Miller KF949009 Owner's manual

Brand: Miller

Model: KF949009

Category: Welding System

Type: Owner's manual

This manual is also suitable for

ROBOT PAC INTERFACE

Miller KF949009 is a Robot PAC Interface that turns a standard robot into a plasma arc cutting system. The system can be used for plasma arc cutting (PAC) or plasma arc gouging (PAG). It operates with Spectrum Matching Torch and 1250 Plasma Arc Cutter Power Supply.

Miller KF949009 is a Robot PAC Interface that turns a standard robot into a plasma arc cutting system. The system can be used for plasma arc cutting (PAC) or plasma arc gouging (PAG). It operates with Spectrum Matching Torch and 1250 Plasma Arc Cutter Power Supply.

Miller.

August

1995

Form:

OM-141

1820

Effective

With

Serial

No.

KF949009

OWNERS

MANUAL







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.

U

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

Robot

PAC

Interface



Plasma

Arc

Cutting

Interface

For

Robotic

Systems



For

Plasma

Arc

Cutting

(PAC)

And

Plasma

Arc

Gouging

(PAG)



Installs

Onto

Standard

Robot

Computer

Interface



Uses

Robot

Computer

Interface

Power

Supply



Operates

With

Spectrum

1250

Plasma

Arc

Cutter



Matching

Torch

For

Power

Supply

Allows

Easy

Connections

cover

5/94



ST-145

177

'

1995

MILLER

Electric

MIg.

Co.

PRINTED

IN

USA

MILLERS

TRUE

BLUEﬁ

LIMITED

WARRANTY

Effective

January

1,

1995

(Equipment

with

a

serial

number

preface

of

KD

or

newer)

This

limited

werrenty

supersedes

eli

previous

MILLER

warranties

snd

is

exclusive

with

no

other

gusrsntees

or

werrenties

espressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

snd

conditions

below,

MILLER

Electric

Mtg.

Co.,

Appleton,

Wisconsin,

wsrrsnts

to

its

originsl

retell

purchsser

thst

new

MILLER

equipment

sold

stter

the

effective

dste

oI

this

limited

wsrrsnty

is

Iree

oI

de

Iects

in

msterisl

end

workmenship

et

the

time

it

is

shipped by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES,

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below,

MILLER

will

repeir

or

replece

eny

war-

rented

perte

orcomponents

thet

teil

due

to

such

detects

in

meteriel

or

workmenahip.

MILLER

must

be

notitied

in

writing

within

thirty

(30)

deye

oI

such

detect

or

teilure,

et

which

time

MILLER

wilt

provide

instructions

on

the

werrenty

cleim

procedures

lobe

tollowed.

MILLER

shell

honor

werrenty

claims

on

warranted

equipment

listed

below

in

the

event

ot

such

e

tailure

within

the

werrenty

lime

periods.

Alt

werrenty

time

periods

etert

on

the

dete

thet

the

equipment

wee

delivered

to

the

original

reteil

purcheser,

or

one

yeer

slIer

the

equipment

is

sent

to

e

North

Americen

distributor

or

eighteen

months

eher

the

equipment

is

sent

to

en

Internetionel

distributor.

1.

5Yeere

Perts3YeereLebor



Original

mein

power

rectitiere

Invertera

(input

end

output

reclitiere

only)

2.

3

Yeere



Perts

end

Lebor

*

Trenetormer/Rectitier

Power

Sources



Ptaeme

Arc

CuBing

Power

Sourcee



Semi-Autometic

end

Autometic

Wire

Feeders



Inverter

Power

Supplies

*

Intellitiga



Robots

3.

2

Years



Peas

end

Labor

-

Engine

Driven

Welding

Generetora

(NOTE:

Engines

ere

werrented

separetely

by

the

engine

menutecturer.)



Air

Compressors

4.

1

Yeer



Peas

end

Labor

*

Motor

Driven

Guns



Process

Controllers

IHPS

Power

Sources

*

Weter

Coolant

Systems



HF

Units



Grids



Spot

Welders

*

Load

Benke



SDX

Tranetormera

*

Running

Geer/Treilere



Plasme

Cutting

Torches

(except

APT,

ZIPCUT

&

PLAZCUT

Models)



Tecumeeh

Engines



Deutz

Engines

(outside

Noah

Americe)

-

Field

Options

(NOTE:

Field

options

ere

covered

under

True

Blueﬁ

br

the

remaining

warmnty

period

ot

the

product

they

ere

instelled

in,

or

tore

minimum

ot

one

yeer



whichever

is

greeter.)

