Miller
January
1993
FORM:
OM-138
992C
Eftective
With
Serial
No.
KD345231
MODEL:
RCSP-XL
Synergic
Pulse
Robot
Control
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
both
this
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equip
ment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if-you
do
not
fully
understand
these
Instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
Miller
Group
Ltd
P.O.
Box
1079
Appleton,
WI
54912
uSA
Tel.
414.734-9821
SC-139
U4
0O~,TEO
IN
USA
I
MILLERS
TRUE
BLUEIM
LIMITED
WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial
number
preface
of
KC
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied
LIMITED
WARRANTY
-
Sublect
to
the
terms
and
conditions
below.
MILLER
Electric
Mtg
Co
.
Aopleton
Wisconsin.
warrants
to
its
original
retail
purchaser
that
new
MILLER
eQuipment
sold
aher
the
effective
date
of
this
limited
warranty
is
tree
of
de
tects
in
material
and
workmanship
at
tne
time
it
is
shioped
by
MILLER
THIS
WAR.
RANN
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES.
EXPRESS
OR
IMPLIED.
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
warranty
periods
listed
below.
MILLER
will
repair
or
replace
any
war
ranted
pans
or
components
that
tail
due
to
such
detects
in
material
or
wprkmansnip
MILLER
must
be
notitied
in
writing
within
thirty
130)
days
Pt
such
detector
failure,
at
which
time
MILLER
will
provide
instrrjctiona
on
the
warranty
claim
prpceoures
to
pa
followed
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
pt
sucn
a
failure
within
the
warranty
time
periods
All
warranty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purcnas.r.
and
are
as
Isllpws
5
Years
Pans
3
Years
Labor
Original
main
power
rectifiers
Accessory
Kits
Replacement
Parts
MILLERS
True
Btuer_
Limited
Warranty
shall
not
apply
to
Items
furnished
by
MILLER.
but
manufactured
by
pttrers.
sucrr
as
engines
or
trade
accessories
These
items
are
covered
by
the
manulacturer
s
warranty
any
2
Consumable
components,
such
as
contact
tips.
cuning
n002ies.
contactors
and
relays
3
Equipment
th5t
has
been
modified
by
any
party
other
trran
MILLER.
or
equip
ment
that
has
been
improperly
installed,
iworoperiy
operated
pr
misused
based
upon
industry
standards,
or
equipment
whicn
trap
not
had
reasonable
and
necessary
maintenance.
Or
equipment
which
has
been
used
for
operetlon
outside
of
the
specifications
for
the
equipment.
MILLER
PRODUCTS
ARE
tNTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
CIALINDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
2 3
Years
Pans
and
Labor
TranstormerlRectifier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
Semi.Automatic
and
Automatic
Wire
Feeders
Robots
3
2
Years
Parts
and
Labor
Engine
Driven
Welding
Generators
(NOTE
Engines
are
warranted
separately
by
the
engine
manufacturer
I
4
t
Year
Parts
and
Labor
Motor
Driven
Guns
Process
Controllers
Water
Coolant
Syatema
HF
Units
Grids
Spot
Welders
Load
Banks
SDX
Transtornrers
Running
Oear,1railers
Field
Options
(NOTE
Field
options
are
covered
under
True
Btuen_
tot
the
remaining
warranty
period
p1
the
product
they
are
installed
in.
or
ton
a
minimum
of
one
year
whichever
is
greater.)
5.
e
Months
Baneries
5.
90
Days
Pans
end
Labor
MIG
GunsITIG
Torches
Ptasma
Cutting
Torches
Remote
Controls
In
the
event
Pt
a
warranty
claim
covered
by
this
warranty.
thff
esciusive
remedies
shall
be.
at
MILLERS
option
(t)
repair,
or
(21
replacement,
Or,
wnere
suthorioed
,n
writing
by
MILLER
in
appropnate
cases,
(3)
the
reasonable
cost
of
repair
or
replace
ment
at
an
authorized
MILLER
service
station,
or
)4)
payment
of
or
credit
to.
the
our
cnase
once
(less
reasonable
depreciation
based
upon
actual
usel
upon
return
of
the
qooos
at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
will
be
F
0
B
.Factory
at
Appleton.
Wisconsin,
or
F
0
B
at
a
MILLER
suttionzed
ser
vice
facility
as
determined
by
MILLER
Therefore
no
compensation
or
reimburse
ment
br
transportation
costs
of
any
kind
will
be
allowed
TO
THE
EXTENT
PERMITTED
BY
LAW.
THE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MtLLER
BE
LIABLE
FOR
DIRECt
tNDIRECt
SPECtAL.
INCIDENTAL
OR
CONSEOUENTIAI.
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CON
TRACT,
TORT
OR
ANY
OTHER
LEGAL
THEORY
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR.
RANTY,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE.
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH.
BUT
FOR
THIS
PROVISION.
MIGHT
ARISE
BY
IMPLICATtON
OPERATION
OF
LAW.
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE.
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER
Some
states
in
the
U.S.A.
do
not
allow
Imitations
Pt
how
long
an
implied
warranty
lasts,
or
the
esclusion
of
incidental,
indirect,
special
or
consequential
damages.
50
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
we
citic
legal
rights,
and
other
nghts
may
be
available,
but
may
vary
1rpm
state
to
state
In
Canada.
legislation
in
some
provinces
provides
tor
certain
additional
warranties
or
remedies
other
than
as
stated
herein,
and
to
the
estent
that
prey
may
not
be
waived,
the
limitations
and
esciusions
set
out
above
may
not
apply
This
Limited
Warranty
provides
specifIc
legal
nghts.
