Miller KD509571 Owner's manual

Millerﬁ

January

1994

Form:

OM-141

438A

Effective

With

Serial

No.

KD509571

OWNERS

MANUAL

Dual Torch

System

Computer

Interfaces

(per

NSPR

9288)

s

Read

and

follow

these

instructions

and

all

U

Give

this

manual

to

the

operator.



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.



IIIfl

U



For

help,

call

your

distributor

or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821

cover

7/93



Ref.

ST-150

613

'

1994

MILLER

Electric

Mfg.

Co.

PRINTED

IN

liSA

MILLERS

TRUE

BLU

ElM

LIMITED

WARRANTY

Effective

January

1.1992

(Equipment

with

a

serial

number

preface

of

KC

or

newer)

This

limited

warranty

supetsedes

all

warranties

and

is

euclusrne

with

no

other

guarantees

or

warranties

espressed

or

implied

LIMITED

WARRANTY



Subtect

to

the

terms

and

conditions

below,

MtLLER

Electric

Mtg

Co

Appleton.

Wisconsin,

warrants

to

Is

original

retail

purchaser

that

new

MtLLER

equipment

sold

after

the

eftectine

date

ot

this

limited

wartanty

is

tree

01

de

tects

in

material

and

workmanship

at

the

time

it

is

shipped

by

MILLER

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIgS.

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTAEILtTY

AND

FIT

NESS.

Within

the

warranty

periods

listed

betow,

MILLER

wilt

repair

or

replace

any

war

ranted

parts

or

components

that

tail

due

to

such

detects

in

material

or

workmanship

MILLER

must

be

notitied

in

writing

within

thirty

(30)

days

01

such

detect

or

failure,

at

which

time

MILLER

will

provide

instructions

on

the

warranty

claim

procedures

to

be

tollowed

MILLER

shalt

honor

warranty

claims

on

~karranted

equipment

listed

below

in

the

event

ot

such

a

lailure

within

the

warrant~

lime

periods

All

warranty

time

periods

start

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser,

or

one

year

aher

the

equipment

is

sent

to

the

distributor,

Years

Parts

3

Yeats

Labor

Original

main

power

rectitiers

2

3

Years



Parts

and

Labor



TranstormeriRectitier

Power

Sources



Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders

Robots

3

2

Years



Pans

and

Labor



Engine

Driven

Welding

Generators

(NOTE

Engines

are

warranted

separately

by

the

engine

manutacturer

tsr

a

period

ol

Iwo

years



Air

Compressors

4

t

Year



Parts

and

Labor



Remote

Controls



Accessory

Kits



Replacement

Pans

MILLERS

True

Bluen

Limited

Warranty

shall

not

apply

to:

I

Items

turniuhed

by

MILLER.

but

manutactured

by

others,

such

as

engines

or

trade

accessories

These

items

are

covered

by

the

manutacturers

warranty,

if

any

2

Consumable

components.

such

as

contact

tips,

cutting

nozzles,

conlaclsrs

and

relays

or

pans

that

tail

due

to

normal

wear,

3

Equipment

that

has

been

moditied

by

any

party

other

than

MILLER.

or

equip.

ment

that

has

been

improperly

installed,

improperly

operated

or

misused

based

upon

industry

standards,

or

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

or

equipment

which

has

been

used

tsr

operation

outside

01

the

speciticatrons

tsr

the

equipment

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT

In

the

event

ot

a

warranty

claim

covered

by

this

warranty,

the

enclusive

remedies

shall

be.

at

MILLERS

sption:

/1)

repair.

or

12)

replacement:

or.

where

authorized

in

writing

by

MILLER

in

appropriate

cases.

(3)

the

reasonable

cosl

of

repair

or

replace

ment

at

an

authorized

MILLER

service

station,

or

)4)

payment

of

or

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

of

the

goods

at

customers

risk

and

espense.

MILLERS

option

01

repair

or

replacement

will

be

PD

B

.Factory

at

Appleton,

Wisconsin,

or

F

G.E.

at

a

MILLER

authorized

ser

vice

tacilrty

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburse

ment

tsr

rransponatisn

costs

ot

any

kind

will

be

altowed.

TO

THE

EXTENT

PERMITTED

BY

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MILLER BE

LIABLE

FOR

DIRECT.

INDIRECT

SPECIAL.

INCIDENTAL

OR

CONSEQUENTIAL

DAMAGES

IINCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CON

TRACT.

TORT

OR

ANY

OTHER

LEGAL

THEORY

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTATION

ASTD

PERFORMANCE.

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

DR

ANY

OTHER

LEGAL

THEORY

WHICH,

BUT

FOR

THIS

PROVISION.

MIGHT

ARISE

BY

IMPLICATION,

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

DR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER

Some

states

in

the

U

S

A

do

not

allow

limitations

of

hsw

long

an

implied

warranty

lasts,

or

the

enclusion

sf

incidental.

indirect.

special

or

consequential

damages,

so

the

above

limitation

or

euclusrsn

may

not

apply

to

you.

This

warranty

provides

spe

cific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

state

to

stale

In

Canada.

legislation

in

some

provinces

provides

tsr

certain

additional

warrantiea

or

remedies

other

than

as

slated

herein,

and

to

the

eutent

that

they

may

not

be

waived,

the

limitations

and

euclusions

set

out

above

may

nst

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

trom

province

to

province

:I~I



Motor

Driven

Guns

Process

Controllers



Water

Coolant

Systems



HF

Units

*

Grids



Spot

Welders



Load

Banks



SDX

Transformers

*

Running

Gear/Trailers

*

Field

Options

(NOTE

Field

options

are

covered under

True

Blue~M

tsr

the

remaining

warranty

period

of

the

product

they

are

installed

in,

or

for

a

minimum

of

one

year



whichever

is

greater.)

6

Months



Batteries

90

Days



Pans

and

Labor

*

MIG

Gues/TIG

Torches



Plasma

Cutting

Tsrches

5.

6.

RECEIVING-HANDLING

BefQre

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

Claims

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number,

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

__________

Serial

or

Style

No.

Date

of

Purchase

miller

9/93

ARC

WELDING

SAFETY

PRECAUTIONS

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes,

6.

When

making

input

connections,

attach

proper

grounding

conductor

first.

7.

Turn

off

all

equipment

when

not

in

use.

8.

Do

not

use

worn,

damaged.

undersized,

or

poorly

spliced

cables.

9.

Do

not

wrap

cables

around

your

body.

10.

Ground

the

workpiece

to

a

good

electrical

(earth)

ground.

11.

Do

not

touch

electrode

if

in

contact

with

the

work

or

ground.

12.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

13.

Wear

a

safety

harness

if

working

above

floor

level.

14.

Keep

all

panels

and

covers

securely

in

place.

a

WARNING

ARC

WELDING

can

be

hazardous.

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

lobs,

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

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

QUALIFIED

PEOPLE.

1.

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.

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.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

ARC

RAYS

can

burn

eyes

and

skin;

~

NOISE

can

damage

hearing.

Arc

rays

from

the

welding

process

produce

intense

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

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

(see

ANSI

Z49.

1

listed

in

Safety

Standards)

to

protect

your

face

and

eyes

when

welding

or

watching.