1

S.

6

Monthe



Betteriee

xw.,

6.

g~

Days



Peas

end

Labor

MIG

Guns/TIG

Torches

APT,

ZIPCUT

&

PLAZCUT

Model

Plesme

Cutting

Torches

Remote

Controls

Accessory

Kits

*

Replecement

Peas

MILLERS

True

Blueﬁ

Limited

Werrenty

shell

not

epply

to:

1.

Items

turnished

by

MILLER,

but

manutactured

by

others,

such

ax

engines

or

trade

accessories.

These

items

are

covered

by

the

manutacturers

warranty,

it

any.

2.

Consumable

components;

such

aa

contact

tips,

cutting

nozzles,

contactora

and

relays

or

parts

that

tail

due

to

normal

wear.

3.

Equipment

that

has

been

moditied

by

any

party

other

then

MILLER,

or

equip

ment

that

has

been

improperiy

installed,

impropedy

operated

or

misused

based

upon

industry

atandarda,

or

equipment

which

has

not

had

reasonable

and

neceasaty

maintenance,

or

equipment

which

haa

been

used

br

operation

outside

ot

the

epecibicationa

br

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

EGUIPMENt

In

the

event

ot

a

warranty

claim

covered

by

this

warranty,

the

exclusive

remediea

shall

be,

at

MILLERS

option:

(1)

repair;

or

(2)

replacement;

or,

where

authorized

in

writing

by

MILLER

in

appropriate

cases,

(3)

the

reasonable

coat

ot

repair

or

replace

ment

at

an

authorized

MILLER

service

station;

or

(4)

payment

ot

or

credit

torthe

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

ot

the

goode

at

customers

risk

and

expense.

MILLERS

option

ot

repair

or

replacement

will

be

FOB.,

Factory

at

Appleton,

Wieconain,

or

FOB.

at

a

MILLER

authorized

ser

vice

tacility

as

determined

by

MILLER.

Theretore

no

compensation

or

reimburse

ment

br

Iranaportation

costs

ot

any

kind

will

be

allowed.

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

CONSEOUENTIAL

DAMAGES

(INCLUDING

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

AS

TO

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

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

IMPUED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

ALL

EOUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

atatea

in

the

U.S.A.

do

not

allow

limilaliona

ob

how

long

an

implied

warranty

lasts,

or

the

exclusion

ot

incidental,

indirect,

special

or

consequential

damages,

so

the

above

limitation

or

exclusion

may

not

apply

to

you.

This

warranty

provides

ape

citic

legal

rights,

and

other

rights

may

be

available,

but

may

vary

trom

state

to

state.

In

Canada,

legislation

in

aome

provinces

provides

br

certain

additional

warrantlea

or

remedies

other

than

as

stated

herein,

and

to

the

extent

that

they

may

not

be

waived,

the

limitations

and

exclusions

set

out

above

may

not

apply.

This

Limited

Warranty

provides

specitic

legal

rights,

and

other

rights

may

be

available,

but

may

vary

trom

province

to

province.

-1.

I

J

tax

RECEIVING-HANDLING

Before

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

6/~5

PLASMA

ARC

CUTTING

SAFETY

PRECAUTIONS

QUALIFIED

PEOPLE

CUTTING

can

cause

fire

or

explosion.

Hot

metal

and

sparks

blow

out

from

the

cutting

arc.

The

flying

sparks

and

hot

metal,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Check

and

be

sure

the

area

is

safe

before

doing

any

cutting.

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

2.

Do

not

cut

where

flying

sparks

can

strike

flammable

material.

3.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

cutting

arc.

If

this

is

not

possible,

tightly

cover

them

with

approved

covers.

4.

Be

alert

that

sparks

and

hot

materials

from

cutting

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

cutting

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

ARC

RAYS

can

burn

eyes

and

skin.

J

Arc

rays

from

the

cutting

process

produce

intense

~r\.J4

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

burn

eyes

and

skin.

1.

Wear

face

protection

(helmet

or

shield)

with

correct

shade

of

filter

to

protect

your

face

and

eyes

when

cutting

or

watching.