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
ii
U
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
clatms
may
be
obtained
from
distributor
and/or
equipment
manufacturer
s
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
me
rattng
label
or
nameplate.
Model
_______
Serial
or
Style
No.
Date
of
Purchase
w4W
5
92
TABLE
OF
CONTENTS
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
General
Information
And
Safety
1
1-2.
Safety
Alert
Symbol
And
Signal
Words
1
SECTION
2-
INTRODUCTION
2-1.
DESCRIPTION
1
SECTION
3-INSTALLATION
3-1.
Synergic
Pulse
Panel
Welding
Power
Source
Connections
I
3-2.
Synergic
Pulse
Panel
Computer
Interface
Connections
2
3-3.
Connection
For
Nonpulse
Welding
2
3-4.
Connections
For
Remote
Pulse/Nonpulse
Control
3
3-5.
Field
installation
Instructions
For
Synergic
Pulse
Panel
RCSP-XL
Onto
Computer
Interface
3
SECTION
4-
ROBOT
PROGRAM
MODIFICATIONS
4-1.
Amendment
To
Robot
Owners
Manual
Section
4
System
Set
Up
4
4-2.
Amendment
To
Robot
Owners
Manual
Section
5
Teaching
4
SECTION
5-OPERATOR
CONTROLS
5-1.
Wire
Size
Select
Switch
And
Standard
Mode
Indicator
Light
6
5-2.
Wire
Size
Indicator
Lights
6
5-3.
Wire
Type
Select
Switch
6
5-4.
Recommended
Shielding
Gas
Indicator
Lights
7
5-5.
No
Program
Indicator
Light
7
SECTION
6-
SEQUENCE
OF
OPERATION
6-1.
Gas
Metal
Arc
Welding
(GMAW)
9
6-2.
Shutting
Down
g
SECTION
7-
MAINTENANCE
&
TROUBLESHOOTING
7-1.
Inspection
And
Upkeep
9
7-2.
Overload
Protection
10
7-3.
Circuit
Board
Handling
Precautions
10
7-4.
Troubleshooting
10
SECTION
8-
ELECTRICAL
DIAGRAMS
Diagram
8-1.
CIrcuit
Diagram
12
Diagram
8-2.
WirIng
Diagram
13
Diagram
8-3.
System
Circuit
Diagram
For
RSCP
Unit
And
Computer
Interface
14
SECTION
9
PARTS
LIST
Figure
9-1.
Main
Assembly
16
LISTOFCHARTS
AND
TABLES
Table
5-1.
Synergic
Pulse
Panel
Welding
Schedules
7
Table
7-1.
Troubleshooting
11
-
-~
I
II
p..
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
inthis
manual
and
on
various
la
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equipment.
B.
Safety
The
installation,
operation,
maintenance,
and
trouble
shooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only
by
qualified
per
sons
in
accordance
with
this
manual
and
all
safety
pre
cautions
listed
in
the
Arc
Welding
Safety
Precautions
in
the
welding
power
source
Owners
Manual.
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
iden
tify
different
levels
of
hazard
and
special
instructions.
a
a
a
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
seri
ous
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
necessafy
for
the
most
efficient
operation
of
this
equip
ment.
SECTION
2-INTRODUCTION
2-1.
DESCRIPTION
The
robot
Synergic
Pulse
panel
is
a
synergic
control
de
signed
to
be
used
with
the
MAXTRON
450
welding
pow
er
source,
MILLER
Computer
Interface,
and
the
robot
system.
The
unit
is
designed
for
Gas
Metal
Arc
Welding
(GMAW)
in
both
nonpuised
and
pulsed
dc
arc
welding
modes.
The
unit
is
shipped
ready
for
pulsed
welding.
The
panel
is
considered
a
synergic
control
because
the
parameters
which
determine
arc
power
and
arc
length
are
programmed
so
that
they
can
be
adjusted
using
a
single
control
as
opposed
to
adjusting
individual
con-
trols.
If
pulse
welding,
arc
power
parameters
are
wire
feed
speed,
background
amperage,
peak
amperage,
pulse
frequency,
and
pulse
width;
arc
length
Is
a
fine
tun
ing
of
pulse
frequency.
If
non-pulse
welding,
arc
power
parameters
are
wire
feed
speed,
arc
voltage,
and
induc
tance;
arc
length
is
a
fine
tuning
of
arc
voltage.
When
used
with
its
associated
equipment,
the
robot
Synergic
Pulse
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.
-
SECTION
3-INSTALLATION
3-1.
SYNERGIC
PULSE
PANEL
WELDING
POWER
SOURCE
CONNEC11ONS
(FIgure
3-1)
Obtain
appropriate
cords
and
make
connections
as
follows:
A.
REMOTE
14
ConnectIons
1.
Align
keyway,
insert
14-socket
plug
into
matching
receptacle
RC1
6
on
panel,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyway,
insert
14-pin
plug
into
matching
REMOTE
14
receptacle
on
welding
power
source,
and
rotate
threaded
collarfully
clockwise.
B.
REMOTE
17
ConnectIons
1.
Align
keyway,
insert
1
7-socket
plug
into
matching
receptacle
RC1
7
on
panel,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyway,
insert
17-pin
plug
into
matching
REMOTE
17
receptacle
on
welding
power
source,
and
rotate
threaded
collarfulty
clockwise.
OM-138
992
P9s
I
U
I
II
I
I
~
I
Ii.
iiul.
U
~
UI
I
U
I
II
Iii.~i.i~
C.