3.

Wear

approved

safety

glasses.

Side

shields

recommended.

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,

fIame-resi~tant

material

(wool

and

leather)

and

foot

protection.

FUMES

AND

GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

to

your

health.

Weldingproducesfumes

andgases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health.

wearing

an

air-supplied

respirator.

Shielding

gases

used

for

welding

can

displace

air

causing

iniury

or

death.

Be

sure

the

breathing

air

is

safe.

a....._..

1

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes,

.

2.

It

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

(MSDS5)

and

the

manufacturers

instruction

for

metals,

consumables,

coatings,

and

cleaners,

6.

7.

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.

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.

WELDING

can

cause

fire

or

explosion.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

flying

sparks

and

hot

metal,

weld

spatter,

hot

workpiece.

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

or

welding

wire

7.

can

cause

fire

on

the

hidden

side.

Do

not

weld

on

closed

containers

such

as

tanks

or

drums.

to

metal

objects

can

cause

sparks,

overheating,

or

fire.

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

9.

unknown

paths

and

causing

electric

shock

and

fire

hazards.

Do

not

use

welder

to

thaw

frozen

pipes.

3.

Removeallflammableswithin35ft(10.7m)oftheweldingarc.lf

this

is

not

possible,

tightly

cover

them

with

approved

covers,

10.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

contact

tip

when

not

in

use.

4.

Be

alert

that

welding

sparks

and

hot materials

from

welding

can

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury,

Chipping

and

grinding

cause

flying

metal.

As

welds

cool,

they

can

throw

off

slag.

1.

2.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

recommended.

Wear

proper

body

protection

to

protect

skin.

Sri

9/92

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,

and

arcs.

2.

Install

and

secure

cylinders

in

an

upright

position

by

chaining

them

to

a

stationary

support

or

equipment

cylinder

rack

to

prevent

falling

or

tipping

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

4.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

5.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

6.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

7.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

8.

Read

and

follow

instructions

on

compressed

gas

cylinders.

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

ENGINE

FUEL

can

cause

fire

or

1.

Stop

engine

before

checking

or

adding

fuel.

explosion.

2.

Do

not

add

fuel

while

smoking

or

if

unit

is

near

any

sparks

or

open

flames.

3.

Allow

engine

to

cool

before

fueling.

If

possible,

check

and add

Eng,ne

fuel

is

highly

flammable.

fuel

to

cold

engine

before

beginning

job.

4.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

5.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

engine.

MOVING

PARTS

can

cause

injury.

3.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

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.

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

Pro

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

srI

9/92

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

Wi

17.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Safe

Practices

For

OccupationAnd

Educational

EyeAr7d

Face

Protec

tion,

ANSI

Standard

Z87.i,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

a

WARNING

ENGINES

can

be

hazardous.

ENGINE

EXHAUST

GASES

can

kill.

1.

Use

equipment

outside

in

open,

well-ventilated

areas.

2.

If

used

in

a

closed

area,

vent

engine

exhaust

outside

and

Engines

produce

harmful

exhaust

gases.

away

from

any

building

air

intakes.

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

eng

ne

before

installing

or

connecting

unit.

4.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

SPARKS

can

cause

BATTERY

GASES

1.

Always

wear

a

face

shield

when

working

on

a

battery.

TO

EXPLODE;

BATTERY

ACID

can

2.

Stop

engine

before

disconnecting

or

connecting

battery

burn

eyes

and

skin,

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Batteries

contain

acid

and

generate

explosive

gases.

4.

5.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

Observe

correct

polarity

(+

and

)

on

batteries.

,

~



~~C

Y

L

STEAM

AND

PRESSURIZED

HOT

COOLANT

can

burn

face,

eyes,

and

skin.

The

coolant

in

the

radiator

can

be

very

hot

and

under

pressure.

1.

2.

3.

Do

not

remove

radiator

cap

when

engine

is

hot.

Allow

engine

to

cool.

Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

Allow

pressure

to

escape

before

completely

removing

cap.

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-

INTRODUCTION

2-1.

Description

1

SECTION

3

INSTALLATION

3-1.

Location

1

3-2.

Installation

Of

EPROM

Chrp

On

Circuit

Board

Inside

Dual

Torch

Adapter

2

3-3.

Wire

Stick

Check

Options

2

3-4.

Setting

DIP

Switches

On

DVC

Board

PCi

3

3-5.

Remote

Jog

Switch

Connections

3

3-6.

Field

Installation

Instructions

For

Dual

Torch

Welding

System

4

3-7.

Connections

For

Computer

Interfaces

5

3-8.

Connections

for

Welding

Power

Sources



Computer

Interfaces

7

SECTION

4-OPERATOR

CONTROLS

4-1.

Computer

Interface

Pilot

Light

8

4-2.

Display

Module

Controls

8

SECTION

5SEQUENCE

OF

OPERATION

5-1.

Gas

Metal

Arc

Welding

(GMAW)

9

5-2.

Shutting

Down

9

5-3.

Operation

Of

Computer

Interfaces

9

5-4.

Wire

Stick

Check

10

SECTION

6

MAINTENANCE

&

TROUBLESHOOTING

6-i.

Inspection

And

Upkeep

10

6-2.

Overload

Protection

11

6-3.

Circuit

Board

Handling

Precautions

ii

6-4.

Troubleshooting

11

6-5.

Use

Of

Indicator

Lights

For

Troubleshooting

13

SECTION

7

ELECTRICAL

DIAGRAMS

Diagram

7-1.

Circuit

Diagram

For

Computer

Interface

With

Dual

Torch

Adapter

Panel

14

Diagram

7-2.

Circuit

Diagram

For

Dual

Torch

Computer

Interface

15

Diagram

7-3.

Wiring

Diagram

For

Dual

Torch

Computer

Interface

16

Diagram

7-4.

Circuit

Diagram

For

Voltage

Board

PCi

18

Diagram

7-5.

Circuit

Diagram

For

Adapter

Board

PC7

20

Diagram

7-6.

Circuit

Diagram

For

Motor

Board

P02

21

Diagram

7-7.

Circuit

Diagram

For

Interface

Board

P04

22

Diagram

7-8.

Circuit

Diagram

For

Display

Module

22

Diagram

7-9.

Circuit

Diagram

For

Display

Module

Meter

Board

PCi

23

Diagram

7-10.

Circuit

Diagram

For

Display

Module

LED

Board

PC2

23

Diagram

7-11.

Circuit

Diagram

For

Gas/Motor

Control

Box

24

Diagram

7-12.

Circuit

Diagram

For

WCR

24

SECTION

8

PARTS

LIST

Figure

8-1.

Main

Assembly

26

Figure

8-2.

Display

Module

31

Figure

8-3.

WCR

Box

32

Figure

8-4.

Control

Box,

Gas/Motor

33

Figure

8-5.

Motor

&

Drive

Assembly

34

Figure

8-6.

Inlet

Cable

System

36

OM-141

438A-1/94

SECTION

1

-

SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

1-1.

GENERAL

INFORMATION

AND

SAFETY

1-2.

SAFETY

ALERT

SYMBOL

AND

SIGNAL

WORDS

A.

