Miller ROBOT INTERFACE NSPR 8933 Owner's manual

ROBOT INTERFACE NSPR 8933
Miller
Brand
Miller
Model
ROBOT INTERFACE NSPR 8933
Type
Owner's manual

This manual is also suitable for

Millerfi
April
1990
FORM:
OM-135
583
MODEL:
Robot
Interface
(per
NSPR
8933)
Gas/Current
Sensing
Control
Hub
And
Spindle
FiLE
COPY
RETURN
TO
FOLDER
OWNERS
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
materiai
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
aliow
untrained
persons
to
instaii,
operate,
or
maintain
this
unit.
Contact
your
distributor
If
you
do
not
fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
MLIr
Grc~
Ltd.,
CcfT~any
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
PRINTED
IN
U.S.A
u-I.
LIMITED
WARRANTY
EFFECTIVE:
FEBRUARY
1,
1990
1.U
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
~~1
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
hereof,
Miller
Electric
Mfg.
Co.,
Appleton,
Wisconsin
warrants
to
its
Distributor/Dealer
that
all
new
arid
unused
Equipment
fur
nished
by
Miller
is
free
from
defect
in
workmanship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
ac
cessories
and
other
items
are
sold
subject
to
the
warranties
of
their
respective
manufacturers,
if
any.
All
engines
are
warran
tied
by
their
manufacturer
fortwo
years
from
date
of
original
pur
chase,
except
Deutz
engines
which
have
a
one
year,
2000
hour
warranty.
Except
as
specified
below,
Millers
warranty
does
not
apply
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLER
MATIC
parts
that
come
in
contact
with
the
welding
wire
includ
ing
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
defect
in
workmanship
or
material.
Miller
shall
be
required
to
honorwarranty
claims
on
warranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
........
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor
1
year
only)
4.
All
welding
guns,
feeder/guns
and
torches
,
.
. .
90
days
5.
All
other
Millermatic
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive
of
labor
.
60
days
7.
Batteries
6
months
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
of
the
date
of
such
failure.
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of Millers
breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be,
at
Millers
option
(1)
repair
or
(2)
replacement
or,
where
authorized
in
writing
by
Miller
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
Miller
service
station
or
(4)
payment
of
or
credit
for
the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacementwill
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB,
at
a
MfLLER
authorized
serv
ice
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
claimant
on
the
war
ranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRE
SENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PRO
VISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FUR
NISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTI
MATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPE
RIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CON
SUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
ii
I
OhI135
583
4190
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use
the
following
spaces
to
record
the
Model
Designa
age
that
may
have
occurred
dunng
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
manufactur-
Model
_______________________________
ers
Transportation
Department.
Senal
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
3
3-4.
Weld
Control
Motor
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
5
3-8.
Preset
Controls
5
3-9.
Peak
Amps/Inductance
Control
6
3-10.
Pref
low,
Postf
low,
And
Bumback
Time
Presets
6
3-11.
Welding
Wire
Installation
6
SECTION
4OPERATOR
CONTROLS
4-1.
Power
Switch
7
4-2.
Jog
Push
Buttons
7
4-3.
Purge
Push
Button
7
4-4.
Voltmeter
7
4-5.
Wire
Speed
Meter
7
4-6.
Peak
Amps/inductance
Meter
7
4-7.
Indicator
Lights
7
SECTION
5
SEQUENCE
OF
OPERATION
5-1.
Input
Signals
From
Robot
Control
Unit
8
5-2.
Output
Signals
From
Robot
Interface
8
Section
No.
Page
No.
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
Routine
Maintenance
8
6-2.
Overload
Protection
9
6-3.
Reinstallation
Of
Hub
Assembly
9
6-4.
Display
Board
PC4
Meter
Check
9
6-5.
Circuit
Board
Handling
Precautions
10
6-6.
Troubleshooting
ii
6-7.
Use
Of
indicator
Lights
For
Troubleshooting
13
SECTION
7
ELECTRICAL
DIAGRAMS
Diagram
7-1.
Circuit
Diagram
For
Robot
Interface
14
Diagram
7-2.
Circuit
Diagram
For
Vo~age
Control
Board
PCi
15
Diagram
7-3.
Circuit
Diagram
For
Motor
Control
Board
PC2
16
Diagram
7-4.
Circuit
Diagram
For
Interface
Board
PC3
17
Diagram
7-5.
Circuit
Diagram
For
Meter
Display
Board
PC4
18
Diagram
7-6.
Circuit
Diagram
For
Isolation
Board
PC5
18
Diagram
7-7.
