Miller KD529373 Owner's manual

Brand: Miller

Model: KD529373

Category: Welding System

Type: Owner's manual

This manual is also suitable for

ROBOTIC INTERFACE CONTROL

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.

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)

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

ON ON

ON ON ON

ON ∆∆ ON

O – On For Optional Soft Start. Turn Off S1 -3.

∆ – On For Optional Hot Start.

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

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*

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

Brand: Miller

Model: KD529373

Category: Welding System

Type: Owner's manual

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ROBOTIC INTERFACE CONTROL

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Miller KD529373 Owner's manual

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Miller KD529373 Owner's manual

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