Millerfi
January
1991
FORM:
OM-138
426-B
MODEL:
Robot
Interface
(Per
NSPR
8945)
gMPORTANT:
SEE
SPECIAL
INSTRUCTIONS
AT
BEGINNING
OF
MANUAL
BEFORE
USE.
FILE
COPY
RETURN
TO
FOLDER
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..
Company
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
41
4-734-9821
PRINTED
IN
U.S.A.
September
9,
1992
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual:
AMENDMENT
TO
SECTION
3
INSTALLATION
Amend
Section
3-5B.
ROBOT
INTERFACE
WELDINO
POWER
SOURCE
CONNECTIONS:
REMOTE
17
Connections
3.
For
units
used
with
Pulstar
450
welding
power
source,
itis
necessary
to
hnge
internal
connectionsin
the
robot
interf~ce.
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/tag
ging
procedures.
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.
a.
Open
front
panel
access
door.
b.
Locate
lead
72
at
pin
F
of
REMOTE
17
receptacle
RC16.
c.
Cut
lead
72
as
close
to
receptacle
as
possible.
d.
Splice
lead
72
to
lead
77
at
REMOTE
14
receptacle
RC13
pin
D.
e.
Cover
splice
with
electrical
tape
or
other
insulation.
f.
Close
and
secure
front
panel
access
door.
AMENDMENT
TO
SECTION
8-
PARTS
LIST
Amend
Parts
List
as
follows:
18-
048029
19-
...
RC16
...
097867
20-
111
122
20-
116964
20-
111
123
Deleted
141
162
134731
079
739
152370
079
534
079
739
ERRATA
SHEET
V
a
Dia.
~
Mkgs.
Part
No.
Replaced
With
Description
Quantity
18-
048
588...
0499700008841
...
BRACKET,
mtg
relay
1
18-
079 844
079 844
.
. .
SPRING,
(qty
chg)
3
18-
027
811
027
811
...
SOCKET,
(qty
chg)
3
048 029
.
..
CLIP,
(qty
chg)
3
18-
026
202
026 202
...
DIODE,
(qty
chg
added
D4)
3
18-
. .
.
.
PCi
....
137
695
+148
320
.
.
.
CIRCUIT
CARD,
voltage
control
1
18-
...
CR5
Added
095
521
...
RELAY,
end
24VDC
4PDT
1
19-
131
054
131
054
...
HOUSING
RECEPTACLE
&
SOCKETS,
(qty
chg
added
PLG26)
2
HOUSING
PLUG
&
PINS,
(consisting
of)
1
CONNECTOR,
circ
pin
push-in
18-i4ga
14
CONNECTOR,
circ
clamp
str
rlf
1
Clamps
are
now
included
w/Connectors
HOUSING
PLUG
&
SOCKETS,
(consisting
of)
....
1
CONNECTOR,
circ
skt
push-in
24-l8ga
14
CONNECTOR,
circ
clamp
str
rif
1
20-
1338640008989
++154
760
.
.
.
CABLE,
interconnecting
1
604
910
120
032
..
.
CABLE,
port
No.186/c
(order
byft)
lOft
Amend
Parts
List
as
follows:
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
AMENDMENT
TO
SECTION
3-
INSTALLATION
Amend
Section
3-5B.
ROBOT
INTERFACE
WELDING
POWER
SOURCE
CONNECTIONS:
REMOTE
17
Connections
3.
For
units
used
with
Pulstar
450
welding
power
source,
itis
necessary
to
change
internal
connections
in
the
robot
interface.
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/ta
g
ging
procedures.
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.
Open
front
panel
access
door.
Locate
lead
72
at
pin
F
of
REMOTE
17
receptacle
RC16.
Cut
lead
72
as
close
to
receptacle
as
possible.
Splice
lead
72
to
lead
77
at
REMOTE
14
receptacle
RC13
pin
D.
Cover
splice
with
electrical
tape
or
other
insulation.
f.
Close
and
secure
front
panel
access
door.
AMENDMENT
TO
SECTION
8
PARTS
LIST
Amend
Parts
List
as
follows:
a
a.
b.
C.
d.
e.
Dia.
~
Mkgs.
Part
No.
Replaced
With
Description
Quantity
. .
18-
048
588...
0499700008841
...
BRACKET,
mtg
relay
1
. .
18-
079
844
079 844
...
SPRING,
(qty
chg)
3
.
.
18-
027
811
027
811
...
SOCKET,
(qty
chg)
3
. .