Circuit
Diagram
For
Isolation
Amp
Board
PC6
19
Diagram
7-8.
Circuit
Diagram
For
Preset
Board
PC7
19
Diagram
7-9.
Circuit
Diagram
For
Gas/Current
Sensing
Control
20
Diagram
7-10.
Circuit
Diagram
For
Gas/Current
Sensing
Control
Feedback
Board
PC6
20
SECTION
8
PARTS
LIST
Figure
8-1.
Circuit
Card,
Voltage
Control
PCi
24
Figure
8-2.
Circuit
Card,
Motor
Speed
Digital
PC2
26
Figure
8-3.
Circuit
Card,
Relay
PC3
28
Figure
8-4.
Circuit
Card,
Meter
PC4
30
Figure
8-5.
Circuit
Card,
Isolation/Ampflifier
PC5
31
Figure
8-6.
Circuit
Card,
Isolation
PC6
32
Figure
8-7.
Circuit
Card,
Feedback
PC6
34
LIST
OF
CHARTS
AND
TABLES
Table
2-1.
Specifications
I
Table
6-1.
Troubleshooting
12
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
vailous
Ia-
used
throughout
this
manual
to
call
attention
to
and
iden
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
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
sen
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
~I1
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
Owners
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
22-1/2
in.
(572
mm)
16-1/2in.
(419
mm)
6~l/4in.*
(159
mm)
38
lbs.
(17
kg)
Total
61
lbs.
(27.7
kg)
Gas/Current
Sensing
Control
4-1/2in.
(108
mm)
5-1/2in.
(140
mm)
10-1/2
in.
(267
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
amperage
or
inductance.
The
robot
interface
control
is
designed
to
interface
with
a
The
gas/current
sensing
control
contains
the
gas
valve,
shunt,
and
current
sensing
reed
relay.
GMF
robot
and
an
Arc
Pak
350,
Deltaweld,
Maxtron,
or
Pulstar
450
welding
power
source.
This
unit
provides
These
components
function
with
the
robot
system
when
digital
display
of
weld
volts,wire
feed
speed,
and
peak
using
the
Gas
Metal
Arc
Welding
(GMAW)
process.
OM-135
583
Page
1
3-3.
GAS/CURRENT
SENSING
CONTROL
INTER
CONNECTIONS
(Figure
3.2)
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
inter
connections.
115
Volts
AC/Contactor
Control
Receptacle
RC13
Voltage
Sensing
Receptacle
RCI2
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
sensing
control,
and
rotate
threaded
collar
fully
clockwise.
B.
Weld
Cable
ConnectIons
For
Electrode
Positive/Reverse
Polanty,
route
cable
from
welding
power
source
POSITIVE
weld
output
ter
minal
to
the
gas/current
sensing
control,
through
the
cur
rent
sensing
reed
relay,
to
the
shunt.
Connect
the
cable
to
the
shunt.
Using
a
second
weld
cable,
connect
to
the
remaining
end
of
the
shunt,
route
the
cable
to
the
wire
drive
assembly,
and
connect
cable
to
weld
cable
termi
nal
(see
Motor/Drive
Assembly
Owners
Manual
for
lo
cation).
C.
Gas
ConnectIons
Connect
hose
from
gas
regulator/f
lowmeter
(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.
3-4.
WELD
CONTROL
-
MOTOR
CONNECTIONS
(FIgure
3-2)
1.
Align
keyways,
insert
14-pin
plug
from
motor
cord
into
matching
receptacle
RC7
on
weld
control,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyways,
insert
14-socket
plug
from
motor
control
cord
into
matching
free-hanging
receptacle
from
motor,
and
rotate
threaded
collar
fully
clock
wise.
3-5.
ROBOT
INTERFACE
WELDING
POWER
SOURCE
CONNECTIONS
(FIgures
3-2
And
3-3)
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
locko
ut/tagging
procedures
before
making
inter
connections.
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
four
cords
supplied
for
interconnection
be
tween
the
robot
interface
and
welding
power
source.
Ex
amine
cords
and
select
proper
cord
for
the
connection.
T8.119
646
A.
REMOTE
14
ConnectIons
Figure
3-2.
RIght
Side
View
1.
Align
keyway,
insert
14-socket
plug
into
matching
receptacle
RC13
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
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.
Motor
Control
Receptacle
RC7
Location
Gas/Current
Sensing
Control
Receptacle
RC9
Strain
Relief
Receptacle
RC16
For
Arc
Pak
Models
Robot
lntedace
Z
Receptacle
RC17
OM-135
583
Page
3
2.
