Miller KD529373 Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

cover 7/93 – Ref. ST-157 095 PRINTED IN USA
1994 MILLER Electric Mfg. Co.
Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit.
Call your distributor if you do not understand
the directions.
Give this manual to the operator.
For help, call your distributor
or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912 414-734-9821
OWNER’S
MANUAL
August 1994 Form: OM-154 145B
Robotic Interface Control
Gas/Current Sensing Control
sr1.1.1 2/94
ARC WELDING SAFETY PRECAUTIONS
WARNING
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR.
In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The
safety information given below is only a summary of the more complete safety information that will be found in the
Safety Standards listed on the next page. Read and follow all Safety Standards.
HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY
QUALIFIED PEOPLE.
ARC WELDING can be hazardous.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
1. Do not touch live electrical parts.
2. Wear dry, hole-free insulating gloves and body protection.
3. Insulate yourself from work and ground using dry insulating
mats or covers big enough to prevent any physical contact with
the work or ground.
4. Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 1910.147 (see Safety Standards).
5. Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
6. Always verify the supply ground – check and be sure that input
power cord ground wire is properly connected to ground
terminal in disconnect box or that cord plug is connected to a
properly grounded receptacle outlet.
7. When making input connections, attach proper grounding
conductor first – double-check connections.
8. Frequently inspect input power cord for damage or bare wiring –
replace cord immediately if damaged – bare wiring can kill.
9. Turn off all equipment when not in use.
10. Do not use worn, damaged, undersized, or poorly spliced
cables.
11. Do not drape cables over your body.
12. If earth grounding of the workpiece is required, ground it directly
with a separate cable – do not use work clamp or work cable.
13. Do not touch electrode if you are in contact with the work,
ground, or another electrode from a different machine.
14. Use only well-maintained equipment. Repair or replace
damaged parts at once. Maintain unit according to manual.
15. Wear a safety harness if working above floor level.
16. Keep all panels and covers securely in place.
17. Clamp work cable with good metal-to-metal contact to
workpiece or worktable as near the weld as practical.
ARC RAYS can burn eyes and skin;
NOISE can damage hearing; FLYING
SLAG OR SPARKS can injure eyes.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Noise from some processes
can damage hearing. Chipping, grinding, and welds
cooling throw off pieces of metal or slag.
NOISE
1. Use approved ear plugs or ear muffs if noise level is high.
ARC RAYS
2. Wear a welding helmet fitted with a proper shade of filter to
protect your face and eyes when welding or watching (see ANSI
Z49.1 and Z87.1 listed in Safety Standards).
3. Wear approved safety glasses with side shields.
4. Use protective screens or barriers to protect others from flash
and glare; warn others not to watch the arc.
5. Wear protective clothing made from durable, flame-resistant
material (wool and leather) and foot protection.
FUMES AND GASES can be hazardous
to your health.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
1. Keep your head out of the fumes. Do not breathe the fumes.
2. If inside, ventilate the area and/or use exhaust at the arc to
remove welding fumes and gases.
3. If ventilation is poor, use an approved air-supplied respirator.
4. Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instruction for metals, consumables, coatings,
cleaners, and degreasers.
5. Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained
watchperson nearby. Welding fumes and gases can displace
air and lower the oxygen level causing injury or death. Be sure
the breathing air is safe.
6. Do not weld in locations near degreasing, cleaning, or spraying
operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
7. Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and if necessary, while
wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
1. Protect compressed gas cylinders from excessive heat,
mechanical shocks, slag, open flames, sparks, and arcs.
2. Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
3. Keep cylinders away from any welding or other electrical
circuits.
4. Never drape a welding torch over a gas cylinder.
5. Never allow a welding electrode to touch any cylinder.
6. Never weld on a pressurized cylinder – explosion will result.
7. Use only correct shielding gas cylinders, regulators, hoses, and
fittings designed for the specific application; maintain them and
associated parts in good condition.
8. Turn face away from valve outlet when opening cylinder valve.
9. Keep protective cap in place over valve except when cylinder is
in use or connected for use.
10. Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
sr1.1.1 2/94
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly
off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal
objects can cause sparks, explosion, overheating, or
fire. Check and be sure the area is safe before doing
any welding.
1. Protect yourself and others from flying sparks and hot metal.
2. Do not weld where flying sparks can strike flammable material.
3. Remove all flammables within 35 ft (10.7 m) of the welding arc.
If this is not possible, tightly cover them with approved covers.
4. Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
5. Watch for fire, and keep a fire extinguisher nearby.
6. Be aware that welding on a ceiling, floor, bulkhead, or partition
can cause fire on the hidden side.
7. Do not weld on closed containers such as tanks, drums, or
pipes, unless they are properly prepared according to AWS
F4.1 (see Safety Standards).
8. Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long,
possibly unknown paths and causing electric shock and fire
hazards.
9. Do not use welder to thaw frozen pipes.
10. Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
11. Wear oil-free protective garments such as leather gloves,
heavy shirt, cuffless trousers, high shoes, and a cap.
12. Remove any combustibles, such as a butane lighter or
matches, from your person before doing any welding.
WARNING
ENGINES can be hazardous.
ENGINE EXHAUST GASES can kill.
Engines produce harmful exhaust gases.
1. Use equipment outside in open, well-ventilated areas.
2. If used in a closed area, vent engine exhaust outside and
away from any building air intakes.
ENGINE FUEL can cause fire or
explosion.
Engine fuel is highly flammable.
1. Stop engine and let it cool off before checking or adding fuel.
2. Do not add fuel while smoking or if unit is near any sparks or
open flames.
3. Do not overfill tank – allow room for fuel to expand.
4. Do not spill fuel. If fuel is spilled, clean up before starting
engine.
MOVING PARTS can cause injury.
Moving parts, such as fans, rotors, and belts can
cut fingers and hands and catch loose clothing.
1. Keep all doors, panels, covers, and guards closed and
securely in place.
2. Stop engine before installing or connecting unit.
3. Have only qualified people remove guards or covers for
maintenance and troubleshooting as necessary.
4. To prevent accidental starting during servicing, disconnect
negative (–) battery cable from battery.
5. Keep hands, hair, loose clothing, and tools away from moving
parts.
6. Reinstall panels or guards and close doors when servicing is
finished and before starting engine.
SPARKS can cause BATTERY GASES
TO EXPLODE; BATTERY ACID can
burn eyes and skin.
Batteries contain acid and generate explosive
gases.
1. Always wear a face shield when working on a battery.
2. Stop engine before disconnecting or connecting battery
cables.