18-
048
029
048
029
...
CLIP,
(qty
chg)
3
.
.
18-
026
202
026 202
...
DIODE,
(qty
chg
added
D4)
3
.
.
18-
.
. . .
PCi
....
137
695
+148 320
...
CIRCUIT
CARD,
voltage
control
1
.
.
18-
...
CR5
Added
095
521
...
RELAY,
end
24VDC
4PDT
1
.
.
19-
131
054
131
054
...
HOUSING
RECEPTACLE
&
SOCKETS,
(qty
chg
added
PLG26)
2
.
.
19-
...
RC16
...
097
867
Deleted
.
.
20-
111
122
141
162
134
731
...
.
.
.
HOUSING
PLUG
&
PINS,
(consisting
of)
.
CONNECTOR,
circ
pin
push-in
18-l4ga
1
14
079
739
. .
.
.
CONNECTOR,
circ
clamp
str
rlf
1
. .
20-
116
964
Clamps
are
now
included
w/Connectors
.
.
20-
111
123
152
370
079
534
...
...
HOUSING
PLUG
&
SOCKETS,
(consisting
of)
..
.
.
CONNECTOR,
circ
skt
push-in
24-l8ga
.
1
14
079
739
...
.
CONNECTOR,
circ
clamp
str
rif
1
. .
20-
1338640008989
++154
760
604
910
120
032
. . .
.
. .
CABLE,
interconnecting
CABLE,
port
No.
186/c
(order
by
ft)
1
lOft
Amend
Parts
List
as
follows:
Dia.
Part
Replaced
**
Mkgs.
No
With
Description
Quantity
21-
072
292
154
098
...
SHAFT,
support
spool
1
21-
Added
+++141
700
RING,
retaining
ext
.625
shaftx.O5Othk
1
21
.....
Added
+++605
941
.
..
WASHER,
flat
stl
.640
ID
x
1.000
OD
x
l4ga
thk
..
1
~First
digit
represents
page
no
digits
following
dash
represent
item
no.
+
Parts
on
page
22
&
23
may
not
represent
actual
board.
++AII
components
remain
the
same
with
listed
exceptions.
+++lncluded
w/I-fub
&
Spindle
Assembly
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-138
426-B
Page
2
OM.1384268
l/9~
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use
the
following
spaces
to
record
the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number
of
your
unit.
The
infor
claims
for
loss
or
damage
with
the
delivering
carrier.
mation
is
located
on
the
data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor,
and/or
the
equipment
man
ufactur-
Model
________________________________
ers
Transportation
Department.
.
Serial
or
Style
No.
___________________
When
requesting
information
about
this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date
of
Purchase
______________________
Number.
TABLE
OF
CONTENTS
Section
No.
Page
No.
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
SPECIFICATIONS
2-1.
Description
1
SECTION
3
INSTALLATION
3-1.
Site
Selection
2
3-2.
Equipment
Installation
2
3-3.
Gas/Current
Sensing
Control
Interconnections
2
3-4.
Voltage
Sensing
Connections
3
3-5.
Robot
Interface
Welding
Power
Source
Connections
3
3-6.
Robot
Interface
Robot
Control
Unit
Connections
4
3-7.
Arc
Failure
Light
Terminal
Strip
Connections
4
3-8.
Welding
Wire
Installation
5
SECTION
4OPERATOR
CONTROLS
4-1.
Power
Switch
6
4-2.
Jog
Push
Buttons
6
4-3.
Purge
Push
Button
6
4-4.
Voltmeter
6
4-5.
Wire
Speed
Meter
6
4-6.
Peak
Amps/Inductance
Meter
6
4-7.
Indicator
Lights
6
4-8.
Burnback
Control
7
SECTION
5-
SEQUENCE
OF
OPERATION
5-1.
Input
Signals
From
Robot
Control
Unit
7
5-2.
Output
Signals
From
Robot
Interface
7
Section
No.
Page
No.
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
Routine
Maintenance
7
6-2.
Overload
Protection
8
6-3.
Reinstallation
Of
Hub
Assembly
8
6-4.
Display
Board
PC4
Meter
Check
8
6-5.
Circuit
Board
Handling
Precautions
9
SECTION
7
ELECTRICAL
DIAGRAMS
Diagram
7-1.
Circuit
Diagram
For
Robot
Interface
10
Diagram
7-2.
Circuit
Diagram
For
Voltage
Control
Board
PCi
11
Diagram
7-3.
