Miller KA000000 Owner's manual

KA000000
Miller
Brand
Miller
Model
KA000000
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Millerfi
May
1990
FORM:
OM-136
224
MODEL:
Computer
Interface
(per
NSPR
9112)
Gas/Current
Sensing
Control
Hub
And
Spindle
Assembly
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
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.
AMiDer
Group
Ltd..
Company
P.O.
Box
1079
Appleton,
WI 54912
USA
Tel.
414-734-9821
PRINTED
IN
U.S.A
OM-136
224
5/90
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
manutactur-
Model______________________________________
ers
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
I
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.
Robot
Interface
Welding
Power
Source
Connections
3
3-5.
Robot
Interface
Robot
Control
Unit
Connections
4
3-6.
Arc
Failure
Light
Terminal
Strip
Connections
5
3-7.
Welding
Wire
Installation
5
SECTION
4
OPERATOR
CONTROLS
4-1.
Power
Switch
7
4-2.
Selector
Switch
7
4-3.
Jog
Push
Button
7
4-4.
Purge
Push
Button
7
4-5.
Voltmeter
7
4-6.
Wire
Speed
Meter
7
4-7.
Ammeter
7
4-8.
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
9
6-2.
Oveiload
Protection
9
6-3.
Reinstallation
Of
Hub
Assembly
10
6-4.
Display
Board
P04
Meter
Check
10
6-5.
Circuit
Board
Handling
Precautions
11
6-6.
Troubleshooting
11
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
Voltage
Board
PCi
15
Diagram
7-3.
Circuit
Diagram
For
Motor
Control
Board
P02
16
Diagram
7-4.
Circuit
Diagram
For
Interface
Board
PC3
18
Diagram
7-5.
Circuit
Diagram
For
Display
Board
P04
18
Diagram
7-6.
Circuit
Diagram
For
Isolation
Board
PC5
19
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,
Interface
P03
26
Figure
8-4.
Circuit
Card,
Meter
PC4
27
Figure
8-5.
Circuit
Card,
Isolation/Amplifier
PC5
28
LIST
OF
CHARTS
AND
TABLES
Table
2-1.
Specifications
1
Table
6-i.
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
various
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
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
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)
16-1/2
in.,
(419
mm)
6-1/4
in.*
(159
mm)
38
lbs.
(17
kg)
Total
61
lbs.
(27.7
kg)
Gas/Current
Sensing
Control
4-1/2
in.
(108
mm)
5-1/2
in.
(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
The
gas/current
sensing
control
contains
the
gas
valve
The
robot
interface
control
is
designed
to
interface
with
and
current
sensing
reed
relay.
an
ABB
robot
and
an
Arc
Pak
350
welding
power
source.
This
unit
provides
preselection
and
digital
display
of
These
components
function
with
the
robot
system
when
weld
volts,
wire
feed
speed,
and
amperage.
using
the
Gas
Metal
Arc
Welding
(GMAW)
process.
OM-136
224
Page
1
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
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
several
cords
supplied
for
gas/current
sens
ing
control
interconnections.
Examine
and
select
the
proper
cord
for
the
following
connections.
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.
Gas/Current
Sensing
Control
Motor
Connec
tions
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.
Align
keyways,
insert
1
4-socket
plug
from
motor
control
cord
into
matching
tree-hanging
receptacle
from
motor,
and
rotate
threaded
collar
fully
clockwise.
C.
Weld
Cable
ConnectIons
For
Electrode
Positive/Reverse
Polarity,
route
cable
from
welding
power
source
POSITIVE
weld
output
ter
minal,
through
the
gas/current
sensing
control,
to
the
wire
drive
assembly,
and
connect
cable
to
weld
cable
terminal
(see
Motor/Drive
Assembly
Owners
Manual
for
location).
D.
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
controi.
The
gas
flow
must
be
accurately
controlled
by
a
regulator/flowmeter
at
the
source.
3-4.
ROBOT
INTERFACE
-
WELDING
POWER
SOURCE
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
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
two
cords
used
for
interconnections
between
the
robot
interface
and
welding
power
source.
