/2 in.
(419 mm)
4-1/2 in.
(108 mm)
II
Side View
9-7/8 in.
(251 mm)
~~.2Hol~s
10-1/2 in.
(267 mm)
Inches Millimeters
A 21-7/8 556
B 13-3/4 349
C 3 76
D 2-1/2 63.5
E 3-1/2 88.9
F 4-1/2 114
G 10-11/16 275
ST-080 486-C
OM-884 Page 2
SECTION 3 INSTALLATION
3-1. SITE SELECTION (Figure 2-1) 3. The interconnecting cords must be routed so that
they are not caught, pinched, or strained during
Select an installation site which provides the following: welding operations.
1. Correct input power supply (see unit nameplate) 4. One weld output cable must be routed to the Gas/
CurrentSensing control.
2. Shielding gas supply (if applicable)
5. Welding wire must be routed so that it does not
3. Water supply (if applicable)
contact the weld control or any other grounded
4. Adequate ventilation and fresh air supply equipment.
5. No flammables C. Equipment Installation
6. A clean and dry area Obtain appropriate mounting brackets or adapter plates
as necessary and mounting hardware. Prepare struc
7. Proper temperature that avoids extremes of heat ture for equipment installation. Secure weld control,
or cold Gas/Current Sensing control, and all other equipment
onto structures in the welding area.
8. Proper airflow around unit
D. Hub Installation (Figure 3-1)
9. Adequate space to open and remove cover and
wrapper for installation, maintenance, and repair The hub assembly is supplied with the robot interface.
functions. Remove the hub assembly from the shipping carton, and
install it as follows:
Mounting holes provide the capability to install and se
cure the system components in a permanent location. 1. Remove hex nut from end ofhub support shaft.
Figure 2-1 gives overall dimensions and mounting hole
2. Align keyway and insert hub support shaft
layout.
through selected hole in hub support. Hole selec
tion in hub support depends on wire spool size. Be
3-2. EQUIPMENT INSTALLATION
sure the brake washers are properly seated in the
A.
hub.
Supplied Equipment
3. Reinstall hex nut onto support shaft. Tighten hex
The following equipment is supplied as standard and re
nut until a slight drag is felt while turning hub.
quires installation or assembly:
4. Install welding wire according to Section 3-7.
1. Weld Control with Gas/Current Sensing Control
Cord, Motor Cord, and Voltage Sensing Cord
2. Gas/Current Sensing Control
B. Equipment Location
Hub Assembly
When deciding on equipment location, consider the fol Hex Nut
lowing:
1. The equipment must be mounted to a structure
capable of supporting the weight of the equip
ment.
Hub Support
2. The lead lengths of the cords supplied with the
equipment will limit the area in which the equip
ment can be located. Some cords can be ex ST.126 870
OM-884 Page 3
3-3. GAS/CURRENT SENSING CONTROL INTER 2. Align keyways, insert 16-pin Amp plug into
CONNECTIONS (Figures 3-2, 3-3 And 3-4) matching receptacle RC16 on gas/current sens
ing control, and rotate threaded collar fully clock
A WARNING: ELECTRIC SHOCK can kill. wise.
______
Do not touch live electrical parts.
B. Gas/Current Sensing Control Motor Connec
Shut down unit, welding power source, and tions
robot, and disconnect input power employing
lockout/tagging procedures before making in Align keyways, insert 14-pin plug from motor cord into
terconnections.
matching receptacle RC7 on gas/current sensing con
Lockout/tagging procedures consist of padlock trol, and rotate threaded collar fully clockwise.
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and C. Weld Cable Connections
red-tagging circuit breaker or other disconnect
ing device. For Electrode Positive/Reverse Polarity, route cable
from welding power source POSITIVE weld output ter
There are several cords supplied for gas/current sens
minal, through the gas/current sensing control, to the
wire drive assembly, and connect cable to weld cable
ing control interconnections. Examine and select the
terminal (see Motor/Drive Assembly Owners Manual for
proper cord for the following connections.
location).
D. Gas Connections
0 0~0 0
0 ~ 0 SOURCE CONNECTIONS (Figures 3-3, 3-4,
Gas/Current Sensing
00000
Control Receptacle RC9. And 3-5)
A. Robot Interface Gas/Current Sensing Control 2. Connect lead with ring terminal to welding power
Connections source POSITIVE weld output terminal as shown
on Figure 3-4.