3. Do not allow tools to cause sparks when working on a battery.
4. Do not use welder to charge batteries or jump start vehicles.
5. Observe correct polarity (+ and –) on batteries.
STEAM AND PRESSURIZED HOT
COOLANT can burn face, eyes, and
skin.
It is best to check coolant level when engine is cold
to avoid scalding.
1. If the engine is warm and checking is needed, follow steps 2
and 3.
2. Wear safety glasses and gloves and put a rag over cap.
3. Turn cap slightly and let pressure escape slowly before
completely removing cap.
PRINCIPAL SAFETY STANDARDS
Safety in Welding and Cutting
, ANSI Standard Z49.1, from American
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
Safety and Health Standards
, OSHA 29 CFR 1910, from Superinten-
dent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances
, Ameri-
can Welding Society Standard AWS F4.1, from American Welding So-
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126
National Electrical Code
, NFPA Standard 70, from National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
Safe Handling of Compressed Gases in Cylinders
, CGA Pamphlet
P-1, from Compressed Gas Association, 1235 Jefferson Davis High-
way, Suite 501, Arlington, VA 22202.
Code for Safety in Welding and Cutting
, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale Bou-
levard, Rexdale, Ontario, Canada M9W 1R3.
S
afe Practices For Occupation And Educational Eye And Face Protec-
tion
, ANSI Standard Z87.1, from American National Standards Insti-
tute, 1430 Broadway, New York, NY 10018.
Cutting And Welding Processes
, NFPA Standard 51B, from National
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
OM-154 145B – 8/94
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. General Information And Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Safety Alert Symbol And Signal Words 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – SPECIFICATIONS
2-1. Description 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION
3-1. Site Selection 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Equipment Installation 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Setting Dip Switches On DVC Board PC8 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Burnback Voltage And Wire Stick DIP Switch On Interface Board PC1 4. . . . . . . . . . . . . . . . .
3-5. Yaskawa/Motoman Robot Control Unit – Robot Interface Set Up 5. . . . . . . . . . . . . . . . . . . . . .
3-6. Hitachi Robot Control Unit – Robot Interface Set Up 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Panasonic Robot Control Unit – Robot Interface Set Up 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Automatix Robot Control Unit – Robot Interface Set Up 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. GMF Robot Control Unit – Robot Interface Set Up 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. ABB Robot Control Unit – Robot Interface Set Up 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Kawasaki Robot Control Unit – Robot Interface Set Up 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12. SMIC Robot Control Unit – Robot Interface Set Up 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13. Gas/Current Sensing Control Interconnections 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14. Voltage Sensing Connections 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-15. Robot Interface – Welding Power Source Connections 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16. Connection For Constant Nonpulse Synergic Welding 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-17. Welding Wire Installation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATOR CONTROLS
4-1. Power Switch And Pilot Light 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Jog Push Buttons 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Purge Push Button 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Voltmeter 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Wire Speed Meter 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Ammeter 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Indicator Lights 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Preflow Control 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Postflow Control 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Burnback Time Control 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Burnback Voltage Control 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Selector Switch 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Manual Controls 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Robotic Interface Command Signals 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – OPTIONAL RCSP-R OPERATOR CONTROLS
5-1. Pulse Parameters 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Wire Size Select Switch And Standard Mode Indicator Light 18. . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Wire Size Indicator Lights 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Wire Type Select Switch 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Recommended Shielding Gas Indicator Lights 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. No Program Indicator Light 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – SEQUENCE OF OPERATION
6-1. Maxtron 450 Control Settings For Welding Processes 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Optional RCSP-R Gas Metal Arc Welding-Pulsed (GMAW-P) 21. . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Shutting Down 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – MAINTENANCE & TROUBLESHOOTING
7-1. Routine Maintenance 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Overload Protection 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Reinstallation Of Hub Assembly 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Circuit Board Handling Precautions 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Troubleshooting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Use Of Indicator Lights For Troubleshooting 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 – ELECTRICAL DIAGRAMS
Diagram 8-1. Circuit Diagram For Robotic Interface Control 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-2. Circuit Diagram For Analog Channel Board PC4 30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-3. Circuit Diagram For Interface Board PC1 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-4. Circuit Diagram For DVC Board PC8 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-5. Circuit Diagram For Motor Board PC6 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-6. Circuit Diagram For Power Supply Board PC5 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-7. Circuit Diagram For Isolation Board PC2 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-8. Circuit Diagram For Display Board PC7 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-9. Circuit Diagram For Filter Board PC9 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-10. Circuit Diagram For Gas/Current Sensing Control 39. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-11. Circuit Diagram For Optional RCSP-R Panel 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-12. Circuit Diagram For Feedback Board PC10 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-13. Circuit Diagram For Optional RCSP-R Offset/Supply Board PC5 41. . . . . . . . . . . . . .
Diagram 8-14. Circuit Diagram For Selector Board PC6 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-15. Circuit Diagram For Optional RCSP-R Interface Board PC1 42. . . . . . . . . . . . . . . . . .
Diagram 8-16. Wiring Diagram For Robotic Interface Control 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-17. Wiring Diagram For Gas/Current Sensing Control 46. . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 8-18. Wiring Diagram For Optional RCSP-R Panel 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 – PARTS LIST
Figure 9-1. Main Assembly 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-2. Control Panel w/Components 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-3. Door Assembly 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9-4. Control Box, Gas Current 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF CHARTS AND TABLES
Chart 3-1. Interface Board DIP Switch Settings For Burnback Voltage Control
And Wire Stick Circuitry 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 3-2. Welding Operation Control By Type Of Mode Selection 5. . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 3-3. Analog Channel Board DIP Switch Settings For 2 Channel Robot 5. . . . . . . . . . . . . . . . .
Chart 3-4. Analog Channel Board DIP Switch Settings For 3 Channel Robot 5. . . . . . . . . . . . . . . . .
Chart 5-1. RCSP-R Modes And Weld Parameters 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 5-1. Synergic Pulse Panel Welding Schedules 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 7-1. Robot Interface Troubleshooting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 7-1. Robot Interface Troubleshooting (Continued) 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 7-2. Optional RCSP-R Troubleshooting 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-154 145 Page 1
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. GENERAL INFORMATION AND SAFETY
A. General
Information presented in this manual and on various la-
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and trou-
bleshooting which should be read, understood, and fol-
lowed for the safe and effective use of this equipment.
B. Safety
The installation, operation, maintenance, and trouble-
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be
installed, operated, and maintained only by qualified
persons in accordance with this manual and all safety
precautions listed in the Arc Welding Safety Precau-
tions.