Examine
and
select
the
proper
cord
for
the
following
connections.
A.
REMOTE
14
ConnectIons
1.
Align
keyway,
insert
14-socket
plug
into
matching
receptacle
RC13
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
Gas/Current
Sensing
Control
Receptacle
RC9.
RC1
3
To
Welding
Power
Source,
REMOTE
14
Receptacle
Rd
5
To
Welding
Power
REMOTE
17
Receptacle
RCI
7
To
Robot
Control
Figure
3-2.
Right
Side
View
TB-hg
646
2.
Align
keyway,
insert
14-pin
plug
into
matching
re
ceptacle
on
welding
power
source,
and
rotate
threaded
collar
fully
clockwise.
OM-136
224
Page
3
B.
REMOTE
17
ConnectIons
1.
Align
keyway,
insert
17-socket
plug
into
matching
receptacle
RC15
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.
Be
sure
the
Arc
Pak
14/17
switch
is
in
the
17
position
and
that
the
MAXIMUM
GTAW
OUTPUT
control
is
in
the
440
(maximum)
position.
3-5.
ROBOT
INTERFACE
-
ROBOT
CONTROL
UNIT
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
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
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
1.
Obtain
a
proper
cord
and
24-pin
Amphenol
plug
(not
supplied).
2.
Connect
conductors
at
one
end
of
cord
to
appropri
ate
pins
in
plug.
3.
Align
keyway,
insert
24-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:
Provides
connection
to
2TA;
for
customer
use.
Socket
B:
Current
Detect
output
to
robot
control
unit
with
respect
to
Socket
D;
isolated
CR1
con
tacts
rated
1
A
at
120
VAC.
Socket
D:
Current
Detect
output
to
robot
control
unit
with
respect
to
Socket
B;
isolated
CR1
con
tacts
rated
at
1A
at
120
VAC.
Socket
E:
Contactor
Control;
+24
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
J
(Circuit
Common).
Socket
F:
Jog
Forward;
+24
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
J
(Circuit
Common).
Socket
G:
Gas
Control;
+24
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
J
(Circuit
Common).
Socket
H:
Wire
Stick
Check;
+24
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
J
(Circuit
Common).
SocketJ:
Circuit
Common
for
Sockets
E,
F,
G,
and
H;
all
circuit
voltages
referenced
to
this
point.
Socket
K:
Jog
Forward;
momentary
contact
output
to
robot
control
unit
with
respect
to
Socket
Q
(Digital
Common).
Socket
L:
Set-Up
and
Weave
Set-Up
output
to
robot
control
unit
with
respect
to
Socket
Q(Digital
Common).
Socket
M:
Weave
Set-Up
output
to
robot
control
unit
with
respect
to
Socket
0
(Digital
Common).
Socket
N:
Wire
Stick
Signal
output
to
robot
control
unit
with
respect
to
Socket
0
(Digital
Common);
indicates
wire
is
stuck
to
work;
isolated
CR2
contacts
rated
1A
at
120
VAC.
Socket
P:
Weld
Standby
output
to
robot
control
unit
with
respect
to
Socket
Q
(Digital
Common);
indicates
robot
interface
is
in
standby;
iso
lated
CR5
contacts
rated
3A
at
120
VAC.
Socket
0:
Digital
Common
for
Sockets
K,
L,
M,
N,
and
P.
Socket
A:
Inductance;
0-10
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
S
(analog
common)
equals
0-maximum
inductance.
Inductance;
analog
common
for
Socket
R.
Wire
Feed
Speed;
analog
common
for
Socket
X
(+
Wire
Feed
Speed).
Socket
X:
+
Wire
Feed
Speed;
0-10
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
W
(analog
common)
equals
0-1
000
1PM.
Socket
Y:
Arc
Volts;
analog
common
for
Socket
Z
(+
Arc
Volts).
Socket
Z:
+
Arc
Volts;
0-10
volts
dc
input
from
robot
control
unit
with
respect
to
Socket?