Align
keyway,
insert
14-pin
plug
into
matching
re
ceptacle
on
welding
power
source,
and
rotate
threaded
collar
fully
clockwise.
B.
REMOTE
17
ConnectIons
1.
Align
keyway,
insert
17-socket
plug
into
matching
receptacle
RC1
6
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyway,
insert
17-pin
plug
into
matching
re
ceptacle
on
welding
power
source,
and
rotate
thread
collar
fully
clockwise.
C.
REMOTE
10
ConnectIons
1.
Align
keyway,
insert
10-socket
plug
into
matching
receptacle
RC1
5
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyway,
insert
plug
into
matching
receptacle
on
the
welding
power
source,
and
rotate
threaded
collar
fully
clockwise.
Figure
3-3.
Voltage
Sensing
Connections
At
Wire
Drive
Assembly
Voltage
Sensing
Connections
Align
keyway,
insert
4-socket
plug
into
matching
re
ceptacle
RCI2
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Connect
lead
with
ring
terminal
to
wire
drive
assem
bly,
along
with
the
weld
cable
from
the
welding
pow
er
source,
as
shown
in
Figure
3-3.
3.
Connect
lead
with
clamp
to
the
workpiece.
3-6.
ROBOT
INTERFACE
-
ROBOT
CONTROL
UNIT
CONNECTIONS
(Figure
3-2)
1.
Obtain
a
proper
cord
and
37-pin
Amphenol
plug
(not
supplied).
2.
Connect
conductors
at
one
end
of
cord
to
appropri
ate
sockets
in
plug.
3.
Align
keyway,
insert
37-pin
plug
into
matching
re
ceptacle
on
robot
interface,
and
rotate
threaded
col
lar
fully
clockwise.
4.
Route
and
connect
conductors
at
remaining
end
of
cord
to
the
robot
control
unit.
The
input
and
output
signals
at
the
sockets
of
receptacle
RC17
by
means
of
the
robot
interface
control
circuitry
are
as
follows:
Socket
A:
+
Arc
Volts;
0-10
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
A
(ana
log
common)
equals
0-50
volts
dc
output.
Socket
B:
Arc
Volts;
analog
common
for
Socket
B
(+
Arc
Volts).
Socket
C:
+
Peak
Amps;
0-10
volts
dc
input
from
ro
bot
control
unit
with
respect
to
Socket
0
(analog
common)
equals
0-500
amperes
dc
output.
Socket
0:
Peak
Amps;
analog
common
for
Socket
C
(+
Peak
Amps).
Socket
E:
+
Wire
Feed
Speed;
0-10
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
F
(analog
common)
equals
0-1000
1PM.
Socket
F:
Wire
Feed
Speed;
analog
common
for
Socket
E
(
Wire
Feed
Speed).
Socket
K:
Voltage
Feedback;
analog
common
for
Socket
J.
Socket
L:
Current
Feedback;
500A
(weld
current)
=
1
OV
(feedback
signal)
with
respect
to
Socket
M.
Socket
M:
Current
Feedback:
analog
common
for
Socket
L.
Wire
Stuck
Signal;
return
for
Socket
P.
Wire
Stuck
Signal
output
to
robot
control
unit
with
respect
to
Socket
N;
indicates
wire
is
stuck
to
work.
Socket
R:
ContactorControl;
contact
closure
from
ro
bot
control
unit
with
respect
to
Socket
a,b
(Circuit
Common).
Socket
5:
Gas
Control;
contact
closure
from
robot
control
unit
with
respect
to
Socketa,b
(Cir
cult
Common).
Socket
U:
Jog
Forward;
contact
closure
from
robot
control
unit
with
respect
to
Socket
a,b
(Cir
cuit
Common).
Socket
V:
Jog
Reverse;
contact
closure
from
robot
control
unit
with
respect
to
Socket
a,b
(Cir
cuit
Common).
Voltage
Sensing
Lead
Ring
Terminal
Location
Nut
Lock
Washer
Flat
Washer
Weld
Cable
Lug
Location
Wire
Drive
Assembly
D.
1.
TA.Io9oQ3
Socket
J:
Voltage
Feedback;
1
OOV
(arc
voftage)
=
1
OV
(feedback
signal)
with
respect
to
Socket
K.
Socket
N:
Socket
P:
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
inter
connections.
Lockout/tagging
procedures
consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
arid
red-tag9ing
circuit
breaker
or
other
disconnect
ing
device.