1-2. SAFETY ALERT SYMBOL AND SIGNAL
WORDS
The following safety alert symbol and signal words are
used throughout this manual to call attention to and
identify different levels of hazard and special instruc-
tions.
This safety alert symbol is used with the signal
words WARNING and CAUTION to call atten-
tion to the safety statements.
WARNING statements identify procedures or
practices which must be followed to avoid seri-
ous personal injury or loss of life.
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
IMPORTANT
statements identify special instructions
necessary for the most efficient operation of this equip-
ment.
SECTION 2 – SPECIFICATIONS
2-1. DESCRIPTION
The robotic interface control is designed to interface a
Maxtron 450 or Deltaweld welding power source to a
welding robot. This unit provides digital display of weld
volts,wire feed speed, and amperage.
The gas/current sensing control contains the gas valve,
current sensing reed relay, and shunt.
These components function with the robot system when
using the Gas Metal Arc Welding (GMAW) and Gas Met-
al Arc Welding - Pulsed Arc (GMAW-P) processes.
The optional RCSP-R panel is a synergic control de-
signed to be used with the Maxtron 450 welding power
source, robot interface, and the robot system. The unit is
designed for Gas Metal Arc Welding (GMAW) in both
nonpulsed and pulsed dc arc welding modes. The unit is
shipped ready for pulsed welding.
The panel is considered a synergic control because
welding parameters which determine arc power and arc
length are programmed for wire type and size selections
to allow adjustment at two controls rather than individual
controls for each parameter. If pulse welding, arc power
parameters are wire feed speed, background amper-
age, peak amperage, pulse frequency, and pulse width;
arc length is a fine tuning of pulse frequency. If non-
pulse welding, arc power parameters are wire feed
speed, arc voltage, and inductance; arc length is a fine
tuning of arc voltage.
When used with its associated equipment, the optional
RCSP-R panel allows the operator to set welding pa-
rameters for optimum welding conditions in a majority of
situations using various types and sizes of welding wire
and shielding gases.
OM-154 145 Page 2
Inches Millimeters
A 21-7/8 556
B 13-3/4 349
C3 76
D 2-1/2 63.5
E 3-1/2 88.9
F 4-1/2 114
G 10-11/16 275
ST-157 095 / ST-080 486-C
9-1/2 in.
(241 mm)
19 in.
(482 mm)
22 in.
(599 mm)
25-3/4 in.
(654 mm)
26-1/2 in.
(673 mm)
Opening For
Receptacle Kit
Installation
10-1/2 in.
(267 mm)
3/8 in.
(10 mm)
7-1/2 in.
(191 mm)
8-3/4 in.
(222 mm)
5/8 in.
(16 mm)
9/32 in. (7 mm)
Dia. 4 Holes
13-1/4 in.
(367 mm)
14 in.
(356 mm)
4 in. (102 mm)
A
B
C
D
G
F
E
Overall Dimensions And
Mounting Hole Locations
3/8 in.
(10 mm)
1-1/2 in.
(38 mm)
5/16 in. (7.9 mm)
Dia. 4 Holes
(7 mm) Dia.
6 Holes
9/32 in.
Figure 2-1. Dimensional Views
OM-154 145 Page 3
SECTION 3 – INSTALLATION
3-1. SITE SELECTION
Select an installation site which provides the following:
1. Correct input power supply (see unit rating label)
2. Shielding gas supply (if applicable)
3. 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.
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. Hub Support
5. 10 ft. (3 m) Weld Control – Welding Power Source
Interconnecting Cords
6. 10 ft. (3 m) 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 ca-
pable of supporting the weight of the equipment.
2. The lead lengths of the cords supplied with the
equipment will limit the area in which the equipment
can be located. Some cords can be extended by us-
ing 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. Two weld output cables must be routed to the Gas/
Current Sensing control.
5. Welding wire must be routed so that it does not con-
tact the weld control or any other grounded equip-
ment.
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.
D. Hub Installation (Figure 3-1)
The hub assembly is supplied with the robot interface.
Remove the hub assembly from the shipping carton,
and install it as follows:
4. Remove hex nut from end of hub support shaft.
5. Align keyway and insert hub support shaft through
selected hole in hub support. Hole selection in hub
support depends on wire spool size. Be sure the
brake washers are properly seated in the hub.
6. Reinstall hex nut onto support shaft. Tighten hex nut
until a slight drag is felt while turning hub.
7. Install welding wire according to Section 3-17.
ST-126 870-A
Hub Support Shaft
Retaining Ring
Brake Washer
Hex
Nut
Hub Assembly
Fiber Washer
Figure 3-1. Hub Assembly Installation
OM-154 145 Page 4
DELTAWELD 300
DELTAWELD 451, 450
DELTAWELD 651, 650
MAXTRON 300, 400
MAXTRON 450
XMT 200/300
ARC PAK 350
SHOPMASTER 300
DIMENSION 400
S2 S1
DVC SWITCH SETTINGS
S-150 864-C
PULSTAR 450
12 12 34 5
ON ON ON
OONON
OONON
ON ON
ON ON ON
ON ON ON
ON ON ON
ON ON ON
ON ∆∆ ON
O – On For Optional Soft Start. Turn Off S1 -3.
– On For Optional Hot Start.
ON
Figure 3-2. DVC DIP Switch Setting Label
3-3. SETTING DIP SWITCHES ON DVC BOARD
PC8 (Figure 3-2)
DIP switches S1 and S2 on DVC Board PC8 allow set-
ting the proper command signal voltage level for control-
ling voltage output at a welding power source. To
change factory set position of DIP switches from a Delta-
weld 451 to another welding power source, 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/tagging procedures before setting
DIP switches.
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. Loosen screws and open control panel door.
2. Locate DVC Board PC8 in lower left portion on
rear panel inside the interface.
3. Set position of DIP switches S1 and S2 according
to label inside interface and Figure 3-2 for ap-
propriate welding power source.
4. Close and secure door.
CAUTION: INCORRECT DVC BOARD DIP
SWITCH POSITION can cause equipment
malfunction.
DVC DIP switch is factory set for operation
with Deltaweld 451 welding power source.
See Figure 3-2 for DVC DIP switch setting when
using another welding power source.
3-4. BURNBACK VOLTAGE AND WIRE STICK DIP
SWITCH ON INTERFACE BOARD PC1
DIP switch S1 on the Interface Board allows enabling or
disabling the burnback voltage front panel control and
wire stick circuitry. To change factory set position of
switches, 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/tagging procedures before setting
DIP switches.