Circuit
Diagram
For
Motor
Control
Board
PC2
12
Diagram
7-4.
Circuit
Diagram
For
Interface
Board
PC3
14
Diagram
7-5.
Circuit
Diagram
For
Meter
Display
Board
PC4
14
Diagram
7-6.
Circuit
Diagram
For
Interlace
Board
PC5
15
Diagram
7-7.
Circuit
Diagram
For
Wire
Touch
Board
PC6
15
Diagram
7-8.
Circuit
Diagram
For
Gas/Current
Control
16
SECTION
8
PARTS
LIST
Figure
8-1.
Circuit
Card,
Voltage
Control
PCi
22
Figure
8-2.
Circuit
Card,
Motor
Speed
Digital
PC2
24
Figure
8-3.
Circuit
Card,
Meter
PC4
26
Figure
8-4.
Circuit
Card,
Interlace
PC5
27
Figure
8-5.
Circuit
Card,
Wire
Touch
PC6
28
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
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
J~
This
safety
alert
symbol
is
used
with
the
signal
troubleshooting
which
should
be
read,
understood,
and
~
words
WARNING
and
CAUTION
to
call
atten
followed
for
the
safe
and
effective
use
of
this
equipment.
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
shooting
of
arc
welding
equipment
requires
practices
ous
personal
injury
or
loss
of
life.
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
Table
2-1.
Specifications
Component
Dimensions
Weight
Height
Width
Depth
Net
Ship
Robot
Interface
22-1/2in.
(572
mm)
16-1/2in.
(419
mm)
6~1/4ifl.*
(159
mm)
381bs.
(17
kg)
Total
61
lbs.
(27.7
kg)
Gas/Current
Sensing
Control
4-1/2
in.
(108
mm)
8-3/4
in.
(222
mm)
14
in.
(355
mm)
5
lbs.
(2.3
kg)
Spool
Support
Assembly+
13-3/4
in.
(349
mm)
8-3/4
in.
(222
mm)
8-1/2
in.
(216
mm)
6
lbs.
(2.7
kg)
Add
2-1/4
in.
(57
mm)
for
brake
resistor.
+Spool
Support
without
optional
wire
reel.
*Add
7/8
in.
(22
mm)
for
front
panel
knob.
2-1.
DESCRIPTION
peak
amperage
or
inductance.
The
robot
interface
control
is
designed
to
interface
with
a
The
gas/current
sensing
control
contains
the
gas
valve,
contactor,
and
current
sensing
reed
relay.
Automatix
robot
and
an
Arc
Pak
350,
Deltaweld,
Max
tron,
or
Pulstar
450
welding
power
source.
This
unit
pro-
These
components
function
with
the
robot
system
when
vides
digital
display
of
weld
volts,wire
feed
speed,
and
using
the
Gas
Metal
Arc
Welding
(GMAW)
process.
OM-138
426
Page
1
SECTION
3
INSTALLATION
3-1.
SITE
SELECTION
Select
an
installation
site
which
provides
the
following:
1.
Correct
input
power
supply
(see
unit
data
card)
Shielding
gas
supply
(if
applicable)
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
se
cure
the
system
components
in
a
permanent
location.
Table
2-1
gives
overall
dimensions.
3-2.
EQUIPMENT
INSTALLATION
A.
Supplied
Equipment
The
following
equipment
is
supplied
as
standard
and
re
quires
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.
Spindle
Support
5.
10
ft.
(3
m)
Weld
Control
Welding
Power
Source
Interconnecting
Cords
6.
lOft.
(3m)
Gas
Hose
7.
Voltage
Sensing
Cord
B.
Equipment
Location
When
deciding
on
equipment
location,
consider
the fol
lowing:
1.
The
equipment
must
be
mounted
to
a
structure
capable
of
supporting
the
weight
of
the
equip
ment.
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
tended
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.
One
weld
output
cable
must
be
routed
through
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
struc
ture
for
equipment
installation.
Secure
weld
control,
Gas/Current
Sensing
control,
and
all
other
equipment
onto
structures
in
the
welding
area.
0.
Hub
Installation
(Figure
3-1)
The
hub
assembly
is
supplied
with
the
robot
interface.
Remove
the
hub
assemblyfrom
the
shipping
carton,
and
install
it
as
follows:
1.
Remove
hex
nut
from
end
of
hub
support
shaft.
2.
Align
keyway
and
insert
hub
support
shaft
through
selected
hole
in
hub
support.
Hole
selec
tion
in
hub
support
depends
on
wire
spool
size.