(analog
common)
equals
0-50
volts
dc
output.
IMPORTANT:
The
remaining
sockets
in
the
receptacle
are
not
used.
_______________________
S-0291
FIgure
3-3.
Front
View
Of
24-Socket
Amphenol
Receptacle
With
Socket
DesIgnatIons
Socket
S:
Socket
W:
OM-136
224
Page
4
3-6.
ARC
FAILURE
LIGHT
TERMINAL
STRIP
CON
NECTIONS
(Figure
3-4)
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
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
doorwhen
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
for
this
connection,
and
proceed
as
follows:
1.
For
robot
control
units
when
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.
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.
Forrobotcontrolunitswhen
115
or24vac,or24vdc
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.
3-7.
WELDING
WIRE
INSTALLATION
(FIgure
3-5)
A.
Installation
Of
Spool-Type
Wire
1.
Remove
retaining
ring.
2.
Slide
spool
of
wire
onto
hub
so
that
wire
feeds
off
bottom
of
spool.
3.
Rotate
spool
until
hole
in
spool
aligns
with
pin
in
hub.
Slide
spool
onto
hub
until
it
seats
against
back
flange
of
the
hub.
4.
Reinstall
retaining
ring
onto
hub.
B.
Installation
Of
Optional
Wire
Reel
And
Reel-
Type
Wire
1.
Remove
retaining
ring
and,
if
applicable,
wire
reel
assembly
from
hub.
2.
Lay
wire
reel
assembly
flat
on
a
table
or
floor.
Robot
Control
Unit
Robot
Interface
Common
Terminal
Weld
Alarm
Terminal
If
So
Equipped
If
So
Equipped
+24VDC
Arc
Failure
1TM
indicator
Ught
Robot
Control
Unit
Common
Terminal
Weld
Alarm
Terminal
If
So
Equipped
If
So
Equipped
To
Voitaqe
Source
(115vAC,
24VAC,
24VDC)
lsoiatlon
Relay
CR1
(~o-o
Robot
Control
Robot
Interface
+24VDC
~
Arc
Faliure
ITM
Indicator
Ught
S-0292
FIgure
3-4.
Arc
FaIlure
Light
Connections
OM-136
224
Page
5
Retaining
Ring
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
i~tate
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
sufticient
to
keep
wire
taut
and
prevent
back
SC127
308
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.
Spanner
Nut
Hub
Hub
Support
FIgure
3-5.
OptIonal
Wire
Reel
And
Reel-Type
WIre
installation
OM-136
224
Page
6
SECTION
4-
OPERATOR
CONTROLS
4-1.
POWER
SWITCH
(Figure
4-1)
Placing
the
POWER
switch
in
the
ON
position
energizes
the
robot
interlace.
The
interface
must
be
on
for
the
ro
bot
to
weld.
Placing
the
POWER
switch
in
the
OFF
posi
lion
shuts
down
the
interface.
4-2.
SELECTOR
SWITCH
(Figure
4-1)
The
SELECTOR
switch
has
three
positions:
RUN,
SET
UP~
and
SET-UP
WEAVE.
Consult
robot
Owners
Manu
al
or
robot
manufacturer
for
SELECTOR
switch
func
tions.
4-3.
JOG
PUSH
BUTTON
(Figure
4-1)
The
JOG
push
button
is
a
momentary-contact
switch.
Consult
robot
Owners
Manual
or
robot
manufacturerfor
JOG
push
button
function.
4-4.
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.
4-5.
VOLTMETER
(Figure
4-1)
The
voltmeter
displays
weld
voltage
to
the
nearest
tenth
of
a
volt
while
welding
and
preset
voltage
while
idling.
4-6.
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.
4-7.
AMMETER
(Figure
4-1)
The
ammeter
displays
weld
amperage
to
the
nearest
ampere
while
welding
and
preset
amperage
while
idling.
4-8.
INDICATOR
LIGHTS
(Figure
4-1)
There
are
five
indicator
lights
on
the
interface.