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. Loosen screws and open control panel door.
2. Locate Interface Board in right center portion on
rear panel inside the interface.
OM-154 145 Page 5
3. Set position of switches according to Chart 3-1
for enabling or disabling the burnback voltage
control or wire stick circuitry.
4. Close and secure door.
Chart 3-1. Interface Board DIP Switch Settings For
Burnback Voltage Control And Wire Stick Circuitry
BURNBACK
12
OFF ON
ON OFF
FUNCTION
DIP SWITCH S1
WIRE STICK
ENABLE DISABLE ENABLE DISABLE
VOLTAGE
CONTROL
CIRCUITRY
3-5. YASKAWA/MOTOMAN ROBOT CONTROL
UNIT – ROBOT INTERFACE SET UP
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 setting
DIP switches or making interconnections.
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.
A. Setting DIP Switch On Analog Channel Board
(Chart 3-2)
IMPORTANT:
Recommended mode selection for 2
channel Yaskawa/Motoman robot is Selector Switch
and Manual Inductance; mode selection for 3 channel
robot is Selector Switch (see Chart 3-2 and Chart 3-3 or
Chart 3-4). When using the selector switch, the inner
settings apply to all robot models except ABB which
uses the outer settings.
DIP switch S1 on Analog Channel Board PC4 allows
setting robot interface control function for all automatic,
all manual, selector switch, preset, or manual induc-
tance for cases where a third analog channel is not avail-
able at the robot control (see Chart 3-2). To change fac-
tory set position of the DIP switch from all automatic
(switches No. 1 thru 5 all OFF), proceed as follows:
1. Loosen screws and open control panel door.
2. Locate Analog Channel Board PC4 in right side
portion of base inside the interface.
3. Set switches No. 1 thru 5 of DIP switch S1 for de-
sired mode selection and the available robot
channels (see Chart 3-3 or Chart 3-4).
4. Close and secure door.
Chart 3-2. Welding Operation Control By Type Of
Mode Selection
MODE WELDING OPERATION
SELECTION CONTROL
PROGRAM DATA FROM ROBOT CONTROL
SETS WELDING PARAMETERS.
ROBOT INTERFACE FRONT PANEL CON-
TROLS SET WELDING PARAMETERS.
AUTOMATIC – SAME AS ABOVE.
MANUAL – SAME AS ABOVE.
SET UP – WELDING OPERATION DRY RUN
USING A SIMULATED CURRENT DETECT
SIGNAL.
SIMILAR TO RUN-IN FUNCTION USING
FRONT PANEL CONTROLS TO SET WELD-
ING PARAMETERS UNTIL ROBOT CON-
TROL DETECTS WELD CURRENT AND
SWITCHES TO PROGRAM DATA WELDING
PARAMETERS.
AUTOMATIC – SAME AS ABOVE.
MANUAL – SAME AS ABOVE.
SET UP – SAME AS ABOVE.
AUTOMATIC
MANUAL
SELECTOR
SWITCH
PRESET
SELECTOR
SWITCH AND
PRESET
Chart 3-3. Analog Channel Board DIP Switch Set-
tings For 2 Channel Robot
AUTOMATIC
12 34 5
OFF OFF OFF OFF OFF
OFF OFF OFF OFF ON
ON OFF ON OFF ON
MODE
DIP SWITCH S1
MANUAL INDUCTANCE*
AUTOMATIC
OFF ON ON OFF ON
ON ON ON OFF ON
SELECTOR SWITCH
MANUAL INDUCTANCE*
PRESET
MANUAL INDUCTANCE*
MANUAL INDUCTANCE*
SELECTOR SWITCH
AND PRESET
SELECTION
OFF OFF ON ON ON
MANUAL
*Inductance only functions with a Maxtron 450 welding power source.
Chart 3-4. Analog Channel Board DIP Switch Set-
tings For 3 Channel Robot
AUTOMATIC
12 34 5
OFF OFF OFF OFF OFF
OFF OFF ON ON ON
ON OFF ON ON OFF
MODE
DIP SWITCH S1
SELECTOR SWITCH
PRESET
MANUAL
OFF ON ON ON OFF
SELECTOR SWITCH
AND PRESET
SELECTION
ON ON ON ON OFF
OM-154 145 Page 6
B. Connection To Receptacles On Robot Interface
(Figure 3-3)
1. Obtain two cords of the proper type and length, and
two 17-pin Amphenol plugs (not supplied).
2. Connect conductors at end of one cord to appropri-
ate pins in one plug.
3. Align keyway, insert 17-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.
5. Repeat Steps 2 thru 4 for remaining cord and plug.
The input and output signals at the sockets of receptacle
RC100 and RC101 by means of the robot interface con-
trol circuitry are as follows:
Receptacle RC100
Socket A: Voltage signal; + 0 to 10 volts = 0 to 50 volts
output.
Socket B: Common for Socket A.
Socket C: Common for Socket D.
Socket D: Wire feed speed signal; +0 to 8 volts = 0 to
800 ipm.
Socket E: Inductance signal; +0 to 10 volts.
Socket F: Common for Socket E.
Socket K: Common for Socket L.
Socket L: Weld on signal.
Socket M: Wire stick check signal positive (+).
Socket N: Wire stick check signal negative (–).
Receptacle RC101
Socket A: Current detect contact.
Socket B: Current detect contact.
Socket D: Gas shortage (terminal strip connection
provided for customer).
Socket E: Wire shortage (terminal strip connection
provided for customer).
Socket F: Circuit common for Sockets G and H.
Socket G: Jog forward command.
Socket H: Jog reverse command.
Socket K: Gas control.
Socket L: Circuit common for Socket K.
IMPORTANT:
The remaining sockets in the receptacle
are not used.
3-6. HITACHI ROBOT CONTROL UNIT – ROBOT
INTERFACE SET UP
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 setting
DIP switches or making interconnections.
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.
A. Setting DIP Switch On Analog Channel Board
(Chart 3-2)
IMPORTANT:
Recommended mode selection for Hita-
chi robot is Automatic and Manual Inductance (see
Chart 3-2 and Chart 3-3 or Chart 3-4). When using the
selector switch, the inner settings apply to all robot mod-
els except ABB which uses the outer settings.
DIP switch S1 on Analog Channel Board PC4 allows
setting robot interface control function for all automatic,
all manual, selector switch, preset, or manual induc-
tance for cases where a third analog channel is not avail-
able at the robot control (Chart 3-2). To change factory
set position of the DIP switch from all automatic
(switches No. 1 thru 5 all OFF), proceed as follows:
1. Loosen screws and open control panel door.
2. Locate Analog Channel Board PC4 in right side
portion of base inside the interface.