OM-135583Page4
Weld
Alarm
Terminal
/
If
So
Equipped
Arc
Failure
2TM
indicator
Light
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.
Robot
Control
Unit
Robot
interface
Robot
Control
Unit
Sockets
a,b:
Circuit
Common
for
Sockets
A,
S,
U,
and
V;
all
circuit
voltages
referenced
to
this
point.
Socket
d:
Current
Detect
output
to
robot
control
unit
with
respect
to
Socket
m.
Socket
h:
Weld
Standby
output
to
robot
control
unit
with
respect
to
Socket
m
(Digital
Com
mon);
indicates
robot
interface
is
in
stand
by.
This
is
a
normally-open
contact.
Socket
m:
Digital
Common
for
Sockets
d
and
h.
Socket
r:
+24
volts
dc.
Socket
s:
Chassis
ground.
IMPORTANT:
The
remaining
sockets
in
the
receptacle
are
not
used.
Common
Terminal
It
So
Equipped
\
CR
3-7.
ARC
FAILURE
LIGHT
TERMINAL
STRIP
CON-
+24vDc
NECTIONS
(Figure
3-4)
There
are
two
terminal
strips
inside
the
robot
interface
for
control
connections.
Loosen
screws
on
strain
relief
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,
and
close
and
secure
front
panel
access
door
when
pro
cedure
is
finished.
.
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
Common
Terminal
Weld
Alarm
Terminal
ii
So
Equipped
~
/
If
So
Equipped
\
CR2
J
(
~b1
I_~or
for
this
connection,
and
proceed
as
follows:
(11~A~1~~)
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
isoiatlon
Relay
CR1
(
~D-
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
inter-
Robot
Control
Robot
Interface
connections.
CR1
2TL
Lockout/tagging
procedures
consist
of
padlock-
ing
line
disconnect
switch
in
open
position,
re
+24vDc
(
~-o~
~o
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
1.
For
robot
control
units
when
24
vdc
is
used
(Figure
3-4):
~
i
Arc
Failure
c~I7
2TM
Indicator
Light
a.
Route
cord
through
strain
relief
on
right
side
panel
of
robot
interface,
and
make
proper
con
Figure
3-4.
Arc
Failure
LIght
Connection:
nections
to
2TL
and
2TM.
3-8.
PRESET
CONTROLS
(FIgure
3-5)
b.
Route
and
connect
remaining
end
of
cord
to
weld
alarm
terminal
and
ground
connection
at
the
robot
control
unit.
Theunitisshippedfromthefactorywithpresetvaluesof
wire
feed
speed
and
voltage
(300
1pm
at
20
volts).
If
a
value
is
not
preset
for
the
voltage
and
wire
feed
speed,
c.
Connect
+24
vdc
to
common
relay
contact
ter-
minal.
the
robot
system
will
not
start.
To
change
preset
values,
proceed
as
follows:
2.
Forrobotcontrolunitswhen
ll5or24vac,or24vdc
is
used
(Figure
3-4):
Ak
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
a.
Route
cord
through
strain
relief
on
right
side
panel
of
robot
interface,
and
make
proper
con-
r~~we!is
appUe
Ito the
weld
control
during
the
~
nections
to
2TL
and
2TM.
1.
Open
interface
control
door.
OM-135
583
Page
5
2.
Locate
Preset
circuit
board
PC7
on
inside
of
door
(see
Figure
3-5).
3.
Locate
WFS
Preset
R3
and
Voltage
Preset
R4
on
PC7.
4.
While
watching
VOLTS
and
WIRE
FEED
meters,
adjust
potentiometers
to
desired
preset
conditions.
5.
Close
and
secure
interface
control
door.
Figure
3-5.
Preset
Board
PC7
3-9.
PEAK
AMPS/INDUCTANCE
CONTROL
F1~:
A-135
511
This
unit
is
shipped
for
use
with
a
two
analog
channel
robot.
This
means
that
peak
amperage
or
inductance
can
be
set
at
the
interface
using
potentiometer
R4.
R4
is
located
beneath
the
snap-in
blank
on
the
lower
left
cor
ner
of
the
interface
front
door.
This
unit
can
be
used
with
a
three
channel
robot
where
the
robot
control
sets
peak
amperage.
A
jumper
link
must
be
moved
on
terminal
strip
iT
to
accomodate
the
three
channel
robot.
4A
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
changing
in
ternal
connections.
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.
1.
Open
interface
control door.
Locate
terminal
strip
1
T.
2.
Move
the
jumper
from
between
1
TE
and
1
TF
to
be
tween
lTD
and
ITE.