These
are
visual
indications
of
various
process
functions.
The
GAS
light
turns
on
when
the
gas
valve
is
energized
to
indicate
shielding
gas
flow.
The
CONTACTOR
light
turns
on
when
the
welding
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
3-6,
and
there
is
an
arc
outage
while
welding.
Gas
indicator
Light
Contactor
Indicator
Light
Wire
Feed
indicator
Light
Arc
Failure
Current
Indicator
Light
indicator
Light
Jog
Push
Button
Switch
Figure
4-1.
Front
Panel
Controls
Ret.
Th-119
645
OM-136
224
Page
7
Robot
Control
Unit
To
Computer
interface
Computer
interface
To
Robot
Control
Unit
SECTION
5-
SEQUENCE
OF
OPERATION
Wire Feed
Speed
0-10V
0-1000
1PM
Output
Volta
0-1OV
0-SOy
Inductance
0.iOV
0-100%
Gas
Control
Contactor
Control
Jog
Fwd.
Check
For
Wire
Stuck
Current Detect
Wire
Stuck
Output
Voltage
Shielding
Gas
Wire
Feed
Figure
5-1.
Input
And
Output
Signal
TIming
Chart
TA-094
382-A
5-1.
INPUT
SIGNALS
FROM
ROBOT
CONTROL
UNIT
(Figure
5-1)
The
robot
interface
receives
input
signals
for
contactor
control,
gas
control,
jog,
welding
volts,
wire
speed,
and
current.
It
also
receives
a
signal
to
initiate
a
check
to
see
if
the
wire
is
stuck
to
the
workpiece
at
the
end
of
the
weld.
5-2.
OUTPUT
SIGNALS
FROM
ROBOT
INTERFACE
(FIgure
5-1)
The
robot
interface
sends
output
signals
to
the
robot
control
unit
for
current
sense,
wire
stuck,
and
weld
standby.
Jog
Normal
Abnormal
OM-136
224
Page
8
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
ROUTINE
MAINTENANCE
A.
Wire
Drive
Motor
Circuit
Breaker
CB1
(Figure
4-1)
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
WARNING:
Read
and
follow
safety
informa
when
necessary.
See
Parts
List
for
part
number
of
tion
at
beginning
of
Section
6-2
before
pro
precautionary/abe/s.
C~diflg.
Usage
and
shop
conditions
determine
the
frequency
Circuit
breaker
CB1
protects
the
wire
drive
motor
from
and
type
of
maintenance.
At
minimum,
inspect
equip-
overload.
If
CB1
opens,
the
wire
feed
motorwould
stop.
ment
every
three
months
as
follows:
~
WARNING:
ELECTRIC
SHOCK
can
kill.
Should
a
motor
overload
occur
and
CB1
open,
proceed
Do
not
touch
live
electrical
parts.
as
follows:
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
1.
Check
for
jammed
wire
or
clogged
gun
liner,
and
lockout/tagging
procedures
before
inspecting,
correct
problem.
If
wire
jams
often,
replace
gun
liner.
maintaining,
or
servicing.
Lockout/tagging
procedures
consist
of
pad-
2.
If
motor
overload
occurs
often,
repairor
replace
wire
drive
motor.
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect-
3.
Check
for
binding
drive
gear
or
misaligned
drive
ing
device,
rolls,
and
correct
problem.
MOVING
PARTS
can
cause
serious
Injury.
4.
Reset
circuit
breaker
by
depressing
the
button.
A
Keep
away
from
moving
parts.
cooling
period
may
be
necessary
before
the
circuit
HOT
SURFACES
can
cause
severe
burns,
breaker
can
be
reset.
Allow
cooling
period
before
servicing.
5.
Resume
operation.
Maintenance
to
be
performed
only
by
qualified
persons.
B.
Main
Fuse
Fl
(Figure
4-1)
1.
Repair
or
replace,
as
required,
all
hose
and
cable;
give
particular
attention
to
frayed
and
cracked
insu
a
WARNING:
Read
and
follow
safety
informa
lation
and
areas
where
it
enters
equipment.
tlon
at
beginning
of
Section
6-2
before
pro-
2.