General

The

following

safety

alert

symbol

and

signal

words

are

used

throughout

this

manual

to

call

attention

to

and

iden

Information

presented

in

this

manual

and

on

various

Ia-

tify

different

levels

of

hazard

and

special

instructions.

bels,

tags,

and

plates

on

the

unit

pertains.to

equipment

A

This

safety

alert

symbol

is

used

with

the

signal

design,

installation,

operation,

maintenance,

and

~

words

WARNING

and

CAUTION

to

call

atten

troubleshooting

which

should

be

read,

understood,

and

tion

to

the

safety

statements.

followed

for

the

safe

and

effective

use

of

this

equipment.

WARNING

statements

identify

procedures

or

B.

Safety

practices

which

must

be

followed

to

avoid

seri

ous

personal

injury

or

loss

of

life.

The

installation,

operation,

maintenance,

and

trouble

shooting

of

arc

welding

equipment

requires

practices

CAUTION

statements

identify

procedures

or

and

procedures

which

ensure

personal

safety

and

the

practices

which

must

be

followed

to

avoid

minor

safety

of

others.

Therefore,

this

equipment

is

to

be

in-

personal

injury

or

damage

to

this

equipment.

stalled,

operated,

and

maintained

only

by

qualified

per

sons

in

accordance

with

this

manual and

all

safety

pre-

IMPORTANT

statements

identify

special

instructions

cautions

listed

in

the

Arc

Welding

Safety

Precautions

in

necessaiy

for

the

most

efficient

operation

of

this

equip-

the

welding

power

source

Owners

Manual.

ment.

SECTION

2-INTRODUCTION

2-1.

DESCRIPTION

Two

Display

Modules

provide

display

of

wire

feed

speed

The

dual

torch

system

allows

use

of

two

welding

guns!

torches

that

connect

to

two

separate

welding

power

sources

for

simultaneous

welding

by

a

single

robot.

The

and

voltage.

Inductance

can

be

set

at

both

Display

Mod

ules.

Indicator

lights

include

power,

gas,

contactor,

wire

feed,

and

current.

system

provides

wire

feed

speed

and

voltage

control

cir

cuitry,

wire

stick

check

circuitry,

and

other

circuitry

to

in-

The

design

application

of

the

dual

torch

system

is

for

use

terface

two

welding

systems

with

the

Robot

Control.

in

the

Gas

Metal

Arc

Welding

(GMAW)

process.

SECTION

3-

INSTALLATION

3-1.

LOCATION

drive

assemblies.

Cord

and

cable

lengths

must

be

con

sidered

when

installing

components

for

the

dual

torch

The

location

of

the

Dual

Torch

System

Computer

Inter-

system.

faces

should

allow

room

to

remove

covers

and

side

pan

els

for

maintenance

and

repair.

The

location

should

also

provide

the

following:

Mounting

holes

are

provided

in

the

base

of

the

Dual

1.

Adequate

ventilation

and

fresh

air

supply

Torch

System

Computer

Interfaces

for

securing

in

a

per-

2.

No

flammables

manent

location.

Install

the

Dual

Torch

System

Comput

er

Interfaces

near

welding

power

sources.

The

supplied

3.

A

clean

and

dry

area

Display

Modules

install

onto

the

module

stand.

The

supplied

WCR

boxes

should

be

installed

in

a

location

4.

Proper

temperature

that

avoids

extremes

of

hot

or

cold

that

will

allow

weld

cables

from

the

welding

power

sources

to

be

easily

routed

through

the

boxes

to

wire

5.

Proper

airflow

around

the

unit.

OM-141

438

Page

1

Communication

Board

P9745W

Ret.

S-0370-B

Figure

3-1.

Location

Of

EPROM

Chip

Installation

On

Computer

Interface

Communication

Board

3-2.

INSTALLATION

OF

EPROM

CHIP

ON

CIR

CUIT

BOARD

INSIDE

DUAL

TORCH

ADAPT

ER

(Figure

3-1)

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

unit,

welding

power

source,

and

robot,

and

disconnect

input

powerem

ployinglocko

ut/tagging

procedures

before

installing

EPROM

chip.

Lockout/tagging

procedures

consist

of

padlocking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

disconnecting

devices.

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.

The

Dual

Torch

Adapter

is

shipped

without

an

EPROM

chip

and

requires

the

chip

to

be

customer-installed

for

the

unit

to

be

operational.

To

install

the

supplied

EPROM

chip,

proceed

as

follows:

1.

Remove

Dual

torch

Adapter

side

panel.

2.

Locate

Communication

board

in

upper

portion

of

Adapter.

3.

Install

EPROM

chip

on

Communication

board

as

follows:

a.

Locate

DIP

sockets

marked

1C002

on

Commu

nication

board

(see

Figure

3-1).

b.

Carefully

install

EPROM

chip

at

DIP

sockets

marked

1C002.

Match

the

notch

in

EPROM

housing

with

notch

outline

etched

on

the

circuit

board,

align

all

EPROM

pins

with

circuit

board

sockets,

and

gently

press

EPROM

down

to

se

cure

pins

into

sockets.

4.

Reinstall

side

panel.

3-3.

WIRE

STICK

CHECK

OPTIONS

(Figure

3-2)

The

Computer

Interface

is

equipped

with

two

DIP

switches

found

on

the

Interface

circuit

board

PC4.

These

switches

are

factory

set

to

provide

no

voltage

ramp

during

wire

stick

check.

If

either

of

these

selections

need

to

be

changed

for

a

particular

welding

application,

proceed

as

follows:

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

robot

and

welding

power

source,

and

disconnect

input

power

employing

lock

out/tagging

procedures

before

inspecting

or

installing.

Lockout/tagging

procedures

consist

of

pad

locking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

disconnect

ing

device.

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.

Remove

Computer

Interface

left

side

panel.

2.

Locate

DIP

switches

on

Interface

circuit

board

PC4

(see

Figure

3-2).

3.

Reposition

appropriate

DIP

switch

using

a

pointed

tool,

such

as

the

edge

of

a

small

noncon

ductive

screwdriver.

4.

Reinstall

left

side

panel.

OM-141

438

Page

2

Figure

3-2.

DIP

Switch

Location

And

Information

3-4.

SETTING

DIP

SWITCHES

ON

DVC

BOARD

PCi

(Figure

3-3)

DIP

switches

Si

and

S2

on

DVC

board

PCi

allow

setting

the

proper

command

signal

voltage

level

for

controlling

voltage

output

at

a

welding

power

source.

To

change

factory

set

position

of

DIP

switches

from

a

Deltaweld

45i

to

another

welding

power

source,

proceed

as

fol

lows:

CAUTION:

INCORRECT

DVC

BOARD

DIP

SWITCH

POSITION

can

cause

equipment

malfunction.



DVC

DIP

switch

is

factory

set

for

operation

with

Delta

weld

451

welding

power

source.

See

Figure

3-3

for

DVC

DIP

switch

setting

when

using

another

welding

power

source.

IMPORTANT:

The

Computer

Interface

does

not

work

with

the

Pulstar

450.

DVC

SWITCH

SETTINGS

DELTAWELD

451,

450

0

ON

DELTAWELD

651,

650

0

ON

MAXTRON

300,

400

ON

MAXTRON

450

ON

XMT200/300

ON

ARC

PAK

350

ON

SHOPMASTER

300

ON

DIMENSION

400

ON

PULSTAR

450

ON

0



On

For

Optional

Soft

Start.