1. Align keyways, insert 14-pin Amp plug into
matching receptacle RC9 on robot interface, and 3. Connect lead with clamp to welding power source
rotate threaded collar fully clockwise. NEGATIVE weld Output terminal.
OM-884 Page 4
Weld Cables
Wire Drive
Assembly S 0290
3-4. Arc Lead And Weld Cable 35. ROBOT INTERFACE ROBOT CONTROL
Figure Sensing
Locations UNIT CONNECTIONS (Figures 3-2, 3-3, And
3-4)
WARNING: ELECTRIC SHOCK kill.
B. Output Control Connections To PULSTAR
Weld cables
Shielding Gas
Supply
Wire Drive
Assembly Ref. S-0290
1. Obtain a proper Cord and 24-socket Amphenol Socket G: Gas Control; +24 volts dc input from robot
plug (not supplied). control unit with respect to Socket J (Circuit
Common).
2. Connect conductors at one end of cord to appro
Socket H: Wire Stick Check; +24 volts dc input from
priate sockets in plug.
robot control unit with respect to Socket J
3. Align keyway, insert 24-socket plug into matching (Circuit Common).
receptacle on robot interface, and rotate threaded Socket J: Circuit Common for Sockets E, F, G, and H;
collar fully clockwise. all circuit voltages referenced to this point.
4. Route and connect conductors at remaining end Socket K: Jog Forward; momentary contact output to
of cord to the robot control unit. robot control unit with respect to Socket 0
(Digital Common).
The input and output signals at the sockets of receptacle
Socket L: Set-Up and Weave Set-Up output to robot
AC 17 by means of the robot interface control circuitry
control unit with respect to Socket 0 (Digital
are as follows:
Common).
Socket A: Provides connection to 2TA; for customer Socket M: Weave Set-Up output to robot control unit
use.
with respect to Socket Q (Digital Common).
Socket B: Current Detect output to robot control unit Socket N: Wire Stick Signal output to robot control unit
withrespect to~Socket D; isolated CR1 con with respect to Socket Q (Digital Common);
tacts rated 1A at 120 VAC. indicates wire is stuck to work; isolated CR2
contacts rated 1A at 120 VAC.
Socket D: Current Detect output to robot control unit
with respect to Socket B; isolated CR1 con Socket P: Weld Standby output to robot control unit
with respect to Socket 0 (Digital Common);
tacts rated at 1A at 120 VAC.
indicates robot interface is in standby; iso
Socket E: Contactor Control; +24 volts dc input from lated CR5 contacts rated 3A at 120 VAC.
robot control unit with respect to Socket J Socket 0: Digital Common for Sockets K, L, M, N, and
(Circuit Common). P.
Socket F: Jog Forward; +24 volts dc input from robot Socket R: + Peak Amps; 0-10 volts dc input from robot
control unit with respect to Socket J (Circuit control unit with respect to Socket S (analog
Common). common) equals 0-500 amperes dc output.
OM-884 Page 6
Socket S: Peak Amps; analog common for Socket A If operation with a DELTAWELD welding power source is
(+ Peak Amps). desired, reconnect jumper link between 2TG and 2TH
on terminal strip 2T.
Socket W: Wire Feed Speed; analog common for
Socket X (+ Wire Feed Speed). B. Arc Failure Light Connections (Figure 3-7)
Socket X: Wire Feed Speed; 0-10 volts dc input from WARNING: Read and follow safety informa
+
robot control unit with respect to Socket W a tion at beginning of Section 3-6 before pro
ceeding.
(analog common) equals 0-1 000 1PM.
Socket Y: Arc Volts; analog common for Socket Z (+ The ARC FAILURE light on the robot interface front pan
Arc Volts). el is turned on and off by a signal from the robot control
unit. Obtain proper length of 18 gauge/2-conductor cord
Socket Z: + Arc Volts; 0-10 volts dc input from robot for this connection, and proceed as follows:
control unit with respect to Socket Y (analog
common) equals 0-50 volts dc output. 1. For robot control units when 24 vdc is used (Fig
ure3-7):
IMPORTANT: The remaining sockets in the receptacle
are not used. a. Route cord through strain relief on right side
panel of robot interface, and make proper con
nections to 1TL and 1TM.
with a PULSTAR 450 welding power source. Figure 3-7. Arc Failure Light Connections
OM-884 Page 7
2. For robot control units when 115 or 24 vac, or 24
vdc is used (Figure 3-7):
3. Rotate spool until hole in spool aligns with pin in DIP switch Si and S2 on voltage control board PCi al
hub. Slide spool onto hub until it seats against low setting the proper command signal voltage level for
back flange of the hub. controlling voltage output at a welding power source. To
4. Reinstall
change factory set position of DIP switches from a Delta-
retaining ring onto hub.
weldfi 451 to another welding power source, proceed as
B. Installation Of Optional Wire Reel And Reel- follows:
Type Wire (Figure 3-8) WARNING: ELECTRIC SHOCK kill.