3. Set switches No. 1 thru 5 of DIP switch S1 for de-
sired mode selection and the available robot
channels (see Chart 3-3 or Chart 3-4).
4. Close and secure door.
B. Connection To Receptacle On Robot Interface
(Figure 3-3)
1. Obtain a cord of the proper type and length, and a
24-socket Amphenol plug (not supplied).
2. Connect conductors at end of cord to appropriate
sockets in plug.
3. Align keyway, insert plug into matching receptacle
on robot interface, and rotate threaded collar fully
clockwise.
4. Route and connect conductors at remaining end of
cord to the robot control unit.
OM-154 145 Page 7
The input and output signals at the pins of receptacle
RC100 by means of the robot interface control circuitry
are as follows:
Receptacle RC100
Pin A: Digital common of Pins B, C, D, and E.
Pin B: Weld Standby signal; contact closure with
respect to Pin A.
Pin C: Current detect signal; contact closure with
respect to Pin A.
Pin D: Arc Failure; normally-open contact.
Pin E: Wire Stuck signal; contact closure with re-
spect to Pin A.
Pin G: Cooling Water Shortage; terminal strip
connection provided for customer use.
Pin H: Low Gas; terminal strip connection pro-
vided for customer use.
Pin J: Welding Wire Shortage; terminal strip con-
nection provided for customer use.
Pin L: Circuit common for Pins M, N, and P.
Pin M: Arc On signal; starts gas flow and wire
feed, and turns on contactor.
Pin N: Jog FWD. signal.
Pin P: Jog REV. signal.
Pin R: Arc Failure; normally-closed contact.
Pin S: Terminal strip connection provided for cus-
tomer use.
Pin T: Terminal strip connection provided for cus-
tomer use.
Pin U: Terminal strip connection provided for cus-
tomer use.
Pin V: Wire feed signal positive (+).
Pin W: Common for Pins V and X.
Pin X: Arc voltage signal positive (+).
Pin Y: Arc Failure; normally-closed contact.
IMPORTANT:
The remaining pins in the receptacle are
not used.
3-7. PANASONIC ROBOT CONTROL UNIT – RO-
BOT INTERFACE SET UP
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 setting
DIP switches or making interconnections.
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.
A. Setting DIP Switch On Analog Channel Board
(Chart 3-2)
IMPORTANT:
Recommended mode selection for Pan-
asonic robot is Automatic and Manual Inductance (see
Chart 3-2 and Chart 3-3 or Chart 3-4). When using the
selector switch, the inner settings apply to all robot mod-
els except ABB which uses the outer settings.
DIP switch S1 on Analog Channel Board PC4 allows
setting robot interface control function for all automatic,
all manual, selector switch, preset, or manual induc-
tance for cases where a third analog channel is not avail-
able at the robot control (see Chart 3-2). To change fac-
tory set position of the DIP switch from all automatic
(switches No. 1 thru 5 all OFF), proceed as follows:
1. Loosen screws and open control panel door.
2. Locate Analog Channel Board PC4 in right side
portion of base inside the interface.
3. Set switches No. 1 thru 5 of DIP switch S1 for de-
sired mode selection and the available robot
channels (see Chart 3-3 or Chart 3-4).
4. Close and secure door.
B. Connection To Receptacle On Robot Interface
(Figure 3-3)
1. Obtain a cord of the proper type and length, and a
24-pin Amphenol plug (not supplied).
2. Connect conductors at end of cord to appropriate
pins in plug.
3. Align keyway, insert plug into matching receptacle
on robot interface, and rotate threaded collar 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
RC100 by means of the robot interface control circuitry
are as follows:
Receptacle RC100
Socket A: Digital common of Sockets B, C, and G.
OM-154 145 Page 8
Socket B: Arc Failure; output signal.
Socket C: Touch Sense; output signal.
Socket G: Current Detect; output signal.
Socket H: Weld Start signal; starts gas flow and wire
feed, and turns on contactor.
Socket J: Circuit common for Sockets H, K, M, P, and
R; all circuit voltages referenced to this
point.
Socket K: Gas Valve; input signal.
Socket L: Circuit common for input signals at Sock-
ets H, K, M, P, and R.
Socket M: Touch Sense; input signal.
Socket N: Circuit common for input signals at Sock-
ets H, K, M, P, and R.
Socket P: Jog FWD.; positive (+) input signal.
Socket Q: Circuit common for input signals at Sock-
ets H, K, M, P, and R.
Socket R: Jog REV.; negative (–) input signal.
Socket S: Circuit common for input signals at Sock-
ets H, K, M, P, and R.
Socket T: Voltage control positive (+) connection.
Socket U: Voltage control command connection; 0 to
10V signal = 0 to 50V output.
Socket V: Voltage control negative (–) connection.
Socket W: Wire feed speed positive (+) connection.
Socket X: Wire feed speed command connection; 0
to 8V signal = 0 to 800 ipm.
Socket Y: Wire feed speed negative (–) connection.
IMPORTANT:
The remaining sockets in the receptacle
are not used.
3-8. AUTOMATIX ROBOT CONTROL UNIT – RO-
BOT INTERFACE SET UP
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 setting
DIP switches or making interconnections.
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.
A. Setting DIP Switch On Analog Channel Board
(Chart 3-2)
IMPORTANT:
Recommended mode selection for Auto-
matix robot is Automatic (see Chart 3-2 and Chart 3-3 or
Chart 3-4). When using the selector switch, the inner
settings apply to all robot models except ABB which
uses the outer settings.
DIP switch S1 on Analog Channel Board PC4 allows
setting robot interface control function for all automatic,
all manual, selector switch, preset, or manual induc-
tance for cases where a third analog channel is not avail-
able at the robot control (see Chart 3-2). To change fac-
tory set position of the DIP switch from all automatic
(switches No. 1 thru 5 all OFF), proceed as follows:
1. Loosen screws and open control panel door.
2. Locate Analog Channel Board PC4 in right side
portion of base inside the interface.
3. Set switches No. 1 thru 5 of DIP switch S1 for de-
sired mode selection and the available robot
channels (see Chart 3-3 or Chart 3-4).
4. Close and secure door.
B. Connection To Receptacles On Robot Interface
(Figure 3-3)
1. Obtain two cords of the proper type and length, and
a 10-pin and 24-pin Amphenol plug (not supplied).
2. Connect conductors at end of one cord to appropri-
ate pins in one plug.