Voltage
Sensing
Cable
Connection
To
Wire
Drive
Assembly
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
welding
power
source,
and
disconnect
input
power
employing
lock
out/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
pad
lockin9
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
1.
Align
keyways,
insert
4-socket
plug
on
end
of
Voltage
Sensing
Cable
into
receptacle
RCI
5,
and
rotate
threaded
collar
fully
clockwise.
2.
Install
and
secure
one
lead
with
ring
terminal
to
weld
cable
terminal
on
wire
drive
assembly
(see
wire
dive
assembly
Owners
Manual
for
location).
3.
Connect
remaining
lead
with
ring
terminal
to
the
woilcpiece.
3-2.
SYNERGIC
PULSE
PANEL
COMPUTER
INTERFACE
CONNECTIONS
(FIgure
3-1)
A.
Plug
PLG14
Connections
Connect
plug
PLG1
4
from
the
papelto
the
Voltage
Sens
ing
Receptade
RCI4
on
the
CO~jter
lntrt
ace
asfol-
OM-138992Page2
lows:
align
keyway,
insert
plug,
and
rotate
threaded
col
lar
fully
clockwise.
B.
Plug
PLGI1
Connections
Connect
plug
PLG1I
from
the
panel
to
receptacle
RC11
on
the
Computer
Interface
as
follows:
align
keyway,
in.
sert
plug,
and
rotate
threaded
collar
fully
clockwise.
3-3.
CONNECTION
FOR
NONPULSE
WELDING
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
welding
powersource,
and
be
sure
equ4oment
cannot
be
acciiently
energized
before
inspecting
or
installing.
This
unit
Is
shipped
from
the
factory
ready
for
pulsed
welding.
If
nonpulsed
weldIng
is
desired,
proceed
as
fol
lows:
1.
Remove
Synergic
Panel
top
cover
and
side
pan
el.
Do
not
disconnect
wiring
harness.
2.
Locate
terminal
strip
21
in
the
Synergic
Panel
be
low
Logic
Circuit
Board
PC2.
3.
Move
jurT~er
link
from
2Tterminals
B
and
C
to
2T
terminals
A
and
B.
4:
RelnataH
unlttopcoverandsldepaneL.
Plug
PLG14
To
Computer
Interface
Receptacle
Fuse
(see
SectIon
7-2)
Plug
PLG11
To
Computer
interface
Receptacle
RCII
Figure
3-1.
SynergIc
Pulse
Panel
Connections
SC.
~39
8M
3-4.
CONNECTIONS
FOR
REMOTE
PULSE/NON-
PULSE
CONTROL
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
welding
power
source,
and
disconnect
input
power
employing
lock
out/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
This
unit
is
shipped
from
the
factory
ready
for
pulsed
welding.
If
selection
of
pulse/nonpulse
is
desired
through
the
use
of
the
robot
Program
Module,
proceed
as
follows:
1.
The
fiber-optic
cable
that
connects
the
Robot
Control
and
Computer
Interface
contains
three
spare
leads,
two
of
which
can
be
used
forthiscon
nection.
2.
Remove
Synergic
Panel
top
cover
and
side
pan
el.
Do
not
disconnect
wiring
harness.
3.
Locate
terminal
strip
2T
in
the
Synergic
Panel
be
low
Logic
Circuit
Board
PC2
(see
Figure
9-1).
4.
Locate
extra
leads
at
fiber-optic
cable
in
the
Com
puter
interface.
Route
leads
to
terminal
strip
2T
in
the
Synergic
Panel.
5.
Crimp
appropriate
terminals
on
leads
and
con
nect
leads
to
terminals
A
and
B
on
2T
In
the
Syn
ergic
Panel.
6.
Reinstall
unit
top
cover
and
side
panel.
7.
Open
Robot
Control
and
locate
extra
leads
from
fiber-optic
cable.
8.
Connect
leads
to
Robot
Control
normally-open
contacts
according
to
instructions
found
in
the
ro
bot
Owners
Manual
Section
4
System
Set-Up:
InputfOutput
Terminal
Block
Connections.
9.
To
program
puise/nonpulse
selection,
see
robot
Owners
Manual
Section
5
Teaching:
Logic
Data
For
Programs.
3-5.
FIELD
INSTALLATION
INSTRUCTIONS
FOR
SYNERGiC
PULSE
PANEL
RCSP-XL
ONTO
COMPUTER
INTERFACE
(FIgures
3-1
And
3.2)
a
WARNING:
ELECTRIC
SHOCK
can
kIlt.
00
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
to
bot
arid
disconnect
in~vt
power
employ
ing
hx4cout?agging
pro
cedures
before
be
ginning
this
installation.
IMPORIANT:
All
directions,
such
as
left
or
right,
are
with
rØspect
to
the
operator
facing
the
Computer
Inter
face
front
panel.
Retain
all
hardware
removed
during
this
procedure
for
reinstallation
unless
specifically
told
otherwise.
Put
on
properly
grounded
wrist
st
rap
BEFORE
handling
circuit
boards.
Transport
circuit
boards
in
proper
static-
shielding
carriers
or
packages.
Perform
worn
only
at
a
static-safe
~,vm
area.
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
move
ment
when
disconnecting
or
connecting
board
plugs
and
removing
or
installing
board.
1.
Remove
Computer
Interface
top
cover
and
side
panels.
2.
DIsconnect
Synergic
Pulse
panel
wiring
harness
from
panel
Interface
circuit
board
PCI.
Remove
side
panel
from
Synergic
Pulse
panel.
Install
frame
onto
left
side
of
Computer
Interface
with
sheet
metal
screws
(see
Figure
3-1).