1. Remove retaining ring and, if applicable, wire reel a Do not touch live electrical parts.
can
S2 Si
1 2 1 2 3 4 5
DELTAWELD 300 ON ON ON
DELTAWELD 451 0 ON ON
DELTAWELD 651 0 ON ON
MAXTRON 450 ON ON ON
XMT 200/300 ON ON ON
SHOPMASTER 300 ON ON ON
DIMENSION 400 ON A A ON
3. Set position of DIP switches Si and S2 according 1. Loosen screw securing front access door on weld
to label inside unit and Figure 3-9 for appropriate control, and open door.
welding power source.
2. Locate voltage control board PCi in left portion of
4. Close and secure front access door.
component mounting panel inside weld control.
3-9. VOLTAGE CONTROL BOARD MODIFICA 3. Mark and disconnect leads from voltage control
TION FOR EARLY MODEL WELDING POWER board PCi.
SOURCES (Figure 3-10)
4. Mark and disconnect plugs from PCi.
If the weld control unit is to be used with
early model
an
Deltaweld 450 or 650 welding power source prior to seri 5. Note position of circuit board and remove from
al number JJ400026, proceed as follows: unit.
7.
so
Locate
that component side is
jumpers Ji thru J8
facing up.
on surface of board
Shut down unit, welding power source, and
(see Figure 3-10).
wire feeder; and disconnect input power em
ploying lockout/tagging procedures before 8. Use a sharp tool to remove sealant coating from
making circuit board modifications. all
jumper locations, and remove foil jumper be
Lockout/tagging procedures Consist of pad tween pads at J2, J4, J6, and J8.
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off 9. Apply a small amount of solder to bridge the foil
and red-tagging circuit breaker or other discon
pads at jumper Ji, J3, J5, and J7.
necting device.
ELECTROSTATIC DISCHARGE (ESD) can
10. Apply a sealant coating over all jumper locations.
damage circuit boards.
ii. Reinstall circuit board into unit in its original posi
Put on properly grounded wrist strap BE
tion.
FORE handling circuit boards.
Transport circuit boards in proper static- 12. Reconnect marked leads and plugs to appropri
shieldingcarriers or packages. ate locations.
OM-884 Page9
Jumper Jumper Jumper
J2 JI 13
4-1. POWER SWITCH (Figure 4-1) purges the shielding gas line of the gun. The PURGE
POWER switch in the ON push button allows the flow meter to be adjusted without
Placing the position energizes
the robot interface. The interface must be on for the ro
energizing the welding circuit.
bot to weld. Placing the POWER switch in the OFF posi
tion shuts down the interface. 4-5. VOLTMETER (Figure 4-1)
OM-884 Page 10
Fuse (See Section 6-2)
Gas Indicator
Light
Contactor Indicator
Light
4-8. INDICATOR LIGHTS (Figure 4-1) burn back to a point where it neither sticks to the work-
piece or the contact tube. To adjust burnback time pro
There are five indicator lights on the interface. These are
ceed as follows:
visual indications of various process functions.
WARNING: ELECTRIC SHOCK kill.
The GAS
to
light turns on when the gas
indicate shielding gas flow.
valve is energized a Do not touch live electrical parts.
can
Burnback is provided by potentiometer R32 on Interface 1. Open front access door on weld control and lo
Circuit Board PC3 inside the unit. cate PC3.
The burnback circuitry in this unit keeps the welding wire 2. Locate potentiometer R32 in upper left corner of
from sticking to the workpiece after the arc is extin PC3.
guished. This circuitry keeps weld output on the welding
3. Rotate R32 clockwise to increase burnback time.
wire from 0 to 0.25 seconds after the wire has stopped
feeding. This delay action permits the welding wire to 4. Close and secure front access door.
5-1. INPUT SIGNALS FROM ROBOT CONTROL to initiate a check to see if the wire is stuck to the work-
UNIT (Figure 5-1) piece at the end of the weld.
Jog Fwd.