Be
sure
the
brake
washers
are
properly
seated
in
the
hub.
3.
Reinstall
hex
nut
onto
support
shaft.
Tighten
hex
nut
until
a
slight
drag
is
felt
while
turning
hub.
4.
Install
welding
wire
according
to
Section
3-8.
Figure
3-1.
Hub
Assembly
Installation
3-3.
GAS/CURRENT
SENSING
CONTROL
INTER
CONNECTIONS
(Figure
3-2)
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
in
terconnections.
Lockout/tagging
procedures
consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
2.
3.
Hub
Support
Shaft
Washer
Hub
Assembly
Hex
Nut
Fiber
Hub
Support
SA.126
870
OM-138
426
Page
2
C.
Gas
Connections
Connect
hose
from
gas
regulator/flowmeter
(customer
supplied)
at
gas
source
to
IN
fitting
on
gas/current
sens
ing
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.
Motor
Connection
Align
keyways,
insert
14-pin
plug
from
motor
cord
into
matching
receptacle
RC7
on
gas/current
sensing
con
trol,
and
rotate
threaded
collar
fully
clockwise.
Lock
Washer
Flat
Washer
Weld
Cable
Lug
Location
S
.040
1
Figure
3-3.
Voltage
Sensing
Connections
At
Wire
Drive
Assembly
Figure
3-2.
Right
Side
View
TB.119 646
A.
Robot
Interface
Gas/Current
Sensing
Control
Connections
1.
Align
keyways,
insert
14-pin
Amp
plug
into
matching
receptacle
RC9
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyways,
insert
16-pin
Amp
plug
into
matching
receptacle
RC16
on
gas/current
sens
ing
control,
and
rotate
threaded
collar
fully
clock
wise.
B.
Weld
Cable
Connections
For
Electrode
Positive/Reverse
Polarity,
route
one
cable
from
welding
power
source
POSITIVE
weld
output
ter
minal
to
the
gas/current
sensing
control,
and
connect
to
the
contactor.
Connect
second
weld
cable
to
remaining
terminal
on
contactor,
route
through
the
current
sensing
reed
relay,
to
the
wire
drive
assembly,
and
connect
cable
to
weld
cable
terminal
(see
Motor/Drive
Assembly
Own
ers
Manual
for
location).
3-4.
VOLTAGE
SENSING
CONNECTIONS
(Figure
3-3)
1.
Align
keyway,
insert
4-socket
plug
into
matching
receptacle
RC1
2
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Connect
lead
with
ring
terminal
to
wire
drive
as
sembly,
along
with
the
weld
cable
from
the
weld
ing
power
source,
as
shown
in
Figure
3-3.
3.
Connect
lead
with
clamp
to
the
workpiece.
3-5.
ROBOT
INTERFACE
WELDING
POWER
SOURCE
CONNECTIONS
(Figures
3-2
And
3-3)
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
five
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
in
terconnections.
Lockout/tagging
procedures
consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
Circuit
breaker
or
other
disconnect
ing
device.
There
are
three
cords
supplied
for
interconnection
be
tween
the
robot
interface
and
welding
power
source.
Ex
amine
cords
and
select
proper
cord
for
the
connection.
Gas/Current
10-Socket
Receptacle
RCI9
Location
Nut
17-Pin
Receptacle
RC1
10-Pin
Receptacle
Ads
Location
Wire
OM-138
426
Page
3
A.
REMOTE
14
Connections
Socket
C:
Peak
Amps/Inductance
signal
wiper.
Sig
1.
Align
keyway,
insert
14-socketplug
into
matching
nal
varies
0-4.8
volts
for
Pulstar
or
0-10
receptacle
RC13
on
robot
interface,
and
rotate
volts
for
Arc
Pak
threaded
collar
fully
clockwise.
Socket
F:
Circuit
Common.
2.
Align
keyway,
insert
14-pin
plug
into
matching
re
ceptacle
on
welding
power
source,
and
rotate
Socket
G:
Jog
signal
with
respect
to
socket
F.
threaded
collar
fully
clockwise.
Socket
L:
Circuit
Common.
B.
REMOTE
17
Connections
Socket
M:
Weld
Start
with
respect
to
socket
N.
1.
Align
keyway,
insert
17-socket
plug
into
matching
receptacle
RC16
on
robot
interface,
and
rotate
Socket
N:
Circuit
Common.
threaded
collar
fully
clockwise.
Socket
P:
Wire
Feed
Speed
signal
positive.