3. Align keyway, insert plug into matching receptacle
on robot interface, and rotate threaded collar fully
clockwise.
4. Route and connect conductors at remaining end of
cord to the robot control unit.
5. Repeat Steps 2 thru 4 for remaining cord and plug.
OM-154 145 Page 9
The input and output signals at the sockets of receptacle
RC100 and RC101 by means of the robot interface con-
trol circuitry are as follows:
Receptacle RC100
Socket A: Inductance; positive (+) signal.
Socket B: Inductance; signal common.
Socket C: Inductance command signal; 0 to 10 volts
for Arc Pak or Maxtron 450 welding power
source.
Socket F: Circuit common for Socket G.
Socket G: Jog FWD. signal.
Socket L: Circuit common.
Socket M: Weld Start positive (+) signal.
Socket N: Circuit common for Socket M.
Socket P: Wire Feed Speed; positive (+) signal.
Socket Q: Wire Feed Speed; signal common.
Socket R: Wire Feed Speed command signal; 0 to 8V
signal = 0 to 800 ipm.
Socket S: Arc Voltage; positive (+) signal.
Socket T: Arc Voltage; signal common.
Socket U: Arc Voltage command signal; 0 to 10V sig-
nal = 0 to 50V output.
Socket V: Arc Failure contact.
Socket W: Arc Failure contact.
Socket X: Current Detect contact.
Socket Y: Current Detect contact.
IMPORTANT:
The remaining sockets in the receptacle
are not used.
Receptacle RC101
Socket A: Torch Position signal with respect to Sock-
et D.
Socket D: Torch Position signal with respect to Sock-
et A.
Socket F: Circuit common for Socket G.
Socket G: Torch Position Initiate signal.
Socket I: Circuit common for Socket J.
Socket J: Gas control signal.
IMPORTANT:
The remaining sockets in the receptacle
are not used.
3-9. GMF ROBOT CONTROL UNIT – ROBOT IN-
TERFACE SET UP
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 setting
DIP switches or making interconnections.
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.
A. Setting DIP Switch On Analog Channel Board
(Chart 3-2)
IMPORTANT:
Recommended mode selection for 2
channel GMF robot is Preset and Manual Inductance;
mode selection for 3 channel robot is Preset (see
Chart 3-2 and Chart 3-3 or Chart 3-4). When using the
selector switch, the inner settings apply to all robot mod-
els except ABB which uses the outer settings.
DIP switch S1 on Analog Channel Board PC4 allows
setting robot interface control function for all automatic,
all manual, selector switch, preset, or manual induc-
tance for cases where a third analog channel is not avail-
able at the robot control (see Chart 3-2). To change fac-
tory set position of the DIP switch from all automatic
(switches No. 1 thru 5 all OFF), proceed as follows:
1. Loosen screws and open control panel door.
2. Locate Analog Channel Board PC4 in right side
portion of base inside the interface.
3. Set switches No. 1 thru 5 of DIP switch S1 for de-
sired mode selection and the available robot
channels (see Chart 3-3 or Chart 3-4).
4. Close and secure door.
B. Connection To Receptacle On Robot Interface
(Figure 3-3)
1. Obtain a cord of the proper type and length, and a
37-pin Amphenol plug (not supplied).
2. Connect conductors at end of cord to appropriate
pins in plug.
3. Align keyway, insert plug into matching receptacle
on robot interface, and rotate threaded collar fully
clockwise.
4. Route and connect conductors at remaining end of
cord to the robot control unit.
OM-154 145 Page 10
The input and output signals at the sockets of receptacle
RC100 by means of the robot interface control circuitry
are as follows:
Receptacle RC100
Socket A: Arc Volts; positive (+) signal from 0 to 10
volts dc input from robot control unit with
respect to Socket A (analog common).
Socket B: Analog common for Socket A.
Socket C: Inductance; positive (+) signal from 0 to 10
volts dc input from robot control unit with
respect to Socket D (analog common).
Socket D: Analog common for Socket C.
Socket E: Wire Feed Speed; positive (+) signal from
0 to 10 volts dc input from robot control unit
with respect to Socket F (analog common)
equals 0 to 1000 IPM from wire drive mo-
tor.
Socket F: Analog common for Socket E.
Socket J: Voltage Feedback; 100V (arc voltage)
equals 10V (feedback signal) with respect
to Socket K.
Socket K: Analog common for Socket J.
Socket L: Current Feedback; 1000A (weld current)
equals 10V (feedback signal) with respect
to Socket M.
Socket M: Analog common for Socket L.
Socket N: Wire Stuck; return for Socket P.
Socket P: Wire Stuck; output signal to robot control
unit with respect to Socket N indicating
wire is stuck to work.
Socket R: Contactor Control; contact closure from
robot control unit with respect to Sockets a
and b (circuit common).
Socket S: Gas Control; contact closure from robot
control unit with respect to Sockets a and b
(circuit common).
Socket U: Jog Forward; contact closure from robot
control unit with respect to Sockets a and b
(circuit common).
Socket V: Jog Reverse; contact closure from robot
control unit with respect to Sockets a and b
(circuit common).
Sockets a,b: Circuit common for Sockets R, S, U, and V
all circuit voltages referenced to this point.
Socket d: Current Detect; output signal to robot con-
trol unit with respect to Socket m.
Socket h: Weld Standby; output signal to robot con-
trol unit with respect to Socket m (digital
common) indicating the robot interface is
in a standby mode. This is a normally-open
contact.
Socket m: Digital common for Sockets d and h.
Socket r: +24 volts dc supply (option for Karel Con-
troller). Only plug into this socket if use of
the option is desired.
Socket s: Chassis ground.
IMPORTANT:
The remaining sockets in the receptacle
are not used.
C. External Jog Connections And Jog Speed Set-
ting
Terminal Strip 3T provides connections for an external
jog switch. To make connections to 3T, proceed as fol-
lows:
1. Loosen screws and open control panel door.
2. Locate terminal strip 3T in left side portion of base
inside the interface.
3. Remove snap-in blank from right side of inter-
face, and install a customer-supplied strain relief.
4. Route switch cord through strain relief and to ter-
minal strip 3T.
5. Strip cord jacket back enough to gain access to
switch leads for installing terminals and connect-
ing to terminal strip.
6. Strip insulation from lead ends, and crimp proper
size spade terminals on end of leads.
7. Connect terminals on end of leads to terminals
3TA and 3TB.
8. Tighten strain relief clamp. Close and secure
door.
The external jog switch provides jog forward operation
to feed welding wire from the gun, and places the unit in
manual operation. To set the jog speed, make the exter-
nal jog switch contact closure and set desired jog wire
feed speed at the WFS/ARC LENGTH control.