Turn

Off

51

-3.



On

For

Optional

Hot

Start.

S-15o

884-C

DELTAWELD

300

S2

2

ON

Si

3

ON

4

5

ON

Figure

3-3.

DVC

DIP

Switch

Setting

Label

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

unit,

welding

power

source,

and

robot,

and

disconnect

input

power

employing

lockout/tagging

procedures

before

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.

Remove

Computer

Interface

left

side

panel.

2.

Locate

DVC

board

PCi

on

center

baff

le

inside

the

interface.

3.

Set

position

of

DIP

switches

Si

and

S2

according

to

label

inside interface

and

Figure

3-5

for

appro

priate

welding

power

source.

4.

Reinstall

left

side

panel.

3-5.

REMOTE

JOG

SWITCH

CONNECTIONS

(Figure

3-4)

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

robot

and

welding

power

source,

and

disconnect

input

power

employing

lock

out/tagging

procedures

before

inspecting

or

installing.

Lockout/tagging

procedures

consist

of

pad

locking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

disconnect

ing

device.

The

Computer

Interface

is

equipped

with

a

terminal

strip

for

connecting

a

remote

jog

switch.

To

make

connec

tions

to

this

terminal

strip,

proceed

as

follows:

i.

Remove

left

side

panel

from

Computer

Interface.

2.

Route

leads

from

remote

jog

switch

through

strain

relief

to

terminal

strip

5T.

Connect

leads

to

5T,

p0-

larity

is

not

important.

Tighten

strain

relief.

3.

Reinstall

left

side

panel.

a

117

4~J-

119

1~-

o

0

CR1

&RSE:J

;i:~

~~R9

l~--

AIR

0

R24

-~-

~

~RI1

~

R21

-OFF

DISABLE

UOLTAGE

RArE

ON

ENABLE VOLTAGE

RNI1P

OH

DISABLE

STICK

CHECKING

OFF

ENABLE

STICK

CHECKING

C

SA-137

112-A

OM-141

438

Page

3

ST-139

887

/

S-0807

3-6.

FIELD

INSTALLATION

INSTRUCTIONS

FOR

DUAL

TORCH

WELDING

SYSTEM

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

robot

and

welding

power

source,

and

disconnect

input

power

employing

lock

out/tagging

procedures

before

inspecting

or

installing.

Lockout/tagging

procedures

consist

of

pad

locking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

disconnect

ing

device.

ELECTROSTATIC

DISCHARGE

(ESD)

can

damage

circuit

boards.



Put

on

properly

grounded

wrist

strap

BE

FORE

handlThg

circuit

boards.



Transport

circuit

boards

in

proper

static

shielding

carriers

or

packages.



Perform

work

only

at

a

static-safe

work

area.

A.

Installation

Instructions

For

Welding

Guns

1.

Disconnect

outlet

cable

from

existing

gun

and

wire

drive

assembly,

and

remove

cable

from

sup

port

arm

on

robot.

2.

Remove

original

welding

gun

from

insulating

plate

on

Axis

5

output

hub.

3.

Install

customer-supplied

dual

torch

mounting

bracket.

4.

Install

supplied

welding

guns

onto

dual

torch

mounting

bracket.

B.

Installation

Instructions

For

Motor/Drive

As

semblies

1.

Remove

spool

support

arm

from

robot.

2.

Disconnect

plug

on

end

of

motor

cord

from

recep

tacle

on

robot,

and

remove

existing

motor/drive

assembly

from

motor

mounting

bracket.

3.

Remove

stabilizer

brace

from

motor

mounting

bracket

and

robot.

4.

Install

supplied

dual

motor/drive

assembly

mounting

bracket

where

spool

support

arm

and

stabilizer

brace

were

attached.

5.

Install

one

supplied

motor/drive

assembly

to

origi

nal

motor

mounting

bracket.

Connect

plug

on

end

of

motor

cord

to

receptacle

on

robot.

6.

Install

Gas/Motor

Control

box

to

rear

of

dual

mo

tor/drive

assembly

mounting

bracket

(see

Figure

3-5).

IMPORTANT:

Install

insulating

strip

between

motor!

drive

assembly

mounting

bracket

and

motor/drive

as

semblyhousing.

Housing

installs

to

outside

frontsurface

of

bracket

with

insulating

strip

between

metal

surfaces.

7.

Install

motor/drive

assembly

to

dual

motor/drive

assembly

mounting

bracket.

Use

insulated

shoul

der

washers

on

bolts

to

secure

motor/drive

as

sembly

to

bracket.

8.

Connect

plug

on

end

of

motor

cord

to

receptacle

on

Gas/Motor

Control

box.

Figure

3-4.

Remote

Jog

Switch

Connections

OM-141

438

Page

4

C.

Installation

Instructions

For

Outlet

Cables

1.

Install

supplied

outlet

cables

to

supplied

motor!

drive

assembly

housings

(see

motor/drive

as

sembly

Owners

Manual).

2.

Install

remaining

end

of

outlet

cables

to

supplied

welding

guns

(see

welding

gun

Owners

Manual).

3.

Secure

one

outlet

cable

to

cable

support

arm

on

robot.

Use

cable

ties

to

secure

remaining

outlet

cable

to

the

other

outlet

cable.

4.

Connect

single

plug

on

end

of

supplied

split

cable

to

matching

shock

sensor

connector

on

robot.

5.

Connect

each

plug

on

remaining

end

of

cable

to

the

shock

sensor

connectors

on

outlet

cables.

D.

Installation

Instructions

For

Display

Modules

1.

Remove

original

Display

Module

from

module

stand.

2.

Disassemble

one

supplied

Display

Module

from

mounting

plate

(see

Figure

3-6).

3.

Install

one

supplied

Display

Module

onto

rear

of

mounting

plate

for

disassembled

supplied

Dis

play

Module

using

existing

holes

(see

Figure

3-6).

4.

Reassemble

Display

Module

onto

mounting

plate.

5.

Install

mounting

plate

onto

module

stand.

Supplied

Motor!



Drive

Assembly

ST-800

590

3-7.

CONNECTIONS

FOR

COMPUTER

INTER

FACES

(Figure

3-7)

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

robot

and

welding

power

source,

and

disconnect

input

power

employing

lock

out/tagging

procedures

before

inspecting

or

installing.

Lockout/tagging

procedures

consist

of

pad

locking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

disconnect

ing

device.

Bolts

And

Insulated

Shoulder

Washers

Dual

Motor/

Drive

Assembly

Mounting

Bracket

Figure

3-5.

Installation

Of

Dual

Motor/Drive

Assembly

Mounting

Bracket

Second

Supplied

Display

Module

Figure

3-6.

Installation

Of

Display

Modules

ST-800

591

OM-141

438

Page

5

Voltage

Sensing

~

Leads

To

Connector

CN4

On

Robot

Base

To

Display

Module

Use

Appropriate

Receptacle

For

Welding

Power

Source

Application

Computer

Interface

Dual

Torch

Adapter

To

WCR

Box

To

Dual

Torch

Computer

Interface

Voltage

Sensinj~

Leads

To

Gas/Motor

~

Control

Box

To

Display

~

Module

Use

Appropriate

Receptacle

For

Welding

Power

Source

Application

Dual

Torch

Computer

Interface

To

WCR

Box

To

Dual

Torch

Adapter

Panel

Ret.