5.
Connect
leads
25
and
27
to
terminals
T
and
U
on
the
Voltage
Control
Board
in
the
Computer
Inter
lace
(polarity
is
not
Important).
6.
Remove
jumper
links
between
terminals
1
TE
and
I
TF,
and
terminals
2TB
and
2TC
In
the
Computer
Interface.
7.
Make
the
following
connections
to
the
terminal
strips
in
the
Computer
Interface.
Terminal
strip
1
T
leads
must
be
routed
through
the
grommet
in
the
center
panel
of
the
Computer
Interface
to
the
right
side
of
the
unit
(see
Figure
3-2).
a.
Conned
lead
38
to
1TA.
b.
Conned
lead
39
to
ITB.
c.
Conned
lead
43
to
I
TE.
d.
Conned
lead
55
to
1TF.
e.
Conned
lead
26
to
2TB.
f.
Conned
lead
45
to
2TC.
g.
Conned
lead
60(0
315.
h.
Conned
gray
lead
to
Computer
Interface
chas
sis
ground
terminal.
8.
PositIon
Synergic
Pulse
panel
side
panel
so
that
the
wiring
harness
can
be
reconnected.
Recon
nect
wiring
harness
to
PCI.
9.
Install
side
panel
onto
Synergic
Pulse
panel.
10.
ReInstall
Computer
Interface
right
side
panel.
11.
Install
supplied
top
cover
onto
the
Computer
In
terf
ace
Synergic
Pulse
panel.
/
OM.laega2Pag.3
CAUTION:
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuIt
boards.
3.
4.
Lockoutttagging
procedures
consist
of
removing
input
power
plug
from
receptacle,
padlocking
bne
disconnect
switch
In
open
po
sition,
removing
fuses
from
fuse
box,
or
shut
tirig
ofl
and
red4aggI~
clrcu~
breaker
or
other
disconnecting
deyice.~
I-.
I~
-
II
I
I~I
II
uIi.
I
.iI
~
II
I~~UuiI
~
II
II
I
liii
~
Ii
I~
i~
~ii~~
Motor
Control
Board
SECTION
4-
ROBOT
PROGRAM
MODIFICATIONS
IMPORTANT:
The
robot
program
must
be
changed
to
accommodate
synergic
welding.
The
following
informa
tion
pertains
to
the
robot
Owners
ManuaL
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
welding
power
source,
and
disconnect
input
power
employing
lock
out/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
luses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
4-1
-
AMENDMENT
TO
ROBOT
OWNERS
MANU
AL
SECTION
4
SYSTEM
SET
UP
Before
the
Synergic
Pulse
panel
will
work,
the
robot
sys
tem
data
must
be
updated.
Update
System
Data
4
(weld
ing
power
source
selection)
to
SYNERGIC
according
to
instructions
in
Section
4.22.1.
If
the
Synergic
Pulse
panel
WIRE
SIZE
SELECT
Switch
is
in
the
STANDARD
position,
robot
system
data
must
be
updated.
Update
System
Data
4
to
GMAW
according
to
instructions
in
Section
4.22.1.
4-2.
AMENDMENT
TO
ROBOT
OWNERS
MANU
AL
SECTION
5TEACHING
Amend
Section
5.12.8
Teaching
The
Arc
Start
Function
When
using
the
Synergic
Pulse
panel,
the
synergic
mode
arc
start
parameters
and
displays
differt
rom
regu
lar
GMAW
welding
displays.
5.12.8
TeachIng
The
Arc
Start
Function
IMPORTANT:
Two
or
more
arc
start
functions
can
be
taught
in
series
and
only
one
arc
end
function
taught
to
end
the
welding
operation
(see
Section
5.12.9).
After
the
arc
start
function
data
is
taught,
an
asterisk
is
put
by
the
next
sequence
movement
data
taught
(linear
or
circular
arc)
to
show
that
the
movement
data
is
part
of
a
welding
function.
Welding
is
possible
within
the
range
of
linearor
circular
arc
movement
data
only.
Welding
parameter
values
can
be
changed
in
Automatic
mode
during
the
welding
operation
by
using
the
DISPLAY
SELECT
keys
to
choose
the
desired
parameter(s)
for
value
changes.
If
the
first
sequence
movement
data
of
a
program
is
the
only
taught
data recorded
before
entering
the
second
sequence
data,
the
display
will
appear
as
shown:
Manual
Op.rstlng
Speed
POOl
SOOl
M6
P
60
t
currant
Recorded
Data
(MayAlso
BQ
Data)
IMPORTAN1~
The
display
examples
used
with
state
ments
such
as
Will
appear
as
shown
may
not
match
ex
actly
with
actual
Program
Module
displays
because
of
different
program
number,
job
number,
sequence
num
ber,
line
number,
manual
operating
speed,
recorded
data,
ormovingspeedforAutomaticrnode.
Natal!
cases
can
be
gwen
for
actual
display
data,
and
the
examples
are
only
for
a
reference
to
supplement
instructions.
Figure
3-2.
ElectrIcal
Installation
$8139
887-A
OM-138992
Page
4
If
the
arc
start
function
data
wifi
be
the
next
data
recorded
after
previous
taught
data,
the
display
will
appear
as
shown:
POOl
S005
M4
a
P
60
It
Previous
Current
Recorded
Recorded
Data
Data
1)
Press
the
ARC
START
key
to
teach
the
arc
start
function,
and
a
typical
display
wifi
appear
as
shown:
POOl
S003
M4
25P
1L
039i
0.5S
I
I
I
I
Arc
Power
Arc
Length
Welding
Speed
Preftow
Tim.