2.
Align
keyway,
insert
17-pin
plug
into
matching
re
ceptacle
on
welding
power
source,
and
rotate
Socket
0:
Wire
Feed
Speed
signal
common.
thread
collar
fully
clockwise.
Socket
A:
Wire
Feed
Speed
signal
wiper.
Signal
va
C.
REMOTE
10
Connections
ries
0-8
volts.
1.
Align
keyway,
insert
10-socket
plug
into
matching
Socket
5:
Arc
Voltage
signal
positive.
receptacle
RC15
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
Socket
1:
Arc
Voltage
signal
common.
2.
Align
keyway,
insert
plug
into
matching
recep-
Socket
U:
Arc
Voltage
signal
wiper.
Signal
varies
tacle
on
the
welding
power
source,
and
rotate
0-10
volts.
threaded
collar
fully
clockwise.
lithe
welding
power
source
is
equipped
with
a
REMOTE
Socket
V:
Arc
Failure
contact.
14/17
selector
switch,
place
the switch
in
the
REMOTE
Socket
W:
Arc
Failure
contact.
14
position.
Make
connections
to
both
REMOTE
14
and
REMOTE
17
receptacles.
Socket
X:
Current
detect
contact.
Socket
Yr
Current
detect
contact.
3-6.
ROBOT
INTERFACE
ROBOT
CONTROL
UNIT
CONNECTIONS
(Figure
3-2)
IMPORTANT:
The
remaining
sockets
in
the
receptacle
are
not
used.
A
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Receptacle
RC1
9
Shut
down
unit,
we/ding
power
source,
and
robot,
and
disconnect
input
power
employing
Socket
A:
Torch
Position
signal
with
respect
to
socket
lockout/tagging
procedures
before
making
in
terconnections.
D.
Lockout/tagging
procedures
consist
of
padlock-
Socket
D:
Torch
Position
signal
with
respect
to
socket
ing
line
disconnect
switch
in
open
position,
re-
A.
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect-
Socket
F:
Circuit
common.
ing
device.
Socket
G:
Torch
Position
Initiate
signal
with
respect
1.
Obtain
proper
cords,10-pin,
and
24-pin
Amphe-
to
socket
F.
nd
plugs
(not
supplied).
Socket
I:
Circuit
common.
2.
Connect
conductors
at
one
end
of
cord
to
appro
priate
sockets
in
plug.
Socket
Jr
Gas
control
with
respect
to
socket
I.
3.
Align
keyway,
insert
plug
into
matching
recep
tacle
on
robot
interface,
and
rotate
threaded
col-
IMPORTANT:
The
remaining
sockets
in
the
receptacle
lar
fully
clockwise,
are
not
used.
4.
Route
and
connect
conductors
at
remaining
end
of
cords
to
the
robotcontrol
unit.
3-7.
ARC
FAILURE
LIGHT
TERMINAL
STRIP
The
input
and
output
signals
at
the
sockets
of
receptacle
CONNECTIONS
(Figure
3-4)
RC1
7
and
RC1
9
by
means
of
the
robot
interface
control
circuitry
are
as
follows:
There
are
two
terminal
strips
inside
the
robot
interface
for
control
connections.
Loosen
screws
on
strain
relief
Receptacle
RC1
7
on
unit
right
side
panel
if
applicable,
open
front
panel
ac
cess
door,
and
locate
appropriate
terminal
strip
for
con
nections.
Tighten
screws
on
strain
relief
if
necessary,
Socket
A:
Peak
Amps/Inductance
signal
positive,
and
close
and
secure
front
panel
access
door
when
pro-
Socket
B:
Peak
Amps/Inductance
signal
common.
cedure
is
finished.
OM-138
426
Page
4
Robot
Control
Unit
Robot
Interface
The
ARC
FAILURE
light
on
the
robot
interface
front
pan
el
is
turned
on
and
off
by
a
signal
from
the
robot
control
unit.
Obtain
proper
length
of
18
gauge/2-conductor
cord
for
this
connection,
and
proceed
as
follows:
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
in
terconnections.
Lockout/tagging
procedures
Consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
For
robot
control
units
when
24
vdc
is
used
(Fig
ure
3-4):
a.
Route
cord
through
strain
relief
on
right
side
panel
of
robot
interface,
and
make
proper
con
nections
to
ilL
and
1TM.
b.
Route
and
connect
remaining
end
of
cord
to
weld
alarm
terminal
and
ground
connection
at
the
robot
control
unit.
c.