Remove
grease
and
grime
from
components;
mois-
Ceedlng.
ture
from
electrical
parts
and
cable.
6-2.
OVERLOAD
PROTECTION
Fuse
Fl
protects
the
robot
interface
from
an
internal
short
or
excessive
overload.
if
fuse
Fl
opens,
the
robot
a
WARNING:
ELECTRIC
SHOCK
can
kill,
interface
shuts
down.
if
the
fuse
opens,
correct
the
prob
Do
not
touch
live
electrical
parts.
lem
and
replace
Fl
as
follows:
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
1.
Depress
and
rotate
fuse
holder
cover
counterclock
lockout/tagging
procedures
before
inspecting,
wise.
maintaining,
or
servicing.
Lockout/tagging
procedures
consist
of
pad-
2.
Pull
out
fuse
with
cover
when
fuse
holder
cover
is
locking
line
disconnect
switch
in
open
position,
free.
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect-
3.
Insert
new
fuse
into
fuse
holder
cover.
ing
device.
4.
Install
fuse
with
fuse
holder
cover
back
into
unit.
INCORRECT
FUSE
can
damage
unit.
Use
only
replacement
fuse
of
same
size,
type,
5.
Depress
and
rotate
fuse
holder
cover
clockwise
until
and
rating
(see
Parts
List).
cover
is
secure.
OM-136
224
Page
9
Retaining
Ring
Wire
Retainer
Figure
6-1.
Hub
And
Reel
Assemblies
6-3.
REINSTALLATION
OF
HUB
ASSEMBLY
(Fig
ure
6-1)
If
it
becomes
necessary
to
replace
part
or
all
of
the
hub
assembly,
reinstall
the
new
hub
assembly
as
follows:
1.
Remove
hub
assembly
from
hub
support,
and
disas
semble
discarding
worn
or
broken
parts.
2.
Slide
the
following
items
onto
the
hub
support
shaft
in
order
given.
a.
Spring
b.
Keyed
Washer
c.
Fiber
Washer
d.
Brake
Washer
e.
Hub
f.
Brake
Washer
g.
Fiber
Washer
3.
Align
keyway,
and
insert
hub
support
shaft
through
selected
hole
in
hub
support.
4~
Install
hex
nut
onto
hub
support
shaft.
Tighten
hex
nut
until
a
slight
drag
is
felt
while
turning
hub.
5.
Install
welding
wire
according
to
Section
3-7.
6-4.
DISPLAY
BOARD
PC4
METER
CHECK
(Figure
6-2)
Check
points
are
provided
on
the
display
board
PC4
for
checking
power
supply
and
input
command
for
the
me
ters.
4A
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Be
sure
that
personnel
performing
testing
procedures
are
familiar
with
and
follow
standard
safety
practices.
Shut
down
unit
before
making
or
changing
meter
or
test
equipment
lead
connections.
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
electronic
components.
Put
on
a
properly
grounded
wrist
strap
BEFORE
handling
circuit
boards.
Transport
all
static-sensitive
components
in
proper
static-shielding
carriers
and
packages.
Perform
work
only
at
a
static-safe
work
area.
1.
Open
robot
interface
access
door.
2.
Locate
display
board
PC4.
3.
Check
voltage
according
to
Figure
6-2.
Wire
Reel
Spanner
Nut
Hub
Support
Shaft
OPTIONAL
Keyed
Washer
Brake
Washer
Hub
Fiber
Fiber
Washer
Brake
Washer
Ref.
SC-127
328
Hub
Support
OM-136
224
Page
10
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
or
command
voltage
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
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.
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.
6-6.
TROUBLESHOOTING
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
inspecting
or
servicing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removingfusesfromfuse
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.
REAR
VIEW
OF
DISPLAY
BOARD
PC4
Input
Command
For
Volts
Meter
O.5V
=
50V
Ref.
SD-117
838-B
FIgure
6-2.