In
Percent
In
1PM
In
Second.
IMPORTANT:
When
using
a
program
initially
pro
grammed
with
System
Data
4
set
to
GMAW,
the
Arc
Length
display
may
show
unusual
alpha-numeric
sym
bols.
The
program
needs
to
be
converted
to
SYNERG
IC.
Use
the
DISPLAY
SELECT
key
to
move
to
the
Arc
Length
parameter.
Press
the
Increase
(INC.)
or
De
crease
(DEC.)
key
to
clear
the
display
for
entr/
of
valid
parameters
(5
to
+5).
2)
To
change
the
welding
parameter
values,
press
the
forward
DISPLAY
SELECT
key
for
each
weld
ing
parameter
value
until
the
appropriate
letter
(P,
L.
i,
S)
after
the
value
to
be
changed
flashes.
POOl
S003
M4
25P
1
L
039
i
0
.5
S
Table
5-2.
Ranges
And
Increments
Of
Arc
Start
Welding
Parameter
Values
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.
Welding
Parameter
SettIng
Range
Increment
Arc
Power
0
to
100
P
1
P
ArcLength
-5to+5L
1L
Welding
Speed
4
to
234
1pm
1
1pm
Preflow
Time
0
to
9,9
sec.
0.1
sec.
3)
Enter
a
number
value
or
press
the
Increase
(INC.)
~or
Decrease
(DEC.)
key
to
change
the
welding
parameter
value
until
the
desired
value
appears
(if
the
QUICK
INCREASE-DECREASE
key
is
pressed
at
the
same
time,
changing
of
the
data
is
performed
rapidly).
4)
Press
the
RECORD
key,
the
sequence
number
will
advance
one
step
to
register
the
current
data
in
the
program,
and
the
display
will
appear
as
shown:
P
001
S004
M4
Cl
AS
Amend
SectIon
5.12.9
Teaching
the
Arc
End
Function
When
using
the
Synergic
Pulse
panel,
the
synergic
mode
arc
end
parameters
and
displays
differ
from
regu
lar
GMAW
welding
displays.
5.12.9
Teaching
The
Arc
End
Function
When
the
arc
end
function
data
is
the
next
data
recorded
after
previous
taught
data,
the
display
will
appear
as
shown:
POOl
S005
M4
AS
*
L
39
I
Pr.vlous
current
Recorded
Recorded
Data
Data
IMPORTAN1~
The
display
examples
used
with
state
menissuchas
will
appear
as
shownmay
not
match
ex
actly
with
actual
Program
Module
displays
because
of
different
piogram
nuri~er,
job
nuriter,
sequence
num
ber,
line
number,
manual
operating
speed,
recorded
data,
ormoving
speed
forAutomatic
mode.
Notall
cases
can
be
given
for
actual
display
data,
and
the
examples
are
only
for
a
reference
to
supplement
instructions.
1)
Pressthe
ARC
END
keyto
teach
the
arc
end
func
tion,
and
a
typical
display
will
appear
as
shown:
IMPORTANT:
Before
pressing
the
RECORD
key,
the
robot
axes
can
be
moved
manually
using
the
Axis
keys
to
allow
changing
axes
position
and/or
welding
gun!
torch
angle.
OM-138992Page5
POOl
S005
M4
18P
1L
0.2S
0.5S
IMPORTANT:
When
using
a
program
initially
pro
grammed
with
System
Data
4
set
to
GMAW,
the
Arc
Length
display
may
show
unusual
alpha-numeric
sym
bols.
The
program
needs
to
be
converted
to
SYNERG
IC.
Use
the
DISPLAY
SELECT
key
to
move
to
the
Arc
Length
parameter.
Press
the
Increase
(INC.)
or
De
crease
(DEC.)
key
to
clear
the
display
for
entry
of
valid
parameters
(5
to
+5).
2)
To
change
the
welding
parameter
values,
press
the
forward
DISPLAY
SELECT
key
for
each
weld
ing
parameter
value
untlithe
appropriate
letter
(P,
L,
S,
S)
after
the
value
to
be
changed
flashes.
POOl
S005
M4
18P
1
L
0.2
S
0
.5
S
Table
5-3.
Ranges
And
Increments
Of
Arc
End
Welding
Parameter
Values
Arc
power
parameters
are
wire
feed
speed,
background
amperes,
peak
amperes,
pulse
frequency,
and
pulse
width.
Arc
length
is
a
line
tuning
of
pulse
frequency.
W
eldlng
Parameter
SettIng
Range
Increment
ArcPower
OtolOOP
ip
Arc
Length
5
to
+5
L
1
L
Crater
Fill
Time
0
to
9.9
sec.
0.1
sec.
Postf
low
Time
0
to
9.9
sec
0.1
sec.
3)
Entera
numbervalue
orpressthe
Increase
(INC.)
or
Decrease
(DEC.)
key
to
change
the
welding
parameter
value
until
the
desired
value
appears
(if
the
QUICK
INCREASE-DECREASE
key
is
pressed
at
the
same
time,
changing
of
the
data
is
performed
rapidly).
2
POOl
S005
M4
8P
1L
0.2S
0.5S
IMPORTANT:
Before
pressing
the
RECORD
key,
the
robot
axes
can
be
moved
manually
using
the
Axis
keys
to
allow
changing
axes
position
and/or
welding
guni
torch
angle.
4)
Press
the
RECORD
key,
the
sequence
number
will
advance
one
step
to
register
the
current
data
in
the
program,
and
the
display
will
appear
as
shown:
POOl
S006
M4
AE
SECTION
5-
OPERATOR
CONTROLS
5-1.