ANSI

Z49.1

(see

Safety

Standards)

suggests

a

No.

9

shade

(with

No.

8

as

minimum)

for

all

cutting

currents

less

than

300

amperes.

Z49.1

adds

that

lighter

filter

shades

may

be

used

when

the

arc

is

hidden

by

the

workpiece.

As

this

is

normally

the

case

with

low

current

cutting,

the

shades

suggested

in

Table

1

are

provided

for

the

operators

convenience.

2.

Wear

approved

safety

glasses

with

side

shields.

3

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

4.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leathers

and

foot

Drotection.

7.

Do

not

cut

on

closed

containers

such

as

tanks

or

drums.

8.

Connect

work

cable

to

the

work

as

close

to

the

cutting

area as

practical

to

prevent

cutting

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

9.

Never

cut

containers

with

potentially

flammable

materials

inside



they

must

be

emptied

and

properly

cleaned

first.

10.

Do

not

cut

in

atmospheres

containing

explosive

dust

or

vapors.

Do

not

cut

pressurized

cylinders,

pipes,

or

vessels.

Do

not

cut

containers

that

have

held

combustibles.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

14.

Do

not

locate

unit

on

or

over

combustible

surfaces.

15.

Remove

any

combustibles,

such

as

a

butane

lighter

or

matches,

from

your

person

before

doing

any

cutting.

a

WARNING

PLASMA

ARC

CUTTING

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

cutting,

as

in

most

jobs,

exposure

to

certain

hazards

occurs.

Cuffing

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

11.

12.

13.

ELECTRIC

SHOCK

can

kill.



Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

burns.

The

torch

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.

Plasma

arc

cutting

recluires

higher

voltages

than

welding

to

start

and

maintain

the

arc

(200

to

400

volts

dc

are

common),

but

also

uses

torches

designed

with

safety

interlock

systems

which

turn

off

the

machine

when

the

shield

cup

is

loosened

or

if

tip

touches

electrode

inside

the

nozzle.

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.

Do

not

touch

torch

parts

if

in

contact

with

the

work

or

ground.

5.

Turn

oft

power

before

checking,

cleaning,

or

changing

torch

parts.

6.

Disconnect

input

power

before

installing

or

servicing

this

equipment.

Lockout/tagout

input

power

according

to

OSHA

CFR

191

0.147

(see

Safety

Standards).

7.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

8.

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



always

verify

the

supply

ground.

9.

When

making

input

connections,

attach

proper

grounding

conductor

first.

10.

Frequently

inspect

input

power

cord

for

damage

or

bare

wiring



replace

cord

immediately

if

damaged



bare

wiring

can

kill.

11.

Turn

off

all

equipment

when

not

in

use.

12.

Inspect

and

replace

any

worn

or

damaged

torch

cable

leads.

13.

Do

not

wrap

torch

cable

around

your

body.

14.

Ground

the

workpiece

to

a

good

electrical

(earth)

ground

if

required

by

codes.

15.

Use

only

well-maintained

equipment. Repair

or

replace

damaged

parts

at

once.

16.

Wear

a

safety

harness

if

working

above

floor

level.

17.

Keep

all

panels

and

covers

securely

in

place.

18.

Do

not

bypass

or

try

to

defeat

the

safety

interlock

systems.

19.

Use

only

torch(es)

specified

in

Owners

Manual.

20.

Keep

away

from

torch

tip

and

pilot

arc

when

trigger

is

pressed.

21.

Clamp

work

cable

with

good

metal-to-metal

contact

to

workpiece

(not

piece

that

will

fall

away)

or

worktable

as

near

the

cut

as

practical.

~-.

NOISE

can

damage

hearing.

I

Prolonged

noise

from

some

cutting

applications

can

damage

hearing

if

levels

exceed

limits

specified

by

OSHA

(see

Safety

Standards).

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

2.

Warn

others

nearby

about

noise

hazard.

Table

1.

Eye

Protection

For

Plasma

Arc

Cutting

Current

Level

In

Amperes

Minimum

Shade

Number

Below

20

I

#4

2040

I

#5

00

6080

I

_______

_________

_________

#8

sr2

11/92

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

wearing

an

air-supplied

respirator.

Fumes

from

cutting

and

oxygen

depletion

can

alter

airquality

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.

6.

Do

not

cut

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

cut

on

coated

metals,

such

as

galvanized,

lead,

or

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

cutting

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

when

cut.