~o~
Computer
Interface ] Power On, Standby
To Robot
Current Detect
Control Unit
~Wire Stuck
Output Voltage
Shielding Gas
Wire Feed
Normal
Abnormal ST-094 382-e
6-1. ROUTINE MAINTENANCE 1. Repair or replace, as required, all hose and cable;
give particular attention to frayed and cracked insu
IMPORTANT: Every six months inspect the labels on lation and areas where it enters equipment.
legibility. All precautionary labels must be
this unit for
maintained in a clearly readable state and replaced 2. Remove grease and grime from components; mois
when necessary. See Parts List for part number of ture from electrical parts and cable.
precautionary labels.
6-2. OVERLOAD PROTECTION
WARNING: ELECTRIC SHOCK kill.
Usage shop conditions determine the frequency
and
and type of maintenance. At minimum, inspect equip
a Do not touch live electrical parts.
can
ment every three months as follows: Shut down unit, welding power source, and
robot, and disconnect input power employing
WARNING: ELECTRIC SHOCK kill. lockout/tagging procedures before inspect
a Do not touch live electrical parts.
can
OM-884 Page 12
Should a motor overload occur and CB1 open, proceed 4. Install fuse with fuse holder cover back into unit.
as follows:
5. Depress and rotate fuse holder cover clockwise
1. Check for jammed wire or clogged gun liner, and until cover is secure.
d.
Fiber Washer
Brake Washer
1. Depress and rotate fuse holder cover counter- 3. Align keyway, and insert hub support shaft
clockwise, through selected hole in hub support.
2. Pull out fuse with cover when fuse holder cover is 4. Install hex nut onto hub support shaft. Tighten hex
free. nut until a slight drag is felt while turning hub.
3. Insert new fuse into fuse holder cover. 5. Install welding wire according to Section 3-7.
Spanner Nut*
Spring
Keyed Washer
Brake Washer
Hub Support
Shaft
Fiber Washer
/
Hub
~ Fiber Washer
Hex Nut
Brake Washer
Hub Support
*Optlonal
ST.127 328
OM-884 Page 13
Input Command For In put Command For
Wire Speed 1PM Meter Volts Meter 0.5V 50V
=
6-4. DISPLAY BOARD PC4 METER CHECK (Fig Transport all static-sensitive components in
ure 6-2) proper static-shielding carriers and pack
Check pointsare provided on the display board PC4 for ages.
checking power supply and input command for the me Perform work only at a static-safe work area.
ters.
_____ Do not touch live electrical parts. 2. Locate display board PC4.
Be sure that personnel performing testing
procedures are familiar with and follow stan 3. Check voltage according to Figure 6-2.
dard safety practices.
4. If a meter power supply and command voltage is
Shut down unit before making or changing
correct and the meter is not working, replace the
meter or test equipment lead connections.
meter (see Section 6-5).
ELECTROSTATIC DISCHARGE (ESD) can
damage electronic components. 5. If the power supply or command voltage is incor
Put properly grounded wrist strap
on a BE rect, replace display board PC4 (see Section
FORE handling circuit boards. 6-5).
Board PC4
Receptacle
Ref. ST-119647C
RC28
Receptacle RC29
Voltage Board PCi
(DELTAWELD) Receptacle RC3O ST-119 648.C
OM-884 Page 15
It is assumed that the unit was properly installed accord- this robot interface. Use this table in
conjunction with the
ing to Section 3 of this manual, the operator is familiar circuit diagram while
performing troubleshooting proce
with the function of controls, the robot interface was dures. If the trouble is not remedied after performing
working properly, and that the trouble is not related to the these procedures, contact the nearest Factory Author-
welding process. ized Service Station. In all cases of equipment malfunc
The following table is designed to diagnose and provide tion, strictly follow the manufacturers procedures and
remedies for some of the troubles that may develop in instructions.
No arc voltage control. Output control connections. Check and secure connections (see Section
3-4).
Arc sensing connections. Check and secure connections (see Section
3-4).
Voltage Board PCi not working if Replace PCi (see Section 6-5).
using Deltaweld power source.
Voltage Board PC8 not working if Replace PC8 (see Section 6-5).
using Puistar power source.
Incorrect robot command voltage. Check robot command voltage at Isolation Board
PC5. Command voltage should be 0-10 vdc be
tween sockets Y (common) and Z at RC17.
Incorrect robot peak command cur- Check robot peak command current at Isolation
rent. Board PC5. Peak command current should be
0-10 vdc between sockets R and S (Common) at
RC17.