S-0648

Figure

3-7.

Connections

At

Computer

Interfaces

1.

Connect

matching

plug

on

end

of

supplied

inter

connecting

cord

to

receptacle

RC1

9

on

Computer

Interface

Dual

Torch

Adapter

panel.

2.

Connect

plug

on

remaining

end

of

interconnect

ing

cord

to

receptacle

RC2O

on

Dual

Torch

Com

puter

Interface.

3.

Connect

matching

plug

on

end

of

supplied

motor

cord

to

receptacle

RC9

on

Dual

Torch

Computer

Interface.

4.

Connect

plug

on

remaining

end

of

motor

cord

to

receptacle

on

Gas/Motor

Control

box.

5.

Connect

plug

on

end

of

one

supplied

WCR

box

to

receptacle

RCB

on

Dual

Torch

Computer

Inter

face.

6.

Connect

plug

on

end

of

remaining

supplied

WCR

box

to

receptacle

RC8

on

Computer

Interface.

IMPORTANT:

Be

sure

that

each

weld

cable

from

posi

tive

weld

output

terminals

on

welding

power

sources

are

routed

through

opening

in

WCR

boxes

before

connect

ing

to

motor/drive

assemblies.

7.

Connect

each

weld

cable

from

positive

weld

out

put

terminals

on

welding

power

sources

to

stud

on

housing

of

motor/drive

assemblies

(see

motor/

drive

assembly

Owners

Manual).

8.

Connect

each

weld

cable

from

negative

weld

out

put

terminals

on

welding

power

sources

to

work-

pieces

or

fixtures.

9.

Connect

one

supplied

voltage

sensing

leads

plug

to

receptacle

RC14

on

Dual

Torch

Computer

In

terface.

10.

Connect

remaining

supplied

voltage

sensing

leads

plug

to

receptacle

RC1

4

on

Computer

Inter

face.

IMPORTANT:

Voltage

sensing

lead

ring

terminals

must

be

installed

on

top

of

weld

cable

lugs

at

motor/drive

as

semblies.

11.

One

lead

with

ring

terminal

from

each

supplied

voltage

sensing

leads

should

be

connected

to

supplied

motor/drive

assemblies

where

weld

cables

from

welding

power

sources

are

con

nected.

12.

Connect

remaining

lead

from

voltage

sensing

leads

to

the

workpieces

or

fixtures

near

weld

cable

connections

from

welding

power

sources.

RC1

4

RC9

RC12

RC8

RC1

0

RC1

4

RC9

RC12

RC8

RC1O

RC2O

RC1

9

OM.141

438

Pago6

13.

Connect

matching

plug

on

one

supplied

cord

to

3-8.

CONNECTIONS

FOR

WELDING

POWER

receptacle

RC12

on

Dual

Torch

Computer

Inter-

SOURCES



COMPUTER

INTERFACES

face.

(Figure

3-7)

14.

ConnectplugonremainingendofcordtooneDis-

~

WARNING:

ELECTRIC

SHOCK

can

kill.

play

Module

on

module

stand.



Do

not

touch

live

electrical

parts.

15.

Connect

matching

plug

on

remaining

supplied



Shut

down

unit,

welding

power

source,

and

cord

to

receptacle

RC12

on

Computer

Interface,

robot,

and

disconnect

input

power

employing

lockout/tagging

procedures

before

making

inter-

16.

Connect

plug

on

remaining

end

of

cord

to

remain-

connections.

ing

Display

Module

on

module

stand.

Lockout/tagging

procedures

consist

of

padlock-

17.

Connect

fitting

on

end

of

one

supplied

short

gas

ing

line

disconnect

switch

in

open

position,

re

moving

fuses

from

fuse

box,

or

shutting

off

and

hose

to

top

fitting

on

Gas/Motor

Control

box.

red-tagging

circuit

breaker

or

other

disconnect-

18.

Connect

remaining

end

of

short

gas

hose

to

ing

device.

barbed

fitting

on

rear

of

motor/drive

assembly

There

are

four

receptacles

to

accommodate

use

of

dif

housingbyslidingendofhoseontobarbedfitting,

ferent

welding

power

sources:

receptacles

RC1O

are

19.

Connectfittingonendofremainingsuppliedshort

17-pin

receptacles

and

ROll

are

14-pin

receptacles.

gas

hose

to

fitting

on

gas

valve

on

robot.

Determine

which

receptacles

are

required

for

the

weld

ing

power

sources

being

used,

select

appropriate

inter-

20.

Connect

remaining

end

of

short

gas

hose

to

connecting

cords,

and

make

connections

as

follows:

barbed

fitting

on

rear

of

motor/drive

assembly

align

keyway,

insert

plugs,

and

rotate

threaded

collars

housing

by

sliding

end

of

hose

onto

barbed

fitting.

fully

clockwise.

21.

Connect

fitting

on

end

of

one

supplied

long

gas

The

remaining

end

of

the

interconnecting

cords

connect

hose

to

bottom

fitting

on

Gas/Motor

Control

box.

to

the

REMOTE

receptacle

on

the

welding

power

sources.

Align

keyway,

insert

plugs,

and

rotate

threaded

22.

Connect

fitting

on

end

of

remaining

supplied

long

collars

fully

clockwise.

gas

hose

to

fitting

on

base

of

robot

column.

If

the

welding

power

sources

are

equipped

with

both

14-

23.

Connect

remaining

ends

of

long

gas

hoses

to

and

17-socket

REMOTE

receptacles,

make

connec

flowmeter/regulator

at

shielding

gas

sources.

tions

to

both

and

place

the

REMOTE

14/17

switches

in

the

14

position.

24.

Install

inlet

guides

on

ends

of

inlet

cables

from

supplied

dual

spindle

and

hub

assemblies

to

both

For

multi-process

welding

power

sources,

rotate

MAXI

motor/drive

assemblies.

MUM

GTAW

OUTPUT

controls

to

maximum.

OM-141438Page7

SECTION

4-

OPERATOR

CONTROLS

Computer

Interface

Display

Module

Circuit

Breaker

CB1

(See

Section

6-2)

Fuse

Fl

(See

Section

6-2)

Wire

Feed

Ground

Current

Light

(See

Section

6-2)

Dispiay

Seiect

Switch

inductance

Control

Ref.

ST-136

571-B

SA-136

572-B

Figure

4-1.

Front

Panel

Views

4-1.

COMPUTER

INTERFACE

PILOT

LIGHT

The

pilot

light

turns

on

when

115

vac

power

is

supplied

to

the

Computer

Interface

from

the

welding

power

source.

4-2.

DISPLAY

MODULE

CONTROLS

A.

Digital

Display

The

digital

display

shows

either

voltage

or

wire

feed

speed

depending

on

the

setting

of

the

Selector

switch.

B.

DISPLAY

SELECT

Switch

The

Selector

switch

is

used

to

select

either

voltage

or

wire

feed

speed

to

appear

on

the

digital

display.