8.

Do

not

cut

containers

with

toxic

or

reactive

materials

inside

or

containers

that

have

held

toxic

or

reactive

materials



they

must

be

emptied

and

properly

cleaned

first.

~

PLASMA

ARC

can

cause

injury.

3.

The

pilot

arc

can

cause

burns



keep

away

from

torch

tip

when

The

heat

from

the

plasma

arc

can

cause

serious

trigger

is

pressed.

burns.

The

force

of

the

arc

adds

greatly

to

the

burn

4.

Wear

proper

flame-retardant

clothing

covering

all

exposed

hazard.

The

intensely

hot

and

powerful

arc

can

body

areas.

__________

quickly

cut

through

gloves

and

tissue.

5.

Point torch

away

from

your

body

and

toward

work

when

pressing

the

torch

trigger



pilot

arc

comes

on

immediately.

6.

Turn

oft

power

source

and

disconnect

input

power

before

1.

Keep

away

from

the

torch

tip.

disassembling

torch

or

changing

torch

parts.

2.

Do

not

grip

material

near

the

cutting

path.

7.

Use

only

torch(es)

specified

in

the

Owners

Manual.

~

FLYING

SPARKS

AND

HOT

METAL

can

1.

Wear

approved

face

shield

or

safety

goggles

with

side

shields.

cause

injury.

2.

Wear

proper

body

protection

to

protect

skin.

Chipping

and

grinding

cause

flying

metal.

As

welds

3.

Wear

flame-resistant

ear

plugs

or

ear

muffs

to

prevent

sparks

cool,

they

can

throw

off

slag.

from

entering

ears.

CYLINDERS

can

explode

if

damaged.

3.

Keep

cylinders

away

from

any

cutting

or

otherelectrical

circuits.

4.

Never

allow

electrical

contact

between

a

plasma

arc

torch

and

a

Gas

cylinders

contain

gas

under

high

pressure.

If

cylinder.

damaged,

a

cylinder

can

explode.

Since

gas

5.

Never

cut

on

a

pressurized

cylinder



explosion

will

result.

cylinders

are

normally

part

of

metalworking

6.

Use

only

correct

gas

cylinders,

regulators,

hoses,

and

fittings

processes,

be

sure

to

treat

them

carefully.

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

7.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

8.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

mechanical

shocks,

slag,

open

flame,

sparks,

and

arcs.

in

use

or

connected

for

use.

2.

Install

and

secure

cylinders

in

an

upright

position

by

chaining

9.

Read

and

follow

instructions

on

compressed

gas

cylinders,

them

to

a

stationary

support

or

equipment

cylinder

rack

to

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

prevent

falling

or

tipping.

Standards.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.i,

from

American

National

Electrical

Code,

NFPA

Standard

70,

from

National

Fire

Pro-

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

FL

33126

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Safe

Hand/mg

of

Compressed

Gases

Th

cylinders,

CGA

Pamphlet

Safetyand

Health

Standards,

OSHA

29

CFR

1910,

from

Superinten-

P-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

High-

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

way

Suite

501

Arlinnton

VA

22202

D.C.

20402.

,

,

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

Wi

17.2,

from

Recommended

Practices

for

Plasma

Arc

Cutting,

American

Welding

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Bou

Society

Standard

AWS

C5.2,

from

American

Welding

Society,

550

levard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

N.W.

LeJeune

Rd,

Miami,

FL

33126

.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Protec

tion,

ANSI

Standard

Z87.i,

from

American

National

Standards

Recommended

Safe

Practices

for

the

Preparation

for

Welding

and

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

of

Containers

That

Have

Held

Hazardous

Substances,

Ameri

can

Welding

Society

Standard

AWS

F4.1,from

American

Welding

So-

Cutting

And

Welding

Processes,

NFPA

Standard

51

B,

from

National

ciety,

550

N.W.

LeJeune

Rd,

Miami,

FL

33126

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

FUMES

AND

GASES

can

be

hazardous

to

your

health.

Cutting

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

cutting

fumes

and

gases.

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

4.

Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

manufacturers

instruction

for

metals

to

be

cut,

coatings,

and

cleaners.

sr2

11/92

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1



SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

1

1-1.

General

Information

And

Safety

1

1-2.

Safety

Alert

Symbol

And

Signal

Words

1

SECTION

2

INTRODUCTION

1

2-1.