Robotmoveswhenwelding Wire stick connection. Be sure that leads from robot are connected to
wire is stuck. sockets H and N at RC17.
Wire speed (1PM) meter Incorrect robot command voltage. Check robot command voltage at Motor Board
goes to zero. PC2. Signal should be 0-10 vdc between pins K
~
and B (common) at RC5.
Motor Board PC2 not working. Replace PC2 (see Section 6-5).
Unit does not operate. Fuse Fl Open. Check Fl, and replace if necessary (see Section
6-2). Correct overload problem before continu
ing operation.
Circuit breaker CB1 tripped. Check Fl, and replace if necessary (see Section
6-2). Correct overload problem before continu
ing operation.
No meter display. Meter not working. Use check points on Display Board PC4 to deter
mine if power is available to meter (see Section
6-4). If check points are okay, replace meter (see
Section 6-5).
Display Board PC4 not working. Use check points to determine if power is avail
able (see Section 6-4). If check points do not test
okay, replace PC4 (see Section 6-5).
No wire feed. Robot signal. Check input signal from robot to Motor Board
PC2. Signal should be 0-10 vdc between pins K
and B (common) on RC5.
OM-884 Page 16
6-7. USE OF INDICATOR LIGHTS FOR TROUBLESHOOTING
On -
Gas Indicator Light Off
1~
Gas flows: Gas does not flow: Gas flows: Gas does not flow:
System normal (on.) Check gas valve operation. Check gas valve operation System normal (off).
and gas line for leaks.
Check interface board PC3.
On ~
Contactor Indicator Light ~
Off
I!
Contactor closed: Contactor open: Contactor closed: Contactor open:
System normal (on). Check interconnecting cords. Check display board PC4. System normal (off).
Check interface board PC3.
Wire feeds: Wire does not feed: Wire feeds: Wire does not feed:
System normal (on). Check circuit breaker CB1. Check input signal from System normal (off).
robot to motor board PC2.
Check relay CR1.
Signal should be 0-10 vdc
Check interface board P03. betwe~n pins K and B
(common) at RC5.
Check motor board P02.
System normal (on). Replace reed relay. Replace reed relay. System normal (off).
~
On Arc Failure Indicator Light ~
Off
1~
No arc: Arc started: No arc: Arc started:
Check weld Check signal from robot. Normal during idling. Normal while welding.
parameters. Signal should be 24 vdc
between terminals 1 TL
and 1 TM.
Check display board P04.
OM-884 Page 17
NOTES
OM-884 Page 18
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P
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H ~~P SC-i
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0
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OM-884 Page 21
SECTION 8 PARTS LIST
6
1
7,
17
35
29
28
27
tiA. I 21
34
26
33
32
31
25
30
SC.119 047.A
1 ..
PLG24... 084 198 HOUSING, term header 6 pin 1
081 378 TERMINAL, female lskt 22-18 wire 6
2.. PLG2O... 081 379 HOUSING, term header 12 pin
081 378 TERMINAL, female lskt 22-18 wire 12
..3...PC4.... 149 339 CIRCUIT CARD, meter (consisting of)
073 756 STAND-OFF, No. 6-32 x .625 Ig 7
5 ... PB1,2 021 105 SWITCH, PB 2
..6...CB1.... 011 991 CIRCUIT BREAKER, man reset 1 P 1 .5A 250V
011 609 SWITCH, tgl SPDT 15A 125V
086 895 SWITCH, rotary
073 487 NUT, speed No. 2 2
10 132 481 CABINET, control 1
11 057 084 BUSHING, snap-in .250 ID x .375mtg hole 1
12 079 683 HEAT SINK, resistor 1
13 030 949 HEAT SINK 1
030941 RESISTOR, WW fxd 100W 5 ohm 1
15 056 170 SHIELD, resistor 1
16 010 193 TUBING, .375 00 x l8ga wall x .250 4
17 010 199 TUBING, .275 IDx.O48walIxl 2
OM-884 Page 22
Item Dia. Part
No. Mkgs. No. Description Quantity
OM-884 Page 23
2
~
12
14 13 SD-119 648-C
OM-884 Page 24
Item Dia. Part
No. Mkgs. No. Description Quantity
..
1 . ..
PC2 . . . .
071 642 ..
CIRCUIT CARD, motor speed dig 1
.
2 . . .
RC5 . . . .
073 730 . .
TERMINAL, header 22 pin 1
..
3 009 335 ..
STAND-OFF, No. 4-40 x 5/8 2
..
4 112 473 ..