Connect
+24
vdc
to
common
relay
contact
ter
minal.
2.
For
robot
control
units
when
115
or
24
vac,
or
24
vdc
is
used
(Figure
3-4):
a.
Route
cord
through
strain
relief
on
right
side
panel
of
robot
interface,
and
make
proper
con
nections
to
1TL
and
1TM.
b.
Obtain
a
115
or
24
vac,
or
24
vdc
isolation
relay
CR1,
and
install
into
robot
control.
c.
Route
and
connect
remaining
end
of
cord
to
one
side
of
the
normally-open
robot
control
relay
contact
and
ground.
d.
Connect
+24
vdc
to
remaining
side
of
normally-
open
robot
control
relay
contact.
e.
Connect
a
lead
from
one
side
of
robot
control
coil
to
weld
alarm
terminal.
f.
Connect
proper
voltage
source
(115
vac,
24
vac,
or
24
vdc)
between
common
terminal
and
remaining
side
of
robot
control
relay
coil.
Figure
3-4.
Arc
Failure
Light
Connections
3-8.
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.
Figure
3-5.
Optional
Wire
Reel
And
Reel-Type
Wire
Installation
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.
Weld
Alarm
Terminal
If
So
Equipped
Robot
Control
Unit
Arc
Failure
Indicator
Light
Common
Terminal
Weld
Alarm
Terminal
If
So
Equip~
1__~~~1
If
So
Equipped
To
Voltage
Source
(I15VAC,
24VAC,
24VDC)
Isolation
Relay
CR1
Robot
Control
Robot
Interface
CR1
Arc
Failure
ITM
Indicator
Light
S-0292
Wire
Retainer
Retaining
Ring
Spanner
Nut
Hub
SC-127
308
OM-138
426
Page
5
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
as
sembly
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
back
lash
when
the
wire
feed
stops.
If
adjustment
is
required,
loosen
or
tighten
the
hex
nut
on
the
end
of
the
hub
sup
port
shaft
accordingly.
SECTION
4-
OPERATOR
CONTROLS
4-1.
POWER
SWITCH
(Figure
4-1)
Placing
the
POWER
switch
in
the
ON
position
energizes
the
robot
interface.
The
interface
must
be
on
for
the
ro
bot
to
weld.
Placing
the
POWER
switch
in
the
OFF
posi
tion
shuts
down
the
interface.
4-2.
JOG
PUSH
BUTTONS
(Figure
4-1)
The
JOG
and
JOG
REV
push
buttons
are
momentary-
contact
switches.
The
JOG
buttons
energize
the
wire
feed
motor
without
energizing
the
welding
power
source
contactor.
Holding
both
JOG
buttons
allows
the
wire
to
reverse
into
the
gun.
4-3.
PURGE
PUSH
BUTTON
(Figure
4.1)
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.
The
voltmeter
displays
weld
voltage
to
the
nearest
tenth
of
a
volt
while
welding
and
preset
voltage
while
idling.
4-5.
WIRE
SPEED
METER
(Figure
4-1)
The
wire
speed
meter
displays
preset
wire
feed
speed
to
the
nearest
inch
per
minute
while
welding
and
idling.
Ac
tual
and
preset
wire
feed
speed
are
the
same
due
to
the
wire
feed
speed
feedback
circuit.
4-6.
PEAK
AMPS/INDUCTANCE
METER
(Figure
When
used
with
the
Puistar
welding
power
source,
the
meter
displays
preset
peak
weld
amperage
to
the
near
est
ampere
while
welding
and
idling.
When
used
with
the
Arc
Pak
welding
power
source,
in
ductance
is
displayed
in
percentage.
4-7.
INDICATOR
LIGHTS
(Figure
4-1)
There
are
seven
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.
Gas
Indicator
Light
Circuit
Breaker
(See
Section
6.2)
Arc
Failure
Wire
Touch
Jog
Push
Light
Indicator
Light
Indicator
Light
Button
Switch
Figure
4-1.
Front
Panel
Controls
4-4.
VOLTMETER
(Figure
4-1)
Jog
Rev
Push
Button
Switch
Rel.
T8-1t9
645
4.1)
OM-138
426
Page
6
The
CONTACTOR
light
turns
on
when
the
welding
pow
er
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
only
when
properly
connected
according
to
instructions
in
Section
3-7,
and
there
is
an
arc
outage
while
welding.