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
pow
er
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
pa
rameters
are
wire
feed
speed,
background
amperes,
peak
amperes,
pulse
frequency,
and
pulse
width.
Arc
length
is
a
fine
tuning
of
pulse
frequency.
If
the
unit
is
operated
in
a
nonpulse
condition,
arc
power
parameters
are
wire
feed
speed,
arc
voltage,
and
induc
tance.
Arc
length
is
a
fine
tuning
of
arc
voltage.
When
the
WIRE
SIZE
SELECT
Switch
is
placed
in
the
STD
position,
the
STANDARD
MODE
Indicator
Lightwill
come
on,
indicating
that
the
Synergic
Pulse
panel
is
in
standard
mode
and
cannot
be used
to
set
the
output
pa
rameters
for
the
welding
power
source
or
robot
wire
drive.
When
the
control
is
in
standard
mode,
the
robot
needs
to
be
reset
to
the
GMAW
mode
through
System
Data
4.
IMPORTANT:
Position
the
WIRE
SIZE
SELECT
Switch
in
the
.045
position
when
welding
with
.047in.
diameter
welding
wire.
5-2.
WIRE
SIZE
INDICATOR
LIGHTS
(FIgure
5-1)
The
top
light
indicates
whether
the
unit
is
set
to
pulse
(tight
on)
or
is
in
STD
(tight
off).
The
remaining
lights
turn
on
when
the
corresponding
wire
size
is
selected
by
the
WIRE
SIZE
SELECT
switch.
5-3.
WiRE TYPE
SELECT
SWITCH
(Flgws
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
relation
ship
of
the
various
arc
power
parameters.
I
Arc
Power
In
Percent
I
I
I
Arc
Length
Crater
Fill
lime
Postflow
Time
In
Second.
In
Second.
OM-138
992
Page
6
Standard
Mode
Indicator
Light
Wire
Type
Selector
Switch
~
No
Program
indicator
Light
Wire
Size
Indicator
Ught
Wire
Sizo
~
Selector
Switch
~Recom
mended
Shielding
Gas
Indicator
Ughts
SB-130
816A
Figure
5-1.
Operator
Controls
if
the
unit
is
operated
in
a
pulse
condition,
arc
power
pa
rameters
are
wire
feed
speed,
background
amperes,
peak
amperes,
pulse
frequency,
and
pulse
width.
Arc
length
is
a
fine
tuning
of
pulse
frequency.
If
the
unit
is
operated
in
a
nonpulse
condition,
arc
power
parameters
are
wire
feed
speed,
arc
voltage,
and
induc
tance.
Arc
length
is
a
fine
tuning
of
arc
voltage.
5-4.
RECOMMENDED
SHIELDING
GAS
INDICA
TOR
LIGHTS
(FIgure
5-1)
The
RECOMMENDED
SHIELDING
GAS
Indicator
Lights
represent
the
types
of
shielding
gases
recom
mended
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
situ
ations
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
Indica
tor
light
does
not
come
on,
refer
to
Table
5-1
for
the
rec
ommended
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
5-4).
5-5.
NO
PROGRAM
INDICATOR
LIGHT
(FIgure
5-1)
The
Synergic
Pulse
panel
has
been
programmed
to
pro
vide
optimum
welding
conditions
in
a
majority
of
situa
tions
using
various
types
and
sizes
of
welding
wire
and
various
shielding
gases.
The
NO
PROGRAM
Indicator
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.
IMPORTAN1~
Use
of
a
nonrecommended
shielding
gas
could
change
weld
characteristics.
Table
5-1.
SynergIc
Pulse
Panel
Welding
Schedules
PULSE
WELDING
U
.
Wire
Type
STL1
STL2
Ni
SS1
SS2
ALl
AL2
SI
BR
CUST.
.
*
*
.
* *
* *
*
.035
98Ar/2
02
75Ar/25
HE
98Ar/2
02
Ar Ar
Ar
.045
98Ar/2
02
75Ar/25
HE
98Ar/2
02
Ar
Ar Ar
98ArI2
02
.062
*
Ar
Ar
*
OM-138
992
Page
7
Table
5-2.
Synergic
Pulse
Panel
Welding
Schedules
(Continued)
NONPULSE
WELDING
Wire
Type
STL1
STL2
NI
SS1
SS2
ALl
AL2
Si
BR
CUST.
.030
CO2
75Ar/25
Co2
SPCL
98Ar/2
02
*
.035
CO2
75Ar/25
Co2
SPCL
98Ar/2
02
Ar
Ar
Ar
.045
CO2
75Ar/25
Co2
SPCL
98Ar/2
02
Ar
Ar
CO2
.062
*
*
*
Ar
Ar
The
Synergic
Pulse
panel
is
not
programmed
for
type
and
size
of
welding
wire
indicated.
DEFINITION
OF TABLE
5-1
DATA
Wire
Type:
STL1
=
Mild
Steel
(Used
with
CO2
shielding
gas
for
short
circuit
welding
from
minimum
to
maximum
wire
feed
speed.)
STL2
=
Mild
Steel
(In
PULSE
mode,
STL2
is
used
with
98
Ar/2
02
shielding
gas
for
pulse
spray
welding
from
mini
mum
to
maximum
wire
feed
speed.
In
NONPULSE
mode,
STL2
is
used
with
75
Ar/25
CO2
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
02
shielding
gas
for
spray
transfer
welding
from
minimum
to
maximum
wire
feed
speed.