DIsplay
Board
Meter
Checks
OM-136
224
Page
11
Table
6-1.
Troubleshooting
TROUBLE
PROBABLE
CAUSE
REMEDY
No
weld
output
control.
~
Output
control
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
robot
command
voltage
at
Isolation
Board
PC5.
Command
voltage
should
be
0-10
vdc
be
tween
sockets
Y
(common)
and
Z
at
RC1
7.
Robot
moveswhenwelding
wire
is
stuck.
Wire
stick
connection.
Be
sure
that
leads
from
robot
are
connected
to
sockets
H
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
CB1,
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
PC4to
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
rized
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
PC7
at
wire
drive
motor
not
working.
Replace
PC7
(see
motor/drive
assembly
Own
ers
Manual).
OM-136
224
Page
12
6-7.
USE
OF
INDICATOR
LIGHTS
FOR
TROUBLESHOOTING
Gas
flows:
Check
gas
valve
operation
and
gas
line
for
leaks.
Check
interface
board
PC3.
Contacotor
open:
Check
interconnecting
cords.
Check
interface
board
PC3.
Contactor
open:
System
normal
(off).
Wire
does
not
feed:
System
normal
(off).
Arc
started:
Replace
reed
relay.
~Off
No
arc:
System
normal
(oft).
Arc
started:
Check
signal
from
robot.
Signal
should
be
24
vdc
between
terminals
1TL
and
1TM.
Check
display
board
PC4.
Gas
flows:
System
normal
(on.)
On
-a
Gas
Indicator
Light
~
Off
Gas
does
not
flow
Check
gas
valve
operation.
Gas
does
not
flow
System
normal
(off).
l~r
Contactor
closed:
System
normal
(on).
On
~
Contactor
Indicator
Light
~
Oft
I
I
Contactor
closed:
Check
display
board
PC4.
On
a
Wire
Feed
Indicator
Light
~
Off
~,
¶1!
1~
Wire
feeds:
Wire
does
not
feed:
System
normal
(on).
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
On
I!
Arc
started:
System
normal
(on).
Current
Indicator
Light
No
arc:
Replace
reed
relay.
No
arc:
Check
weld
parameters.
On
~
Arc
Failure
Indicator
Light
~
Off
I
I
No
arc:
Normal
during
idling.
~1~
Arc
started:
Normal
while
welding.
OM-136
224
Page
13
0
C.)
0)
r.)
F~)
D) CD
4..
A
B
CDL
F
PH
J
AL
N
~
0
01~JC
~.O
0
0
0
0
0
0
/
~
~
6/
~
~
A
B
CD
FF6
H
J
AL
N
21
0
0
O~JI
0
0
0
O~J~
0
0
0
~5
iap
~o
~
/09
/6
69
__
C/)
m
C)
-4
0
z
m
ii
C)
-I
C)
I
0
G)
U)
REPC~E
J.I~EP
NI
F~
CC
~ATI~1.
Circuit
Diagram
No.
SC-i
36
029
0
PCI)
Y~
Diagram
7-1.
Circuit
Diagram
For
Robot
Interface
Diagram
7-2.
Circuit
Diagram
For
Voltage
Board
PCi
Circuit
Diagram
No.
C-131
262
@1
'
/L/J
_flPL
fi
__IIL_JlllflIL
ALL
WAV~~
AT
300
IPN-~CT~
Rt~r1IJ~G
ALL
VQTAOES
~A~P~)
WITH
RE~~C1
TO
Ct1I~4
POINT
~
EX~PT
H.
IA9.~E
H
WITH
RE~ECT
TO
POINT
~K.
Diagram
7-3.
Circuit
Diagram
For
Motor
Control
Board
PC2
U
x
fi~
R
OM-136
224
Page
16
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34

Miller KA000000 Owner's manual

KA000000
Miller
Brand
Miller
Model
KA000000
Category
Welding System
Type
Owner's manual
This manual is also suitable for
Download PDF
report

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI

Related papers

Other documents