C.

INDUCTANCE

Control

This

control

sets

inductance

in

percentage

(0

to

100%)

when

the

welding

power

source

connected

to

the

Com

puter

Interface

uses

inductance.

D.

PURGE

Switch

Pressing

the

PURGE

switch

energizes

the

gas

valve

on

the

robot.

Use

the

PURGE

switch

to

purge

the

gas

line

before

beginning

welding.

E.

Indicator

Lights

There

are

five

indicator

lights

on

the

interface.

These

are

visual

indications

of

various

process

functions.

The

POWER

light

turns

on

when

115

vac

is

supplied

to

the

Computer

Interface

control

and

thereby

the

Display

Module.

The

GAS

light

turns

on

when

the

gas

valve

is

energized

to

indicate

shielding

gas

flow.

The

CONTACTOR

light

turns

on

when

the

welding

pow

er

source

contactor

is

energized

to

indicate

that

weld

output

is

available.

The

WI

RE

FEED

light

turns

on

when

the

wire

drive

motor

is

energized

to

indicate

that

wire

is

feeding.

The

CURRENT

light

turns

on

when

the

current

detect

relay

is

energized

to

indicate

that

an

arc

is

established.

Digitai

Dispiay

Pilot

Light

Computer

interface

Purge

Switch

Lights

OM-141

438

Page

8

SECTION

5-

SEQUENCE

OF

OPERATION

WARNING:

ELECTRIC

SHOCK

can

kill;

MOVING

PARTS

can

cause

serious

injury;

IMPROPER

AIRFLOW

AND

EXPOSURE

TO

ENVIRONMENT

can

damage

internal

parts.



Do

not

touch

live

electrical

parts.



Keep

all

covers

and

panels

in

place

while

operating.



Do

not

touch

welding

wire

or

any

metal

part

in

contact

with

it

while

welding.

The

welding

wire

and

all

metal

parts

in

contact

with

it

carry

weld

output

when

the

welding

power

source

contactor

is

energized.

Warranty

is

void

if

any

of

the

equipment

is

oper

ated

with

any

portion

of

the

outer

enclosure

removed.

ARC

RAYS,

SPARKS,

AND

HOT

SURFACES

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.



Wear

correct

eye,

ear,

and

body

protection.

FUMES

AND

GASES

can

seriously

harm

your

health.



Keep

your

head

out

of

the

fumes.



Ventilate

to

keep

from

breathing

fumes

and

gases.



If

ventilation

is

inadequate,

use

approved

breathing

device.

HOT

METAL,

SPATTER,

AND

SLAG

can

cause

fire

and

burns.



Watch

for

fire.



Keep

a

fire

extinguisher

nearby,

and

know

how

to

use

it.



Do

not

use near

flammable

material.



Allow

work

and

equipment

to

cool

before

handling.

WELDING

WIRE

can

cause

puncture

wounds.



Do

not

point

gun

toward

any

part

of

the

body,

any

conductive

surface,

or

other

personnel.

MAGNETIC

FIELDS

FROM

HIGH

CURRENTS

can

affect

pacemaker

operation.



Wearers

should

consult

their

doctor

before

going

neararc

welding,

gouging,

orspot

weld

ing

operations.

See

Arc

Welding

Safety

Precautions

in

the

weld

ing

power

source

Owners

Manual

for

basic

welding

safety

information.

3.

Wear

dry

insulating

gloves

and

clothing.

4.

Prepare

for

welding

by

connecting

work

clamp(s)

to

clean,

bare

metal

at

workpiece(s).

5.

Turn

on

and

adjust

shielding

gas

at

its

source.

6.

Energize

robot

system.

7.

Wear

welding

helmet

with

proper

filter

lens

ac

cording

to

ANSI

Z49.1.

8.

Begin

welding.

5-2.

SHUTTING

DOWN

1.

Stop

welding.

2.

Shut

down

robot

system.

3.

Turn

off

all

associated

equipment.

3.

Turn

off

shielding

gas

at

the

source.

a

WARNING:

HIGH

CONCENTRATION

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shut

off

gas

supply

when

not

in

use.

a

5-1.

GAS

METAL

ARC

WELDING

(GMAW)

1.

Install

and

connect

robot

system

according

to

its

Owners

Manuals.

2.

Connect

Computer

Interfaces

according

to

Sec

tion

3.

5-3.

OPERATION

OF

COMPUTER

INTERFACES

(Chart

5-1)

The

Computer

Interfaces

use

signals

from

the

welding

power

sources

and

Robot

Control

to

control

the

gas

valves,

weld

output,

and

wire

feed

speed.

Chart

5-1.

Sequence

Of

Operation

Timing

Arc

initiation

Weld

Start

Relay

Open

Wire

Feed

Speed

n~p~

Weld

Voltage

Command

Close

I

______

I

4Oto1OV~~~Crater

~~

~

Crater

Open

-

Close

Wire

inching

hH

Wire

Feed Motor

Gas

Valve

PrefiowTlmej

~

Postflow

Time

0.2

to

0.3

sec.

Wire

Stick

Check

~i1s

Wire

Stick

Check

(at

Arc

End)

Start

Time

S-0384

OM-141

438

Page

9

5-4.

WIRE

STICK

CHECK

(Chart

5-2)

IMPORTANT:

Wire

stick

check

timing

sequence

only

applies

if

DIP

switches

are

set

to

enable

this

function

(see

Section

3-2).

1.

A

signal

from

the

robot

control

indicates

to

the

Computer

Interface

that

the

welding

power

source

contactor

is

open

at

the

end

of

a

weld.

IMPORTANT:

Voltage

ramp

only

applies

if

DIP

switches

are

set

to

enable

this

function

and

the wire

stick

check

(see

Section

3-2).

2.

A

voltage

command

signal

is

sent

to

the

welding

power

source

that

ramps

up

from

the

value

of

the

burnback

setting.

This

increasing

voltage

com

mand

signal

lasts

until

100

milliseconds

after

the

wire

is

freed.

3.

The

stick

check

circuitry

is

enabled

after

the

weld

current

relay

opens

at

the

end

of

the

weld.

There

is

a

delay

of

approximately

8

milliseconds.

The

welding

power

source

contactor

pulses

on

for

a

50

to

75

millisecond

time

span.

The

weld

current

relay

closes.

During

this

pulse

of

the

contactor,

a

signal

is

sent

to

the

robot

control

indicating

that

current

is

flowing.

6.

The

robot

looks

for

a

20

millisecond

period

of

time

that

the

weld

current

relay

remains

open.

This

in

dicates

that

the

wire

is

free

of

the

weld

and

the

ro

bot

can

continue.

7.

If

the

Computer

Interface

sees

the

weld

current

relay

close,

it

cycles

through

another

50

millisec

ond

period

of

pulsing

the

contactor.

The

voltage

command

signal

continues

to

ramp

up.

8.

This

process

of

checking

the

weld

current

relay

and

pulsing

the

contactor

continues

until

the

wire

is

free

of

the

weld

or,

at

the

end

of

500

millisec

onds,

a

weld

abnormal

code

appears

on

the

robot

Program

Module,

if

the

wire

stick

function

is

en

abled

in

the

Robot

System

Data

3

for

Cl

Robot

Control.