Description

1

SECTION

3

INSTALLATION

3-1.

Field

Installation

Instructions

For

PAC

Interface

Panel

To

Computer

Interface

3-2.

Shock

Sensor

Unit

Assembly

And

Installation

To

Robot

3-3.

Torch

And

Torch

Cable

Installation

To

Robot

3-4.

Ground

Cable

Connections

3-5.

Ground

Cable,

Torch

Cable,

And

PAC

lntertace

Panel

Cord

Internal

Connections

To

Power

Source

3-6.

PAC

Interface

Panel



Computer

Interface

Connection

3-7.

PAC

Interface

Panel



Power

Source

Connection

3-8.

Computer

Interface



Input

Power

Connections

SECTION

4-

ROBOT

PROGRAM

MODIFICATIONS

4-1.

Setting

Up

Plasma

Torch

For

MRV-6

Robot

4-2.

Amendment

To

Robot

Owners

Manual

Section

4



System

Set

Up

SECTION

5-

ELECTRICAL

DIAGRAMS

Diagram

5-1.

Circuit

Diagram

For

Robot

PAC

System

Diagram

5-2.

Circuit

Diagram

For

Robot

PAC

Interface

Panel

Diagram

5-3.

Wiring

Diagram

For

Robot

PAC

Interface

Panel

SECTION

6

PARTS

LIST

16

N

OTE

~

I

Considerations

About

Magnetic

Fields

The

following

is

a

quotation

from

the

General

Conclusions

Section

Welding

And

The

Effects

Of

Low

Frequency

Electric

And

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

of

the

U.S.

Congress,

Office

of

Technology

Assessment,

Biological

procedures:

Effects

of

Power

Frequency

Electric

&

Magnetic

Fields



Background

Paper,

OTA-BP-E-53

(Washington,

DC:

U.S.

Government

Printing

Office,

May

1989):

.

. .

there

is

now

a

very

1.

Keep

cables

close

together

by

twisting

or

taping

them.

~

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

large

volume

of

scientific

findings

based

on

experiments

at

the

3.

Do

not

coil

or

drape

cables

around

the

body.

cellular

level

and

from

studies

with

animals

and

people

which

clearly

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

complex.

Current

scientific

understanding

does

not

yet

allow

us

to

interpret

the

evidence

in

a

4.

Keep

welding

power

source

and

cables

as

far

away

as

practical.

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

possible.

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

About

Pacemakers:

allow

us

to

draw

definite

conclusions

about

questions

of

possible

risk

or

to

offer

clear

science-based

advice

on

strategies

to

minimize

The

above

procedures

are

among

those

also

normally

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

or

avoid

potential

risks.

complete

information.

modlO

1

4/93

1

2

3

4

5

6

7

7

7

7

7

7

14

14

15

15

OM-141

182C6/95

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

troubleshooting

which

should

be

read,

understood,

and

followed

for

the

safe

and

effective

use

of

this

equipment.

B.

Safety

The

installation,

operation,

maintenance,

and

trouble

shooting

of

plasma

arc

cutting

equipment

requires

prac

tices

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

applica

ble

codes

such

as,

but

not

limited

to,

those

listed

in

Plasma

Arc

Cutting

Safety

Precautions

in

the

power

source

Owners

Manual.

1-2.

SAFETY

ALERT

SYMBOL

AND

SJGNAL

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.

a

This

safety

alert

symbol

is

used

with

the

signal

words

WARNING

and

CAUTION

to

call

atten

tion

to

the

safety

statements.

a

a

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-

INTRODUCTION

2-1.

DESCRIPTION

211),

MILLER

Computer

Interface,

and

MRV-6

robot

The

robot

PAC

interface

panel

is

a

control

designed

to

system

for

the

Plasma

Arc

Cutting

(PAC)

process.

The

be

used

with

a

Spectrum

1250

plasma

arc

cutter

robotTeach

Pendant

must

have

afiberoptic

kit

(MILLER

equipped

with

a

shielded

torch

(MILLER

Part

No.

169

Part

No.

042

471)

installed.

SECTION

3-

INSTALLATION

Robot

Computer

Interface

Robot

Computer

interface

Input

Power

Receptacle

RC11

Location

(see

Section

3-8

and

Computer

Interface

Owners

Manual)

SC-145

177

PAC

Interface

Panel

Receptacle

RC2O

(see

Section

3-7)

Figure

3-1.