PANEL, mtg components 1
.
5 605 741 . .
CLIP, mtg resistor 5/16 ID 4
..
6 . ...
R3 .. . .
079 497 ..
RESISTOR, WW fxd 25W 2K ohm 1
.
7 . ...
Ri ... .
030 651 .. RESISTOR, WW fxd 25W 10 ohm
.
8 . ...
T2 . . .
116 847 ..
TRANSFORMER, control 1
..
9 ..
CR1 ... .
109 006 ..
RELAY~ end 24VAC DPDT 1
..
10 . ...
Ti .. . .
116 848 ..
TRANSFORMER, control 1
ii . .
1T,2T . .
038 783 . .
BLOCK, term 20A 12P 2
601 219 . .
LINK, jumper 2
.
12 110391 . .
GUIDE, mtg circuit card 3
..
13. ..
PC5 .. .
118550 .
CIRCUIT CARD, isolation/amp
PLG28-30 .
135 787 .
HOUSING PLUG & SOCKETS, (consisting of) 1
081 378 . . . .
TERMINAL, female iskt 22-18 wire 7
.
14 110 375 ..
STAND-OFF SUPPORT, PC card No. 6 screw 8
.
15 048 029 . .
CLIP, retaining socket relay
..
16 049 970 .
BRACKET, mtg relay I
..
17 027 811 ..
SOCKE1~ relay 14 pin 1
.
18 . ..
CR2 . . . .
095 521 ..
RELAY, end 24VDC 4PDT 1
..
19 079 844 ..
SPRING, holddown relay
..
20. ..
PC8 . . . .
116528 ..
CIRCUIT CARD, voltage 1
PLG21 . . .
081 380 . . TERMINAL, header 14 pin 1
081 378 . .
TERMINAL, female iskt 22-18 wire 14
PLG22 . . .
090 469 . .
TERMINAL, header 10 pin 1
081 378 . .
TERMINAL, female iskt22-18 wire 10
PLG23 . . .
135 557 . .
HOUSING PLUG & SOCKETS, (consisting of) 1
079 747 . . . .
TERMINAL, contact header 24-18 wire 2
..
21 . ..
PCi . . . .
148 320 .
CIRCUIT CARD, voltage control 1
PLG14 . . .
079 748 . .
HOUSING, term header 18 pin
079 747 . . TERMINAL, contact header 24-18 wire 18
PLG25 . . .
131 054 ..
HOUSING RECEPTACLE & SOCKETS, (consisting of)
113 746 . . . . TERMINAL, female lskt 2
..
22 . ..
PC3 ..
+141 308 ..
CIRCUIT CARD, interlace 1
PLG18 . . .
135 559 ..
HOUSING PLUG & SOCKETS, (consisting of) 1
079 747 . . . .
TERMINAL, contact header 24-18 wire 12
PLG19 . . .
079 748 . . HOUSING, term header 18 pin 1
079 747 .
TERMINAL, contact header 24-18 wire 18
..
23 . ...
Cl .. . .
031 692 ..
CAPACITOR, elctlt 750uf 200VDC 1
..
24 006 426 ..
CLAMP, capacitor 2 in dia 1
..
25 . ...
T3 .. . .
116 849 .. TRANSFORMER, control 1
042 452 . .
CLIP, component .687dia mtg adh back 2
..
26 . ..
SRi . . .
035 704 ..
RECTIFIER, integ 30A 600V 1
..
27 083 147 .. GROMMET, scr 8-10 push in 2
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-884 Page 25
Item Part
No. No. Description Quantity
072 094 ..
HUB & SPINDLE, (consisting of) 1
2... 058428 .... HUB, spool 1
.3... 058 628 . . . .
WASHER, steel brake 2
.4... 010 191 .. ..
WASHER, fiber .656 ID x 1.500 OD x .l25thk 2
.5... 135 205 . . . .
NUT, sti slflkg hex reg .625-11 1
.6... 057 971 . . . .
WASHER, flat sti keyed 1 .500dia x .l25thk 1
.7... 010 233 ....
SPRING, compression 1
.8... 072 292 ....
SHAFT, spool support 1
058 427 ....
RING, retaining spool 1
10... 092 989 ..
SUPPORT, spindle (consisting of) 1
121 316 .... LABEL, warning general precautionary 1
10
8
6
4
3
ST.070 884.A
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-884 Page 26
Item Dia. Part
No. Mkgs. No. Description Quantity
7~
14
11
ST109 680.A
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM.884 Page 27