An

error

code

appears

on

the

robot

Teach

Pendant

if

the

parameter

is

set

to

ON

in

PARMTERIWELDIWIRE

STICK

CHECK

for

C2

Robot

Control.

If

System

Data

3

Wire

Stick

Check

is

set

to

no

(disabled)

for

Cl

Robot

Control

or

PARMTER/WELD/WIRE

STICK

CHECK

is

set

to

OFF

for

C2

Robot

Control,

the

robot

may

try

to

move

even

after

the

Computer

Interface

de

tects

that

the

wire

is

stuck.

An

error

code

is

likely

to

ap

pear

in

this

instance.

The

Computer

Interface

may

detect

wire

stuck

even

though

the

wire

is

free

of

the

weld.

Reset

the

robot

and

continue

operation.

If

this

occurs

frequently,

contact

the

nearest

Factory

Authorized

Service

Station/Service

Dis

tributor.

Chart

5-2.

Wire

Stick

Check

Timing

80

MillIseconds

Shortest

Stick

I

8

50

20

SECTION

6-

MAINTENANCE

&

TROUBLESHOOTING

IMPORTANT:

Evenj

six

months

inspect

the

labels

on

this

unit

for

legibility.

All

precautionaiy

labels

must

be

maintained

in

a

clearly

readable

state

and

replaced

when

necessary.

See

Parts

List

for

part

number

of

precautionary

labels.

6-1.

INSPECTION

AND

UPKEEP

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

robot

and

welding

power

source,

and

disconnect

input

power

employing

lock

out/ta

g9ing

procedures

before

inspecting,

maintaining,

or

servicing.

Lockout/tagging

procedures

consist

of

pad

locking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

disconnect

ing

device.

HOT

SURFACES

can

cause

severe

burns.



Allow

cooling

period

before

servicing.

Maintenance

and

troubleshooting

to

be

per

formed

only

by

qualified

persons.

Usage

and

shop

conditions

will

determine

the

frequency

and

type

of

maintenance.

At

minimum,

inspect

equip

ment

every

three

months

as

follows:

1.

Inspect

all

interconnecting

cords

for

damage

to

or

breaks

in

the

insulation

jacket,

particularly

at

the

plugs.

Repair

or

replace

the

cord(s)

as

necessary.

2.

Remove

grease

and

dirt

from

components

and

moisture

from

electrical

parts

and

cables.

4.

5.

500

MillIseconds

Longest

Stick

Check

Time

(in

Milliseconds)

The

number

of

contactor

pulses

varies

with the

welding

power

source

used.

S-0385

OM-141

438

Page

10

6-2.

OVERLOAD

PROTECTION

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

robot

and

welding

power

source,

and

disconnect

input

power

employing

lock

out/tagging

procedures

before

inspecting,

maintaining,

or

servicing.

Lockoutltagging

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.

IMPROPER

FUSE

can

damage

unit.



Be

sure

replacement

fuse

is

same

size,

type,

and

rating

(see

Parts

List).

A.

Wire

Drive

Motor

Circuit

Breaker

CB1

a

WARNING:

Read

and

follow

safety

informa

tion

at

beginning

of

Section

6-2

before

pro

ceeding.

Circuit

breaker

CB1

protects

the

wire

drive

motor

from

overload.

If

CB1

opens,

the

wire

feed

circuit

shuts

down.

If

the

breaker

trips,

correct

the

problem,

and

manually

reset

CB1.

B.

Main

Fuse

Fl

a

WARNING:

Read

and

follow

safety

informs-

6-4.

tion

at

beginning

of

Section

6-2

before

pro

ceeding.

Fuse

Fl

protects

the

Computer

Interface

from

an

inter

nal

short

or

excessive

overload

.

If

fuse

Fl

opens,

the

Computer

Interface

shuts

down.

If

the

fuse

opens,

cor

rect

the

problem

and

replace

Fl

as

follows:

1.

Press

and

rotate

fuse

holder

cover

counterclock

wise.

2.

Pull

out

fuse

with

cover

when

fuse

holder

cover

is

free.

3.

Insert

new

fuse

into

fuse

holder

cover.

4.

Install

fuse

with

fuse

holder

cover

back

into

unit.

5.

Press

and

rotate

fuse

holder

cover

clockwise

until

cover

is

secure.

C.

Wire

Feed

Ground

Current

Light

This

light

turns

on

when

there

is

an

overcurrent

condition

at

the

wire

drive

motor

grounding

conductor.

An

emer

gency

stop

signal

is

sent

to

the

Robot

Control

and

servo

power

is

turned

ott.

Reset

by

turning

power

to

the

Com

puter

Interface

off,

correcting

the

condition

that

caused

the

shutdown,

and

turning

power

back

on.

6-3.

CIRCUIT

BOARD

HANDLING

PRECAUTIONS

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

robot

and

welding

power

source,

and

disconnect

input

power

employing

lock

out/tagging

procedures

before

inspecting,

maintaining,

or

servicing.

Lockout/tagging

procedures

consist

of

pad

locking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

disconnect

ing

device.

ELECTROSTATIC

DISCHARGE

(ESD)

can

damage

circuit

boards.



Put

on

properly

grounded

wrist

strap

BEFORE

handling

circuit

boards.



Transport

circuit

boards

in

proper

static-

shielding

carriers

or

packages.



Perform

work

only

at

a

static-safe

work

area.

INCORRECT

INSTALLATION

or

misaligned

plugs

can

damage

circuit

board.



Be

sure

that

plugs

are

properly

installed

and

aligned.

EXCESSIVE

PRESSURE

can

break

circuit

board.



Use

only

minimal

pressure

and

gentle

move

ment

when

disconnecting

or

connecting

board

plugs

and

removing

or

installing

board.

TROUBLESHOOTING

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

robot

and

welding

power

source,

and

disconnect

input

power

employing

lock

out/ta

g9ing

procedures

before

inspecting,

maintaining,

or

servicing.

Lockout/tagging

procedures

consist

of

pad

locking

line

disconnect

switch

in

open

position,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

disconnect

ing

device.

Troubleshooting

of internal

parts

to

be

per

formed

only

by

qualified

persons.

It

is

assumed

that

proper

installation

has

been

made

ac

cording

to

Section

3

of

this

manual,

the

operator

is

famil

iar

with

the

function

of

controls,

the

unit

was

working

properly,

and

that

the

trouble

is

not

the

welding

process.

The

following

chart

is

designed

to

diagnose

and

provide

remedies

for

some

of

the

troubles

that

may

develop

in

this

unit.

Use

this

chart

in

conjunction

with

the

circuit

diagram

while

performing

troubleshooting

procedures.

If

the

trouble

is

not

remedied

after

performing

these

proce

dures,

contact

the

nearest

Factory

Authorized

Service

Station/Service

Distributor.

In

all

cases

of

equipment

malfunction,

strictly

follow

the

manufacturers

recom

mendations.

OM-141

438

Page

11

Table

6-1.

Troubleshooting

TROUBLE

PROBABLE

CAUSE

REMEDY

Unit

does

not

operate.

Fuse

Fl

open.

Check

Fl,

and

replace

if

necessary

(Section

6-2).