In
NONPULSE
mode,
SS1
is
used
with
Tn-Mix
shielding
gas
for
short
circuit
transfer
welding
from
minimum
to
maximum
wire
feed
speed.)
SS2
=
Stainless
Steel
(SS2
is
used
with
98
Ar/2
02
shielding
gas
for
spray
transfer
welding
from
minimum
to
maxi
mum
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:
Carbon
Dioxide
=
75%
Argon
25%
Carbon
Dioxide
=
Tn-Mix:
90%
Helium
7.5%
Argon
2.5%
Carbon
Dioxide
=
Argon
=
98%
Argon
2%
Oxygen
=
75%
Argon
25%
Helium
NI
sS1
ALl
AL2
SI
BR
*CUST.
CO2
75
Ar/25
CO2
SPCL
AR
98
Ar/2
02
~75
Ar/25
HE
This
shielding
gas
is
not
included
on
nameplate
of
the
Synergic
Pulse
panel.
OM-138
992
Page
8
SECTION
6-
SEQUENCE
OF
OPERATION
a
WARNING:
ELECTRIC
SHOCK
can
kill;
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
MOVING
PARTS
can
cause
serious
injury;
can
aftect
pacemaker
operation.
IMPROPER
AIRFLOW
AND
EXPOSURE
TO
Wearers
should
consult
their
doctor
before
ENVIRON
MENT
can
damage
internal
parts.
going
near
arc
welding,
gouging,
or
spot
weld-
Do
not
touch
live
electrical
parts.
ing
operations.
Keep
all
covers
and
panels
in
place
while
See
Section
1
Safety
Rules
For
Operation
Of
operating.
Arc
Welding
Power
Source
in
the
welding
power
Do
not
touch
welding
wire
or
any
metal
part
in
source
Owners
Manual
for
basic
welding
safety
information.
contact
with
it
while
we/ding.
The
welding
wire
and
all
metal
parts
in
contact
with
it
carry
weld
output
when
the
welding
power
source
contactor
is
energized.
6-1.
GAS
METAL
ARC
WELDING
(GMAW)
Warranty
is
void
if
any
of
the
equipment
is
oper
ated
with
any
portion
of
the
outer
enclosure
1.
Install
and
connect
robot
system
according
to
its
removed.
Owners
Manuals.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
2.
Connect
panel
according
to
Section
3.
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
3.
Position
WIRE
SIZE
SELECT
Switch
for
size
wire
Wear
correct
eye,
ear,
and
body
protection.
used
(see
Section
5-1).
FUMES
AND
GASES
can
seriously
harm
4.
Position
WIRE
TYPE
SELECT
Switch
for
type
your
health.
wire
used
(see
Section
5-2).
Keep
your
head
Out
of
the
fumes.
Ventilate
to
keep
from
breathing
fumes
and
5.
Place
welding
power
source
front
panel
adjust
gases.
ment
control(s)
to
the
maximum
setting.
If
ventilation
is
inadequate,
use
approved
6.
Turn
on
shielding
gas
at
its
source.
breathing
device.
WELDING
WIRE
can
cause
puncture
7.
Energize
robot
system.
wounds.
8.
Begin
welding.
Do
not
point
gun
toward
any
part
of
the
body,
any
conductive
surface,
or
other
personnel.
HOT
METAL,
SPATTER,
AND
SLAG
can
6-2.
SHUTTING
DOWN
cause
fire
and
burns.
1.
Stop
welding.
Watch
for
fire.
Keep
a
fire
extinguisher
nearby,
and
know
2.
Shut
down
robot
system.
how
to
use
it.
3.
Turn
off
shielding
gas
at
the
source.
Do
not
use
near
flammable
material.
Allow
work
and
equipment
to
cool
before
WARNING:
HIGH
CONCENTRATION
OF
handling.
SHIELDING
GAS
can
harm
health
or
kill.
Shut
off
gas
supply
when
not
in
use.
SECTION
7-
MAINTENANCE
&
TROUBLESHOOTING
IMPORTANT:
Every
six
months
inspect
the
labels
on
7-1.
INSPECTION
AND
UPKEEP
this
unit
for
legibility.
All
precautionary
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
Usage
and
shop
conditions
will
determine
the
frequency
when
necessary.
See
Parts
J.ist
for
part
number
of
and
type
of
maintenance.
At
minimum,
inspect
equip
precautionary
labels.
ment
every
three
months
as
follows:
OM-138
992
Page
9
II
I
II
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
welding
power
source,
and
disconnect
input
power
employing
lock
out/tagging
procedures
before
inspecting,
maintaining,
or
servicing.
Lockout/tagging
procedures
Consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
MOVING
PARTS
can
cause
serious
injury.
Keep
away
from
moving
parts.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
servicing.
Maintenance
and
troubleshooting
to
be
per
formed
only
by
qualified
persons.
Inspect
all
interconnecting
cords
for
damage
to
or
breaks
in
the
insulation
jacket,
particularly
at
the
plugs.
Repair
or
replace
the
cord(s)
as
necessary.
2.
Remove
grease
and
dirt
from
components
and
moisture
from
electrical
parts
and
cables.
7-2.
OVERLOAD
PROTECTION
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
welding
power
source,
and
disconnect
input
power
employing
lock
out/ta
gging
procedures
before
inspecting,
maintaining,
or
servicing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
INCORRECT
FUSE
can
damage
unIt.
Use
only
replacement
fuse of
same
size,
type,
and
rating
(see
Parts
List).
Fuse
Fl
protects
the
unit
from
overload.
If
fuse
Fl
should
open,
the
Synergic
Pulse
panel
would
not
func
tion.