3.
Close
and
secure
interface
control
door.
3-10.
PREFLOW,
POSTFLOW,
AND
BURNBACK
TIME
PRESETS
On
the
left
side
of
the
interface
control
there
are
three
snap-in
blanks.
Beneath
these
snap-in
blanks
are
screwdriver
adjustable
potentiometers.
The
top
poten
tiometer
sets
preflow
time
from
0
to
6
seconds.
The
middle
potentiometer
sets
postf
low
time
from
0
to
6
sec
onds.
The
bottom
potentiometer
sets
burnback
time
from
approximately
5
to
250
milliseconds.
3-11.
WELDING
WIRE
INSTALLATION
(FIgure
3-6)
Retaining
Ring
Wire
Retainer
SC-127
308
Figure
3-6.
Optional
Wire
Reel
And
Reel-Type
Wire
Installation
A.
Installation
Of
Spool-Type
Wire
1.
Remove
retaining
ring.
2.
Slide
spool
of
wire
onto
hub
so
that
wire
feeds
off
bottom
of
spool.
3.
Rotate
spool
until
hole
in
spool
aligns
with
pin
in
hub.
Slide
spool
onto
hub
until
it
seats
against
back
flange
of
the
hub.
4.
Reinstall
retaining
ring
onto
hub.
B.
Installation
Of
Optional
Wire
Reel
And
Reel-
Type
Wire
1.
Remove
retaining
ring
and,
if
applicable,
wire
reel
assembly
from
hub.
2.
Lay
wire
reel
assembly
fiat
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.
Wire
Reel
Spanner
Nut
Hub
Hub:
OM-135
583
Page
6
SECTION
4
OPERATOR
CONTROLS
Voltmeter
Wire
Speed
Peak
Ampel
Fuse
1PM
Meter
Inductance
Meter
(See
Section
6-2)
Circuit
Breaker
_________
~
/_~
Section
6-2)
/
Power
Switch
Gas
Indicator
Purge
Push
Light
~
I
~
~
r.~\\\
Button
Switch
Contactor
Jog
REV
Push
Button
indicator
Ught
Arc
Failure
Switch
Location
Jog
FWD
Push
Wire
Feed
Current
indicator
Ugh
Button
Location
Indicator
Ught
Indicator
Ught
Ref.
TB-hg
645
Figure
4-1.
Front
Panel
Controls
4-1.
POWER
SWITCH
(Figure
4.1)
4-6.
PEAK
AMPS/INDUCTANCE
METER
(Figure
4-1)
Placing
the
POWER
switch
in
the
ON
position
energizes
the
robot
interface.
The
interface
must
be
on
for
the
~
When
used
with
the
Puistar
welding
power
source,
the
bot
to
weld.
Placing
the
POWER
switch
in
the
OFF
P05i-
meter
displays
preset
peak
weld
amperage
to
the
near
tion
shuts
down
the
interface.
est
ampere
while
welding
and
idling.
4-2.
JOG
PUSH
BUTTONS
(Figure
4-1)
When
used
with
the
Arc
Pak
welding
power
source,
in-
The
JOG
FWD
and
JOG
REV
push
buttons
are
momen-
ductance
is
displayed
in
percentage.
tary-contact
switches.
4-7.
INDICATOR LIGHTS
(Figure
4.1)
4-3.
PURGE
PUSH
BUTTON
(Figure
4-1)
There
are
five
indicator
lights
on
the
interface.
These
are
The
PURGE
push
button
is
a
momentary-contact
visual
indications
of
various
process
functions.
switch.
This
switch
energizes
the
gas
solenoid
and
purges
the
shielding
gas
line
of
the
gun.
The
PURGE
The
GAS
light
turns
on
when
the
gas
valve
is
energized
push
button
allows
the
flow
meter
to
be
adjusted
without
to
indicate
shielding
gas
flow.
energizing
the
welding
circuit.
The
CONTACTOR
light
turns
on
when
the
welding
pow
er
source
contactor
is
energized
to
indicate
that
weld
4-4.
VOLTMETER
(Figure
41)
output
is
available.
The
voltmeter
displays
weld
voltage
to
the
nearest
tenth
The
WIRE FEED
light
turns
on
when
the
wire
drive
motor
of
a
volt
while
welding
and
preset
voltage
while
idling.
is
energized
to
indicate
that
wire
is
feeding.
4-5.
WIRE
SPEED
METER
(Figure
4-1)
The
CURRENT
light
turns
on
when
the
current
detect
relay
is
energized
to
indicate
that
an
arc
is
established.