Correct

overload

before

continuing

operation.

Circuit

breaker

CB1

tripped.

Check

CB1,

and

reset

if

necessary

(Section

6-2).

Correct

overload

before

continuing

operation.

No

meter

display

on

Display

Module.

Meter

not

working.

Replace

meter

(see

Section

6-3

and

contact

Factory

Authorized

Service

Station/Service

Distributor).

Meter

board

PCi

not

working.

Replace

PCi

(see

Section

6-3

and

contact

Factory

Authorized

Service

Station/Service

Distributor).

No

wire

feed.

Relay

CR1

not

working.

Replace

CR1.

Motor

board

PC2

not

working.

Replace

PC2

(see

Section

6-3

and

contact

Factory

Authorized

Service

Station/Service

Distributor).

Interface

board

PC4

not

work-

ing.

Replace

PC4

(see

Section

6-3

and

contact

Factory

Authorized

Service

Station/Service

Distributor).

Wire

feeds

at

maximum.

Tach

board

at

wire

drive

motor

not

working.

Replace

tach

board.

See

wire

drive

assembly

Own-

ers

Manual.

No

arc

voltage

control.

Voltage

control

connections.

Check

and

secure

connections

(Section

3-8).

Voltage

sensing

connections.

Check

and

secure

connections

(Section

3-7).

Remote

Voltage

control

switch

on

welding

power

source.

Remote

Voltage

control

switch

on

welding

power

source

must

be

in

remote

control

position.

Welding

power

source

MAXI-

MUM

GTAW

OUTPUT

control.

Rotate

control

to

maximum

position.

Welding

power

source

corn-

rnand

signal.

,

Check

command

signal

at

voltage

board

PC1.Com-

rnand

signal

should

be

0-10

vdc

at

RC1

pins

9

and

lOonPCl.

Robot

command

voltage.

Check

robot

command

voltage

to

voltage

board

PCi.

Signal

should

be

0-10

vdc

between

2TB

and

ilK

(common).

Voltage

board

PCi

not

working.

Replace

PCi

(see

Section

6-3

and

contact

Factory

Authorized

Service

Station/Service

Distributor).

Interface

board

PC4

not

work-

ing.

Replace

PC4

(see

Section

6-3

and

contact

Factory

Authorized

Service

Station/Service

Distributor).

Robot

moves

when

welding

wire

is

stuck.

Wire

stick

check

DIP

switches.

Be

sure

DIP

switches

are

in

desired

position

(Sec

tion

3-3).

Current

sensing

connections.

Check

and

secure

connections

(Section

3-7).

Wire

speed

meter

goes

to

zero.

Robot

command

voltage.

Check

robot

command

voltage

to

motor

board

PC2.

Signal

should

be

0-10

vdc

between

lIE

and

11K

(common).

Motor

board

PC2

not

working.

Replace

PC2

(see

Section

6-3

and

contact

Factory

Authorized

Service

Station/Service

Distributor).

No

wire

retract.

Communication

board

PC3

not

working.

Replace

PC3

(see

Section

6-3

and

contact

Factory

Authorized

Service

Station/Service

Distributor).

Robot

command

voltage.

Check

robot

command

voltage

at

motor

board

PC2.

Signal

should

be

0-10

vdc

between

lIE

and

ilK

(common).

Robot

shuts

down.

Looseweldoutputconnections.

Clean

and

tighten

connections.

Interconnecting

cords.

Check

all

interconnecting

cords

for

breaks;

repair

or

replace.

Check

and

secure

all

connections.

Communication

board

PC3

not

working.

Replace

PC3

(see

Section

6-3

and

contact

Factory

Authorized

Service

Station/Service

Distributor).

OM-141

438

Page

12

6-5.

USE

OF

INDICATOR

LIGHTS

FOR

TROUBLESHOOTING

On

Gas

Indicator

Light

Off

I

________

Gas

flows:

Gas

does

not

flow

Gas

flows:

Gas

does

not

flow

System

normal

(on.)

Check

gas

valve

operation.

Check

gas

valve

operation

System

normal

(off).

and

gas

line

for

leaks.

Check

interface

board

PC3.

On

~

Contactor

Indicator

Light

~

Off

Contactor

closed:

Contactor

open:

Contactor

open:

System

normal

(on).

Check

interconnecting

System

normal

(off).

cords.

Check

interface

board

PC4.

On

~

Wire

Feed

Indicator

Light

~

Off

1~

Wire

feeds:

Wire

does

not

feed:

Wire

feeds:

Wire

does

not

feed:

System

normal

(on).

Check

circuit

breaker

CB1

Check

relay

CR1.

System

normal

(off).

Check

relay

CR1.

Check

input

signal

from

robot

to

motor

board

PC2.

Signal

should

be

0-10

vdc

between

1TE

and

1TK

(common).

Check

interface

board

PC4.

Check

motor

board

PC2.

On

~

Current

Indicator

Light

~

Off

4,

Arc

started:

No

arc:

Arc

started:

No

arc:

System

normal

(on).

Replace

weld

current

Replace

weld

current

System

normal

(off).

relay.

On

~

Power

Indicator

Light

~

Off

Interface

Control

On:

Interface

Control

On:

Interface

Control

Off:

Normal.

Check

connections

between

System

normal

(off).

Interface

Control

and

Display

Module.

OM-141

438

Page

13

<<BCA-3 <<RCA-S

<<RCA-I

<<RCB-3

PLO

I

0/PLOP

I

CD

RCII

POWER

sasa

a

(a)

-U

5)

(0

0

a

.1

IT

A

0

.74

B

0

.39

C

0

40

0

fl

E~0

42

F0

~

0

2/

H

0

20

.1

0

.IV

4T

A

0

67

B

04

2T

A

0

22

B~.0

20

C0

45

0

2/

1

0

.~

~

H

1/

.10

ST

A

0

20

B

0

2/

H

C

ICT~

.3

0

TAOOTEB

0

F

A

PLO

IA

C~

H4~

P1019

RRR

PC4

INTERFACE

BOARD

BC

I/P1G3

BCA/P102

0

BC9

U)

m

C,

-I

0

z

-4

m

r

m

C,

-I

C)

r

a

C)

U)

A

~~i~0AG

VALVE

B

f

RCI/PLGI2

BC6/PLGA

BC2/P1G22

BC1/PIG7

BC3/PIG3O

RCA/PIGS

RC4/P104

RC9/PLG9

60

BC

I

2

K

I

.3

H

A

H

B

C

0£

F

-V.

REICTE

CQ4TRO

IIC.CTAWEE

45

DRCE?Cy

BT~

!~

~

u.vv-v-v-v-v-v-v.v-v-v-v-v-v-v-v-v.v.

N~MttMtI~?tMt??

AAAA~AAAAAA~A~AtVPCA~A/C

~

APBCDEFGHJKLHN

BC

9

PC

~I&IIICATID4

BOARD

XC

104

Circuit

Diagram

No.

SC-i

64

341-A

Diagram

7-i.

Circuit

Diagram

For

Computer

Interface

With

Dual

Torch

Adapter

Panel

Page is loading ...

Miller KD509571 Owner's manual

This manual is also suitable for

Miller KD509571 Owner's manual

Related papers

Other documents