To
replace
fuse
Fl,
proceed
as
follows:
1.
Depress
and
rotate
fuse
holder
cover
counter
clockwise.
2.
Pull
Out
fuse
with
cover
when
fuse
holder
cover
is
free.
3.
Insert
new
fuse
into
fuse
holder
cover.
4.
Install
new
fuse
with
fuse
holder
cover
back
into
unit.
5.
Depress
and
rotate
fuse
holder
cover
clockwise
until
cover
is
secure.
7-3.
CIRCUIT
BOARD
HANDLING
PRECAUTIONS
a
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
welding
power
source,
and
disconnect
input
power
employing
lock
out/tagging
procedures
before
inspecting,
maintaining,
or
servicing.
Lockout/tagging
procedures
Consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
CAUTION:
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
properly
grounded
wrist
strap
BEFORE
handling
circuit
boards.
Transport
circuit
boards
in
proper
static-
shielding
carriers
or
packages.
Perform
work
only
at
a
static-safe
work
area.
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
move
ment
when
disconnecting
or
connecting
board
plugs
and
removing
or
installing
board.
IMPORTANT:
The
circuit
boards
in
this
unit-Interface
Circuit
Board
PCi,
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
PCi
is
at
the
top
of
the
stack.
7-4.
TROUBLESHOOTING
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
welding
power
source,
and
disconnect
input
power
employing
lock
out/tagging
procedures
before
inspecting,
maintaining,
or
servicing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
Troubleshooting
of
internal
parts
to
be
per
formed
only
by
qualified
persons.
It
is
assumed
that
proper
installation
has
been
made
ac
cording
to
Section
3
of
this
manual,
the
operator
isfamil
ar
with
the
function
of
controls,
the
unit
was
working
property,
and
that
the
trouble
is
not
related
to
the
welding
process.
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
unit.
OM
138
992
Page
10
Use
this
chart
in
conjunction
with
the
circuit
diagram
should
be
contacted.
In
all
cases
of
equipment
malfunc
while
performing
troubleshooting
procedures.
It
the
tion,
the
manufacturers
recommendations
should
be
trouble
is
not
remedied
after
performing
these
proce-
strictly
followed.
dures,
the
nearest
Factory
Authorized
Service
Station
Table
7-1.
Troubleshooting
TROUBLE
PROBABLE
CAUSE
REMEDY
No
weld
output.
POWER
Switch
on
welding
power
source
in
OFF
position.
Place
POWER
Switch
on
welding
power
source
in
ON
position.
Fuse(s).
Check
fuse
on
Computer
Interface
and
Synergic
Pulse
pane~.
Replace
necessary
parts.
Welding
gun.
See
welding
gun
Owners
Manual.
No
control
of
weld
output.
Control
cords
nat
secure.
Secure
all
connections
between
Synergic
Pulse
panel,
Computer
Interface,
welding
power
source,
and
wire
drive
assembly.
Voltage
Sensing
Cable
connec-
tions.
Check
routing
of
voltage
sensing
cable
and
Se
cure
connections.
Work
connection
loose
or
in-
complete
due
to
rust,
paint,
etc.,
on
surface
of
workpiece.
Check
work
connection
for
good
metal-to-metal
contact.
Synergic
Pulse
panel
not
pro-
grammed
for
weld
conditions
set
by
WIRE
SIZE
SELECT
and
WIRE
TYPE
SELECT
switches
(NO
PROGRAM
Indicator
light
will
be
on.)
Reselect
wire
type
and
wire
size
to
be
used.
Computer
Interface.
See
Computer
Interface
Owners
Manual.
Synergic
Pulse
panel
controls
not
functional.
Interface
Circuit
Board
PCi
.
See
Section
7-3
and
contact
nearest
Factory
Au-
thorized
Service
Station.
Memory
Circuit
Board
PC3.
See
Section
7-3
and
contact
nearest
Factory
Au
thorized
Service
Station.
Logic
Circuit
Board
PC2.
See
Section
7-3
and
contact
nearest
Factory
Au
thorized
Service
Station.
Erratic
weld;
incorrect
weld
characteristics.
Incorrect
settings
on
WIRE
TYPE
SELECT
and/or
WIRE
SIZE
SELECT
switches.
Reselect
wire
type
and
wire
size
to
be
used.
Incorrect
arc
length.
Adjust
ARC
LENGTH
control
on
the
robot
Pro
gram
Module.
Voltage
Sensing
Cable
connec-
tions.
Check
routing
of
voltage
sensing
cable
and
Se
cure
connections.
Work
Connection
loose
or
in-
complete
due
to
rust,
paint,
etc.,
on
surface
of
workpiece.
Check
work
connection
for
good
metal-to-metal
contact.
OM-138
992
Page
ii
.
.~.
I...
I
SECTION
8
ELECTRICAL
DIAGRAMS
Diagram
8-i.
Circuit
Diagram
pCo
SELECTOR
BOARD
~L0
10/PCI
B C
PLG2O/PC2
a-fl
6026
~JUMPER
FACTORY
INSTALLED
FR~4
21(B)
TO
CI
FOR
BEICTE
SELECTIOS
OF
NOFLLSE
SYIEPOIC
WELDING.
INSTALL
.flER
FROM
21(A)
10
(B)
F~
MANAJA~
NOtCtLSE
SYNERGIC
WELDING.
Circuit
Diagram
No.
SB-i
45
345-A
OM438
992
Page
12
~J~G9IE
P1
4%)IT-4)
4%
(11-SI
PLG6/RCb
PC
I
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