The
wire
speed
meter
displays
preset
wire
feed
speed
to
the
nearest
inch
perminute
while
welding
and
idling.
Ac-
The
ARC
FAILURE
light
turns
on
only
when
properly
tual
and
preset
wire
feed
speed
are
the
same
due
to
the
connected
according
to
instructions
in
Section
3-7,
and
wire
feed
speed
feedback
circuit.
there
is
an
arc
outage
while
welding.
OM-135
583
Page
7
Wire
Feed
Speed
0by
=
0-1000
ipm
Output
Volts
0-by
=
0-50V
Peak
Amps
0-500
Amps
Output
(Po=.~
On.
Sl.ndby
Weld
Control
J
Corrsnl
D.i~l
To
Robot
StoCb
5-i.
INPUT
SIGNALS
FROM
ROBOT
CONTROL
UNIT
(Figure
5-1)
The
robot
interface
receives
input
signals
for
contactor
control,
gas
control,
jog,
welding
volts,
and
wire
speed.
5-2.
OUTPUT
SIGNALS
FROM
ROBOT
INTER
FACE
(Figure
5-1)
The
robot
interface
sends
output
signals
to
the
robot
control
unit
for
current
sense,
wire
stuck,
and
weld
standby.
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
Pacts
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:
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
IWe
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
inspecting,
maintaining,
or
sericing.
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.
SECTION
5-
SEQUENCE
OF
OPERATION
Robot
To
Weld
Control
Jog
Adanc.
Jog
PaEiSCt
0as
On
Arc
On
Oo(pot
VoIt.gs
Shi.ldIflg
Gas
WI..
F..d
Normal
Abnormal
Figure
5-1.
Input
And
Output
Signal
liming
Chart
Ref.
TA~095
014
OM-135
583
Page
8
MOVING
PARTS
can
cause
serious
injury,
interface
shuts
down.
If
the
fuse
opens,
correct
the
prob
Keep
away
from
moving
parts.
lem
and
replace
Fl
as
follows:
HOT
SURFACES
can
cause
severe
burns.
1.
Depress
and
rotate
fuse
holder
cover
counterclock
wise.
Allow
cooling
period
before
servicing.
Maintenance
to
be
performed
only
by
qualified
2.
Pull
out
fuse
with
cover
when
fuse
holder
cover
is
free.
persons.
3.
Insert
new
fuse
into
fuse
holder
cover.
1.
Repair
or
replace,
as
required,
all
hose and
cable;
give
particular
attention
to
frayed
and
cracked
insu-
4.
Install
fuse
with
fuse
holder
cover
back
into
unit.
lation
and
areas
where
it
enters
equipment.
5.
Depressandrotatefuseholdercoverclockwiseuntil
2.
Remove
grease
and
grime
from
components;
mois-
cover
is
secure.
ture
from
electrical
parts
and
cable.
6-3.
REINSTALLATION
OF
HUB
ASSEMBLY
(Fig.
6-2.
OVERLOAD
PROTECTION
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,
weldmg
power
source,
and
1.
Remove
hub
assembly
from
hub
support,
and
disas
robot,
and
disconnect
input
power
employing
semble
discarding
worn
or
broken
parts.
lockout/tagging
procedures
before
inspecting,
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
Useonlyreplacement
fuse
of
same
size,
type,
e.
Hub
and
rating
(see
Parts
List).
f.
Brake
Washer
A.
Wire
Drive
Motor
Circuit
Breaker
CB1
(Figure
g.
Fiber
Washer
4.1)
a
WARNING:
Read
and
follow
safety
lnforma-
3.
Align
keyway,
and
insert
hub
support
shaft
through
tlon
at
beginning
of
Section
6-2
before
pro-
selected
hole
in
hub
support.
ceeding.
4.
Install
hex
nut
onto
hub
support
shaft.
Tighten
hex
Circuit
breaker
CB1
protects
the
wire
drive
motor
from
nut
until
a
slight
drag
is
felt
while
turning
hub.
overload.
If
CB1
opens,
the
wire
feed
motorwould
stop.
5.
Install
welding
wire
according
to
Section
3-11.
Should
a
motor
overload
occur
and
CB1
open,
proceed
as
follows:
6-4.
DISPLAY
BOARD
PC4
METER
CHECK
(Figure
6-2)
1.
Check
for
jammed
wire
or
clogged
gun
liner,
and
correct
problem.
If
wire
jams
often,
replace
gun
liner.