3-10. ABB ROBOT CONTROL UNIT – ROBOT IN-
TERFACE SET UP
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 setting
DIP switches or making interconnections.
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.
OM-154 145 Page 11
A. Setting DIP Switch On Analog Channel Board
(Chart 3-2)
IMPORTANT:
Recommended mode selection for ABB
robot is Automatic (see Chart 3-2 and Chart 3-3 or
Chart 3-4). When using the selector switch, the inner
settings apply to all robot models except ABB which
uses the outer settings.
DIP switch S1 on Analog Channel Board PC4 allows
setting robot interface control function for all automatic,
all manual, selector switch, preset, or manual induc-
tance for cases where a third analog channel is not avail-
able at the robot control (see Chart 3-2). To change fac-
tory set position of the DIP switch from all automatic
(switches No. 1 thru 5 all OFF), proceed as follows:
1. Loosen screws and open control panel door.
2. Locate Analog Channel Board PC4 in right side
portion of base inside the interface.
3. Set switches No. 1 thru 5 of DIP switch S1 for de-
sired mode selection and the available robot
channels (see Chart 3-3 or Chart 3-4).
4. Close and secure door.
B. Connection To Receptacle On Robot Interface
(Figure 3-3)
1. Obtain a cord of the proper type and length, and a
24-pin Amphenol plug (not supplied).
2. Connect conductors at end of cord to appropriate
pins in plug.
3. Align keyway, insert plug into matching receptacle
on robot interface, and rotate threaded collar 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
RC100 by means of the robot interface control circuitry
are as follows:
Receptacle RC100
Socket A: Provides connection to terminal strip in-
side robot control unit (customer use).
Socket B: Current Detect; output signal to robot con-
trol unit with respect to Socket D. Isolation
relay CR1 contacts are rated 1A at 120 V.
Socket D: Current Detect; output to robot control unit
with respect to Socket B. Isolation relay
CR1 contacts are rated 1A at 120 V.
Socket E: Contactor Control; +24 volts dc input sig-
nal from robot control unit with respect to
Socket J (circuit common).
Socket F: Jog Forward; +24 volts dc input signal from
robot control unit with respect to Socket J
(circuit common).
Socket G: Gas Control; +24 volts dc input signal from
robot control unit with respect to Socket J
(circuit common).
Socket J: Circuit common for Sockets E, F, G, and H;
all circuit voltages referenced to this point.
Socket K: Jog Forward; momentary contact closure
output signal to robot control unit with re-
spect to Socket Q (digital common).
Socket L: Set-Up; output signal to robot control unit
with respect to Socket Q (digital common).
Socket M: Weave Set-Up; output signal to robot con-
trol unit with respect to Socket Q (digital
common).
Socket N: Wire Stick Check; output signal to robot
control unit with respect to Socket Q (digi-
tal common) indicating wire is stuck to
work.
Socket P: Weld Standby; output signal to robot con-
trol unit with respect to Socket Q (digital
common) indicating robot interface is in
standby mode.
Socket Q: Digital common for output signals at Sock-
ets K, L, M, N, and P.
Socket R: Inductance; positive (+) 0 to 10 volts dc in-
put signal from robot control unit with re-
spect to Socket S (analog common).
Socket S: Analog common for Socket R.
Socket W: Analog common for Socket X.
Socket X: Wire Feed Speed; positive (+) 0 to 10 volts
dc input signal from robot control unit with
respect to Socket W (analog common)
equals 0 to 1000 ipm.
Socket Y: Analog common for Socket Z.
Socket Z: Arc Volts; positive (+) 0 to 10 volts dc input
signal from robot control unit with respect
to Socket Y (analog common) equals 0 to
50 volts dc output at welding power
source.
IMPORTANT:
The remaining sockets in the receptacle
are not used.
OM-154 145 Page 12
3-11. KAWASAKI ROBOT CONTROL UNIT – RO-
BOT INTERFACE SET UP
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 setting
DIP switches or making interconnections.
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.
A. Setting DIP Switch On Analog Channel Board
(Chart 3-2)
IMPORTANT:
Recommended mode selection for Ka-
wasaki robot is Selector Switch and Manual Inductance
(see Chart 3-2 and Chart 3-3 or Chart 3-4). When using
the selector switch, the inner settings apply to all robot
models except ABB which uses the outer settings.
DIP switch S1 on Analog Channel Board PC4 allows
setting robot interface control function for all automatic,
all manual, selector switch, preset, or manual induc-
tance for cases where a third analog channel is not avail-
able at the robot control (see Chart 3-2). To change fac-
tory set position of the DIP switch from all automatic
(switches No. 1 thru 5 all OFF), proceed as follows:
1. Loosen screws and open control panel door.
2. Locate Analog Channel Board PC4 in right side
portion of base inside the interface.
3. Set switches No. 1 thru 5 of DIP switch S1 for de-
sired mode selection and the available robot
channels (see Chart 3-3 or Chart 3-4).
4. Close and secure door.
B. Connection To Receptacle On Robot Interface
(Figure 3-3)
1. Locate supplied cord.
2. Align keyway, insert plug into matching receptacle
on robot interface, and rotate threaded collar fully
clockwise.
3. Route and connect conductors at remaining end of
cord to the robot control unit.
The input and output signals at the pins of receptacle
RC100 by means of the robot interface control circuitry
are as follows:
Receptacle RC100
Pin A: Circuit common for Pins B, C, and L.
Pin B: Arc On signal; starts gas flow and wire
feed, turns on contactor.
Pin D: Jog FWD. signal.
Pin E: Current Detect signal; contact closure
from robot control unit with respect to
Socket H.
Pin G: Wire stick check signal; contact closure
from robot control unit with respect to
Socket J.
Pin H: Current Detect signal; contact closure
from robot control unit with respect to
Socket E.
Pin J: Wire stuck signal; contact closure from ro-
bot control unit with respect to Socket G.
Pin K: Circuit common for Pin D.
Pin M: Wire feed signal; 0 to 8V signal = 0 to 800
ipm.
Pin P: Analog common for Pins M and R.
Pin R: Arc voltage signal; 0 to 10V signal = 0 to
50V output.
IMPORTANT:
The remaining pins in the receptacle are
not used.
3-12. SMIC ROBOT CONTROL UNIT – ROBOT IN-
TERFACE SET UP
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 setting
DIP switches or making interconnections.
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.