The
WIRE
TOUCH
light
turns
on
when
the
torch
position
initiate
contact
at
socket
G
of
RC19
is
closed
and
the
welding
wire
touches
the
workpiece
during
torch
posi
tioning
and
set
up.
The
WELD
ENABLE
light
turns
on
when
the
system
is
energized
and
remains
on
unless
the
torch
position
initi
ate
contact
at
pin
G
of
RC19
is
closed.
4-8.
BURNBACK
CONTROL
Burnback
is
provided
by
potentiometer
R32
on
Interface
Circuit
Board
PC3
inside
the
unit.
The
burnback
circuitry
in
this
unit
keeps
the
welding
wire
from
sticking
to
the
workpiece
after
the
arc
is
extin
guished.
This
circuitry
keeps
weld
output
on
the
welding
wire
from
0
to
0.25
seconds
after
the
wire
has
stopped
feeding.
This
delay
action
permits
the
welding
wire
to
burn
back
to
a
point
where
it
neither
sticks
to
the
work-
piece
or
the
contact
tube.
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
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.
Open
front
access
door
and
locate
P03
2.
Locate
potentiometer
R32
in
upper
left
corner
of
PC3.
3.
Rotate
R32
clockwise
to
increase
burnback
time.
4.
Close
and
secure
front
access
door.
SECTION
5
SEQUENCE
OF
OPERATION
5-1.
INPUT
SIGNALS
FROM ROBOT
CONTROL
5-2.
OUTPUT
SIGNALS
FROM
ROBOT
INTER-
UNIT
FACE
The
robot
interface
receives
input
signals
for
contactor
The
robot
interface
sends
output
signals
to
the
robot
control,
gas
control,
jog,
welding
volts,
peak
amperage,
control
unit
for
current
sense,
arc
failure,
and
torch
inductance,
torch
positioning,
and
wire
speed.
positioning.
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
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
equip
ment
every
three
months
as
follows:
j~
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
inspect
ing,
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
to
be
performed
only
by
qualified
persons.
1.
Repair
or
replace,
as
required,
all
hose
and
cable;
give
particular
attention
to
frayed
and
cracked
in
sulation
and
areas
where
it
enters
equipment.
2.
Remove
grease
and
grime
from
components;
moisture
from
electrical
parts
and
cable.
OM-138
426
Page
7
6-2.
OVERLOAD
PROTECTION
6-3.
REINSTALLATION
OF
HUB
ASSEMBLY
(Fig.
ure
6-1)
~
WARNING:
ELECTRIC
SHOCK
can
kill.
If
it
becomes
necessary
to
replace
part
or
all
of
the
hub
Do
not
touch
live
electrical
parts.
assembly,
reinstall
the
new
hub
assembly
as
follows:
Shut
down
unit,
welding
power
source,
and
1.
Remove
hub
assembly
from
hub
support,
and
robot,
and
disconnect
input
power
employing
disassemble
discarding
worn
or
broken
parts.
lockout/tagging
procedures
before
inspect
ing,
maintaining,
or
servicing.
2.
Slide
the
following
items
onto
the
hub
support
shaft
in
order
given.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
a.
Spring
removing
fuses
from
fuse
box,
or
shutting
off
and
b.
Keyed
Washer
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
c.
Fiber
Washer
INCORRECT
FUSE
can
damage
unit.
d.
Brake
Washer
Use
only
replacement
fuse
of
same
size,
type,
and
rating
(see
Parts
List).
e.
Hub
f.
Brake
Washer
A.
Wire
Drive
Motor
Circuit
Breaker
CB1
(Figure
g.
Fiber
Washer
4-1)
a
WARNING:
Read
and
follow
safety
informa-
3.
Align
keyway,
and
insert
hub
support
shaft
tion
at
beginning
of
Section
6-2
before
pro-
through
selected
hole
in
hub
support.
ceeding.
4.
Install
hex
nutonto
hub
support
shaft.
Tighten
hex
nut
until
a
slight
drag
is
felt
while
turning
hub.
Circuit
breaker
CB1
protects
the
wire
drive
motor
from
5.
Install
welding
wire
according
to
Section
3-8.
overload.
If
CB1
opens,
the
wire
feed
motor
would
stop.
Should
a
motor
overload
occur
and
CB1
open,
proceed
64.
DISPLAY
BOARD
PC4
METER
CHECK
(Fig.
as
follows:
ure
6-2)
1.
Check
for
jammed
wire
or
clogged
gun
liner,
and
Check
points
are
provided
on
the
display
board
PC4
for
correct
problem.