Check
points
are
provided
on
the
display
board
PC4
for
checking
power
supply
and
input
command
for
the
me-
2.
If
motoroverload
occurs
often,
repairor
replace
wire
ters.
drive
motor.
~
WARNING:
ELECTRIC
SHOCK
can
kill.
3.
Check
for
binding
drive
gear
or
misaligned
drive
Do
not
touch
live
electrical
parts.
rolls,
and
correct
problem.
Be
sure
that
personnel
performing
testing
4.
Reset
circuit
breaker
by depressing
the
button.
A
procedures
are
familiar
with
and
follow
standard
cooling
period
may
be
necessary
before
the
circuit
safety
practices.
breaker
can
be
reset.
Shut
down
unit
before
making
or
changing
5.
Resume
operation.
meter
or
test
equipment
lead
connections.
ELECTROSTATIC
DISCHARGE
(ESD)
can
B.
Main
Fuse
Fl
(Figure
4-1)
damage
electronic
components.
a
WARNING:
Read
and
follow
safety
lnforma-
Put
on
a
properly
grounded
wrist
strap
tlon
at
beginning
of
SectIon
6-2
before
pro-
BEFORE
handling
circuit
boards.
ceeding.
Transport
all
static-sensitive
components
in
Fuse
Fl
protects
the
robot
interface
from
an
internal
proper
static-shielding
carriers
and
packages.
short
or
excessive
overload.
If
fuse
Fl
opens,
the
robot
Perform
work
only
at
a
static-safe
work
area.
aM-i
35
583
Page
9
Ring
Figure
6-1.
Hub
And
Reel
Assemblies
Input
Command
For
Volts
Meter
-O.5V
50V
Hex
Nut
Hub
Support
Ref.
SC-127
328
1.
Open
robot
interface
access
door.
2.
Locate
display
board
PC4.
3.
Check
voltage
according
to
Figure
6-2.
4.
If
a
meter
power
supply
and
command
voltage
is
correct
and
the
meter
is
not
working,
replace
the
me
ter
(see
Section
6-5
and
contact
nearest
Factory
Au
thorized
Service
Station).
5.
If
the
power
supply
orcommand
vo~age
is
incorrect,
replace
display
board
PC4
(see
Section
6-5
and
contact
nearest
Factory
Authorized
Service
Sta
tion).
6-5.
CIRCUIT
BOARD
HANDLING
PRECAUTIONS
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,
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.
Wire
Reel
Spanner
Nut
OPTIONAL
Keyed
Washer
Brake
Washer
Hub
Hub
Support
Shaft
Fiber
Washer
Fiber
Washer
input
Command
For
Wire
Rear
View
Of
Speed
1PM
Meter
Display
Board
PC4
0.8V
=
800
1PM
in
put
Command
For
Ammeter
-0.1V
=
100A
FIgure
6-2.
DIsplay
Board
Meter
Checks
Power
Supply
For
Volts
Meter
And
Ammeter
0-
SVDC
OM-135
583
Page
10
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
minima!
pre
ssure
and
gentle
move
ment
when
disconnecting
or
connecting
board
plugs
and
removing
or
Inst
ailing
board.
6-6.
TROUBLESHOOTING
4~
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
locko
ut/tagging
procedures
before
inspecting
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.
Troubleshooting
to
be
performed
only
by
qualified
persons.
It
is
assumed
that
the
unit
was
properly
installed
accord
ing
to
Section
3
of
this
manual,
the
operator
is
familiar
with
the
function
of
controls,
the
robot
interface
was
working
properly,
and
that
the
trouble
is
not
related
to
the
welding
process.
The
following
table
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
robot
interface.
Use
this
table
in
conjunction
with
the
circuit
diagram
while
performing
troubleshooting
proce
dures.
If
the
trouble
is
not
remedied
after
performing
these
procedures,
contact
the
nearest
Factory
Author
ized
Service
Station.
In
all
cases
of
equipment
malfunc
tion,
strictly
follow
the
manufacturers
procedures
and
instructions.
a
OM-135
583
Pa9e
11
Table
6-1.
TroubleshootIng
TROUBLE
PROBABLE
CAUSE
REMEDY
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.
Replace
PCI
(see
Section
6-5
and
contact
near
est
Factory
Authorized
Service
Station).
Incorrect
robot
command
voltage.
Check
robotcommand
voltage
at
Isolation
Board
PC5.
Command
voltage
should
be
0-10
vdc
be
tween
sockets
A
(common)
and
B
at
Rd
7.
Incorrect
robot
peak
command
cur-
rent.