A. Setting DIP Switch On Analog Channel Board
(Chart 3-2)
IMPORTANT:
Recommended mode selection for SMIC
robot is Selector Switch and Manual Inductance (see
Chart 3-2 and Chart 3-3 or Chart 3-4). When using the
selector switch, the inner settings apply to all robot mod-
els except ABB switch which uses the outer settings.
DIP switch S1 on Analog Channel Board PC4 allows
setting robot interface control function for all automatic,
all manual, selector switch, preset, or manual induc-
OM-154 145 Page 13
tance for cases where a third analog channel is not avail-
able at the robot control (see Chart 3-2). To change fac-
tory set position of the DIP switch from all automatic
(switches No. 1 thru 5 all OFF), proceed as follows:
1. Loosen screws and open control panel door.
2. Locate Analog Channel Board PC4 in right side
portion of base inside the interface.
3. Set switches No. 1 thru 5 of DIP switch S1 for de-
sired mode selection and the available robot
channels (see Chart 3-3 or Chart 3-4).
4. Close and secure door.
B. Connection To Receptacle On Robot Interface
(Figure 3-3)
1. Obtain a cord of the proper type and length, and a
24-pin Amphenol plug (not supplied).
2. Connect conductors at end of cord to appropriate
pins in plug.
3. Align keyway, insert plug into matching receptacle
on robot interface, and rotate threaded collar 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
RC100 by means of the robot interface control circuitry
are as follows:
Receptacle RC100
Socket A: Wire Feed Speed command signal; 0 to 8V
signal = 0 to 800 ipm.
Socket B: Wire Feed Speed common.
Socket C: Arc Volts command signal; 0 to 10V
signal = 0 to 50V output.
Socket D: Arc Volts common.
Socket E: Jog FWD. signal.
Socket F: Circuit common for Socket E.
Socket G: Arc On signal; starts gas flow and wire
feed, and turns on contactor.
Socket H: Circuit common for Socket G.
Socket J: Jog REV. signal.
Socket K: Circuit common for Socket J.
Socket L: Circuit common for Socket M.
Socket M: Arc detect signal.
Socket N: Circuit common for Sockets P and Q.
Socket P: Wire Stuck signal.
Socket Q: Arc Failure signal.
Socket R: Touch Sense signal; contact closure from
robot control unit with respect to Socket S.
Socket S: Touch Sense signal; contact closure from
robot control unit with respect to Socket R.
IMPORTANT:
The remaining sockets in the receptacle
are not used.
3-13. GAS/CURRENT SENSING CONTROL IN-
TERCONNECTIONS (Figure 3-3)
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.
ST-157 096
Fuse F1
(See Section 7-2)
Circuit Breaker CB1
(See Section 7-2)
19-Socket Motor/Gas
Control Receptacle
RC2
14-Pin Welding Power
Source Receptacle RC1
17-Pin Receptacle
RC4
4-Pin Arc Sensing
Receptacle RC5
Location Of Receptacle(s)
For Robot Control
Unit Connections
Figure 3-3. Right Side View
A. Robot Interface – Gas/Current Sensing Control
Connections
1. Align keyways, insert 19-pin plug into matching re-
ceptacle RC2 on robot interface, and rotate
threaded collar fully clockwise.
2. Align keyways, insert 19-pin plug into matching re-
ceptacle RC3 on gas/current sensing control, and
rotate threaded collar fully clockwise.
B. Weld Cable Connections
For Direct Current Electrode Positive (DCEP), proceed
as follows:
1. Remove wrapper from gas/current sensing control.
2. Connect a weld cable to positive (+) weld output ter-
minal on welding power source.
3. Route cable through reed relay, and connect to
shunt terminal marked POWER SOURCE +.
4. Route a weld cable through opening on opposite
end of control, and connect to shunt.
OM-154 145 Page 14
5. Connect remaining end of weld cable to weld cable
terminal on wire drive assembly (see Motor/Drive
Assembly Owner’s Manual for location).
6. Connect a weld cable to negative (–) weld output
terminal on welding power source.
7. Connect remaining end of weld cable to workpiece.
For Direct Current Electrode Negative (DCEN), reverse
cable connections at welding power source.
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. Gas/Current Sensing Control – Motor Connec-
tions
Align keyways, insert 14-socket plug from motor control
cord into matching receptacle RC5 on gas/current sens-
ing control, and rotate threaded collar fully clockwise.
3-14. VOLTAGE SENSING CONNECTIONS
(Figure 3-4)
IMPORTANT:
Voltage sensing connections are polarity
sensitive. Connect lead with red band to weld cable ter-
minal on wire drive assembly.
1. Align keyway, insert 4-socket plug from voltage
sensing cord into matching receptacle RC5 on robot
interface, and rotate threaded collar fully clockwise.
2. One lead should be connected to the wire drive as-
sembly, along with the weld cable from the welding
power source, as shown in Figure 3-4.
3. Connect remaining lead to the workpiece.
Nut
Lock Washer
Flat Washer
Weld Cable Lug
Location
Voltage Sensing
Lead Ring
Terminal Location
Wire Drive
Assembly
S-0401
Figure 3-4. Voltage Sensing Connections
At Wire Drive Assembly
3-15. ROBOT INTERFACE – WELDING POWER
SOURCE CONNECTIONS (Figure 3-3)
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.
There are two cords supplied with the receptacle kit for
interconnection between the robot interface and weld-
ing power source. Examine cords and select the proper
cord(s) for the connection.
A. REMOTE 14 Connections
1. Align keyway, insert 14-socket plug into matching
receptacle RC1 on robot interface, and rotate
threaded collar fully clockwise.
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 For Maxtron 450
IMPORTANT:
Place the REMOTE 14/17 selector
switch in the REMOTE 14 position, and make connec-
tions to both the REMOTE 14 and REMOTE 17 recep-
tacles. For the Maxtron 450 welding power source,
place the Arc Force/Inductance And CC/CV Control
Switch in the REMOTE 17 position.
1. Align keyway, insert 17-socket plug into matching
receptacle RC4 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
threaded collar fully clockwise.
3-16. CONNECTION FOR CONSTANT NONPULSE
SYNERGIC WELDING
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shut down robot and welding power source,
and be sure equipment cannot be accidently
energized before inspecting or installing.
IMPORTANT:
To provide switching capability between
pulse/nonpulse synergic welding, connect a set of dry
contacts between terminals A and B on terminal strip 1T
at the RCSP-R panel. A contact closure will provide non-
pulse synergic welding and open contacts will provide
pulse synergic welding.
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Miller KD529373 Owner's manual

Category
Welding System
Type
Owner's manual
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