PAC

Interface

Panel

OM-141

182

Page

1

3-1.

FIELD

INSTALLATION

INSTRUCTIONS

FOR

PAC

INTERFACE

PANEL

TO

COMPUTER

IN

TERFACE

(Figures

3-1

And

3-2)

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

robot

and

power

source,

and

dis

connect

input

power

employing

lockout/tag

ging

procedures

before

beginning

this

instal

lation.

Lockoutltagging

procedures

consist

of

padlocking

line

disconnect

switch

in

open

posi

tion,

removing

fuses

from

fuse

box,

or

shutting

off

and

red-tagging

circuit

breaker

or

other

dis

connecting

device.

ELECTROSTATIC

DISCHARGE

(ESD)

can

damage

circuit

boards.



Put

on

properly

grounded

wrist

strap

BEFORE

handling

circuit

boards.



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.

IMPORTANT:

All

directions,

such

as

left

or

right,

are

with

respect

to

the

operator

facing

the

Computer

Inter

face

front

panel.

Retain

all

hardware

removed

during

this

procedure

for

reinstallation

unless

specifically

told

otherwise.

1.

Remove

Computer

Interface

top

cover

and

left

side

panel.

2.

Remove

side

panel

from

PAC

Interface

panel.

3.

Install

PAC

Interface

frame

onto

left

side

panel

of

Computer

Interface

with

sheet

metal

screws

re

moved

in

Step

1

(see

Figure

3-1).

4.

Make

the

following

internal

connections

to

the

Computer

Interface

(see

Figure

3-2).

a.

Remove

jumper

link

between

terminals

B

and

C

on

terminal

strip

2T.

b.

Connect

lead

26

from

the

PAC

Interface

panel

to

terminal

B

on

terminal

strip

2T.

c.

Connect

lead

60

from

the

PAC

Interface

panel

to

top

mounting

screw on

filter

FL1.

d.

Connect

green

lead

from

the

PAC

Interface

panel

to

the

ground

stud

located

directly

above

terminal

strip

2T.

Motor

Control

Board

PC2

Ground

Stud

Location

Left

Side

View

Of

Computer

Interface

o~

or-i

Voltage

Control

Board

PCi

1

Interface

J~.

Board

PC4

PC4

Switch

Si

Location

Mounting

Screw

Location

Figure

3-2.

Computer

Interface

Internal

Connections

]

00

ITh

Terminal

Strip

2T



PC4

Receptacle

RC1

Location

Filter

FL1

Ref.

SB-139

887-C

OM-141

182

Page

2

IMPORTANT:

Remove

the

outside

star

washer

from

the

ground

stud

to

make

room

for

the

green

lead

terminal.

e.

Remove

plug

PLG3

from

receptacle

RC1

on

In

terface

Board

PC4.

f.

Connect

plug

PLG1O

from

the

PAC

Interface

panel

to

Interlace

Board

PC4

receptacle

RC1

where

plug

PLG3

was

removed

in

Step

4e

(plug

PLG3

is

not

connected

for

this

application).

5.

Locate

switch

Si

on

Interface

Board

PC4

(see

Figure

3-2).

Remove

varnish

and

potting

com

pound

from

Si

and

place

the

two

DIP

switches

on

Si

in

the

following

positions:

a.

Si-i

(Disable

Voltage

Ramp)

in

OFF

position.

b.

Si-2

(Disable

Stick

Checking)

in

ON

position.

6.

Reinstall

side

panel

onto

PAC

Interface

panel.

7.

Install

supplied

top

cover

onto

the

Computer

In

terface



PAC

Interface

panel.

3-2.

SHOCK

SENSOR

UNIT

ASSEMBLY

AND

IN

STALLATION

TO

ROBOT

(Figure

3-3)

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

robot

and

power

source,

and

dis

connect

input

power

employing

lockout/tag

ping

procedures

before

inspecting

or

install

ing.

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.

MOVING

PARTS

can

cause

serious

injt~ry.



Keep

away

from

moving

parts.

HOT

SURFACES

can

cause

severe

burns.



Allow

cooling

period

before

sen/icing.

To

assemble

and

install

the

shock

sensor

unit,

refer

to

Figure

3-3

and

proceed

as

follows:

1.