Check
robot
peak
command
current
at
Isolation
Board
PC5.
Peak
command
current
should
be
0-10
vdc
between
sockets
C
and
0
(common)
at
RC17.
Robot
moveswhenwelding
wire
is
stuck.
Wire
stick
connection.
Be
sure
that
leads
from
robot
are
connected
to
sockets
P
and
N
at
RC17.
Wire
speed
(1PM)
meter
goes
to
zero.
Incorrect
robot
command
voltage.
Check
robot
command
voltage
at
Motor
Board
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
and
contact
near
est
Factory
Authorized
Service
Station).
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
CBI,
and
reset
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
and
contact
nearest
Factory
Autho
nzed
Service
Station).
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
and
contact
nearest
Factory
Authorized
Service
Station).
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.
Relay
CR1
not
working.
Replace
CR1.
Motor
Board
PC2
not
working.
Replace
PC2
(see
Section
6-5
and
contact
near
est
Factory
Authorized
Service
Station).
Wire
feeds
at
maximum
only.
Tach
board
at
wire
drive
motor
not
working.
Replace
tach
board
(see
motor/drive
assembly
Owners
Manual).
OM-135
583
Page
12
6-7.
USE
OF
INDICATOR
LIGHTS
FOR
TROUBLESHOOTING
1~
Gas
does
not
flow
Check
gas
valve
operation.
Contactor
closed:
Check
display
board
PC4.
Contactor
open:
System
normal
(off).
DOff
Wire
does
not
feed:
System
normal
(off).
On~
Arc
started:
System
normal
(on).
4
No
arc:
Replace
reed
relay.
Arc
started:
Replace
reed
relay.
Arc
started:
Check
signal
from
robot.
Signal
should
be
24
vdc
between
terminals
2TL
and
2TM.
Check
display
board
PC4.
On
Gas
Indicator
Light
Gas
flows:
System
normal
(on.)
F
Gas
flows:
Check
gas
valve
operation
and
gas
line
for
leaks.
Check
interface
board
PC3.
Off
Gas
does
not
flow
System
normal
(Off):
On
~
Contactor
Indicator
Light
Off
I
I
Contactor
closed:
System
normal
(on).
On~
Contacotor
open:
Check
interconnecting
cords.
Check
interface
board
PC3.
Wire
feeds:
System
normal
(on).
Wire
Feed
Indicator
Light
4
Wire
does
not
feed:
Check
circuit
breaker
CB1
Check
relay
CR1.
Check
interface
board
PC3.
Wire
feeds:
Check
input
signal
from
robot
to
motor
board
PC2.
Signal
should
be
0-10
vdc
between
pins
K
and
B
(common)
at
RC5.
Check
motor
board
PC2
Current
Indicator
Ught
Off
No
arc:
System
normal
(off).
No
arc:
Check
weld
parameters.
On
~
Arc
Failure
Indicator
Light
Off
I
I
No
arc:
Normal
during
idling.
3
Arc
started:
Normal
white
welding.
OM-135
583
Page
13
r~
~a
~
Q1(fltL
~Ia
0.
Pta
S
StI
lOt
.0IOt
0.
11(10
Ttt
lO1ll0(
/7
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31
0
0
0
0
0
0
Circuit
Diagram
No.
D-135
855-A
U)
m
C~)
-t
0
z
1
m
r
m
C)
-I
z
C)
r
C
C)
z
U)
0
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0
0.a
a
a
a
a
F/I/l
0.
Il
I
0.
0.
/7
It
~
1/
0.
Diagram
7-1.
Circuit
Diagram
For
Robot
interface
0
3
U
(ii
cD
(.3
SI
cD
DIagram
7-2.
CIrcuit
Diagram
For
Voltage
Control
Board
PCi
PO~G~
lETS
P~
OIIPS
*50
4-.ISV.
11.ISV
*51
9.*j55
4ISV
*52
e..15v.
4-t~v
053
~..*I5V.
4-lEO
*54
-
4-15V.
4.-055
Circuit
Diagram
No.
C-135
518
fiQIIOUIMOIIJI
fiLiLJ
fi
/J/1
I
I
fiJ1J1
_JIIIJL_JlIlltll.
Circuit
Diagram
No.
SD-083
388-A
Diagram
7-3.
CircuIt
Diagram
For
Motor
Control
Board
PC2
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Miller ROBOT INTERFACE NSPR 8933 Owner's manual

ROBOT INTERFACE NSPR 8933
Miller
Brand
Miller
Model
ROBOT INTERFACE NSPR 8933
Type
Owner's manual
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