If
wire
jams
often,
replace
gun
checking
power
supply
and
input
command
for
the
me
liner.
ters.
2.
If
motor
overload
occurs
often,
repair
or
replace
WARNING:
ELECTRIC
SHOCK
can
kill.
wire
drive
motor.
Do
not
touch
live
electrical
parts.
3.
Check
for
binding
drive
gear
or
misaligned
drive
rolls,
and
correct
problem.
Be
sure
that
personnel
performing
testing
procedures
are
familiar
with
and
follow
stan
4.
Reset
circuit
breaker
by
depressing
the
button.
A
dard
safety
pra
ctices.
cooling
period
may
be
necessary
before
the
cir
cuit
breaker
can
be
reset.
Shut
down
unit
before
making
or
changing
meter
or
test
equipment
lead
connections.
5.
Resume
operation.
ELECTROSTATIC
DISCHARGE
(ESD)
can
B.
Main
Fuse
Fl
(Figure
4-1)
damage
circuit
boards.
Put
on
a
properly
grounded
wrist
strap
a
WARNING:
Read
and
follow
safety
informa-
BEFORE
handling
circuit
boards.
tion
at
beginning
of
Section
6-2
before
pro
ceeding.
Transport
all
static-sensitive
components
in
proper
static-shielding
carriers
and
pack-
Fuse
Fl
protects
the
robot
interface
from
an
internal
ages.
short
or
excessive
overload.
If
fuse
Fl
opens,
the
robot
Perform
work
only
at
a
static-safe
work
area.
interface
shuts
down.
If
the
fuse
opens,
correct
the
prob-
1.
Open
robot
interface
access
door.
lem
and
replace
Fl
as
follows:
2.
Locate
display
board
PC4.
1.
Depress
and
rotate
fuse
holder
cover
counter-
3.
Check
voltage
according
to
Figure
6-2.
clockwise.
4.
If
a
meter
power
supply
and
command
voltage
is
2.
Pull
out
fuse
with
cover
when
fuse
holder
cover
is
correct
and
the
meter
is
not
working,
replace
the
free.
meter
(see
Section
6-5
and
contact
nearest
Fac
3.
Insert
new
fuse
into
fuse
holder
cover,
tory
Authorized
Service
Station).
5.
If
the
power
supply
or
command
voltage
is
incor
4.
Install
fuse
with
fuse
holder
cover
back
into
unit.
rect,
replace
display
board
PC4
(see
Section
6-5
5.
Depress
and
rotate
fuse
holder
cover
clockwise
and
contact
nearest
Factory
Authorized
Service
until
cover
is
secure.
Station).
OM-138
426
Page
8
6-5.
CIRCUIT
BOARD
HANDLING
PRECAUTIONS
j~
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
inspect
ing,
maintaining,
or
servicing.
Lockout/tagging
procedures
consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
a
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.
Fiber
Washer
Hex
Nut
Hub
Support
Ref.
SC-127
328
Ref.
SD-Ill
838-8
Retainer
Wire
Reel
Retaining
Ring
Spanner
Nut
OPTIONAL
Spring
Keyed
Washer
Brake
Washar
Hub
Support
Shaft
Hub
Fiber
Washer
FIgure
6-1.
Hub
And
Reel
Assemblies
Input
command
For
Volts
Meter
.-O.5V
=
50V
Input
Command
For
Ammeter
-O.1V
=
bOA
Figure
6-2.
Display
Board
Meter
Checks
Power
Supply
For
Volts
Meter
And
Ammeter
0-
5VDC
OM-138
426
Page
9
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7-i.
Circuit
Diagram
For
Robot
Interface
0
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Circuit
Diagram
No.
SC-i
35
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Diagram
7-2.
Circuit
Diagram
For
Control
Board
PCi
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Diagram
7-3.
Circuit
Diagram
For
Motor
Control
Board
PC2
W
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OM-138
426
Page
12
ii
0
r
C
P
Circuit
Diagram
No.
SD-083
388-A
OM.138
426
Page
13
cn
Circuit
Diagram
No.
SB-114
483-A
Diagram
7-5.
Circuit
Diagram
For
Meter
Display
Board
PC4
POI.~RIGR~JAD
lETS
~OP
CI4IPS
P1
4.GND
9..151.J
UI
9~GND
P..ISU
Diagram
7-4.
Circuit
Diagram
For
Interface
Board
PC3
Circuit
Diagram
No.
SB-141
311
A-p
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OM-138
426
Page
14
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