If

applicable,

remove

existing

shock

sensor

from

robot

arm.

2.

Assemble

shock

sensor,

mounting

bracket,

and

torch

clamp

as

shown

in

Figure

3-3.

3.

Install

shock

sensor

unit

to

robot

insulating

block

with

screws

removed

in

Step

1.

Robot

Arm

Ret.

ST-Boo

476

Shock

Sensor

Torch

Clamp

Figure

3-3.

MRV

Shock

Sensor

Unit

Assembly

And

Installation

OM-141

182

Page

3

3-3.

TORCH

AND

TORCH

CABLE

INSTALLATION

TO

ROBOT

(Figure

3-4

And

Figure

3-5)

a

WARNING:

ELECTRIC

SHOCK

can

kill.



Do

not

touch

live

electrical

parts.



Shut

down

robot

and

power

source,

and

dis

connect

input

power

employing

lockout/tag

ging

procedures

before

inspecting

or

install

ing.

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.

MOVING

PARTS

can

cause

serious

injury.



Keep

away

from

moving

parts.

HOT

SURFACES

can

cause

severe

burns.



Allow

cooling

period

before

servicing.

1.

Remove

the

outlet

cable

support

arm

and

wire

drive

assembly

from

the

robot

Axis

3

housing.

2.

Install

supplied

torch

cable

support

bracket

onto

robot

Axis

3

housing

using

the

existing

mounting

holes.

Position

supplied

insulator

plate

between

bracket

and

robot,

align

holes

and

secure

with

supplied

hardware

(see

Figure

3-5).

3.

Install

supplied

servo

light

box

onto

robot

Axis

3

housing

directly

in

front

of

torch

cable

support

bracket

using

the

existing

mounting

holes

(see

Figure

3-5).

Position

supplied

insulator

plate

be

tween

light

box

and

robot,

align

holes

and

secure

with

supplied

hardware.

Connect

plug

on

light

box

cord

to

nearby

matching

receptacle

located

on

the

side

of

the

Axis

3

housing.

The

receptacle

on

the

light

box

is

not

used

for

this

application.

4.

Install

cable

hanger

assembly

with

tool

balancer

onto

robot

Axis

3

housing.

5.

The

torch

cable

is

shielded

and

enclosed

in

a

black

protective

case.

Position

torch

handle

so

that

there

is

approximately

4

in.

(96

mm)

between

the

bottom

of

the

torch

clamp

and

the

torch

tip.

Clamp

torch

cable

to

tool

balancer

on

cable

hang

er

and

route

cable

through

support

bracket.

6.

Route

remaining

end

of

torch

cable

to

the

power

source

for

internal

connections

(see

Section

3-5B).

IMPORTANT:

Before

operating,

see

Section

4

and

ro

bot

Owners

Manual

for

instructions

for

absolute

offset

adjustment.

Install

position

gauge

(I-bar)

onto

robot

out

put

hub

bracket.

Remove

the

shield

cup

and

tip

from

torch

and

Install

the

supplied

brasØ

tip

gauge

and

holder

(see

Figure

3-4).

Torch

ccID

~

Brass

Tip

Gauge

~

Standard

Assembly

Teach

Tip

ST-801

330

Figure

3-4.

Torch

Brass

Tip

Gauge

For

Absolute

Offset

Adjustment

And

Teach

Tip

7.

The

supplied

high

frequency

filter

box

is

installed

onto

and

is

internally

connected

to

the

Robot

Controller

(see

Figure

3-5

and

Step

8).

The

filter

box

receptacle

provides

a

connection

point

for

the

supplied

35

ft.

(10.5

m)

shielded

shock

sensor

cable.

To

install

shock

sensor

cable

and

connect

to

shock

sensor,

proceed

as

follows:

a.

Route shock

sensor

cable

under

the

torch

cable

securing

straps

on

the

outside

of

the

protective

casing.

b.

Connect

cable

connector

to

shock

sensor.

8.

To

install

the

high

frequency

filter

box

onto

the

Ro

bot

Controller

and

make

internal

connections

re

fer

to

Section

4.10.1

in

the

MRV

Cl

robot

Owners

Manual

or

Section

4.12

in

the

MRV

C2

robot

Owners

manual

and

proceed

as

follows:

ft_

WARNING:

ELECTRIC

SHOCK

can

kill.

_____



Do

not

touch

live

electrical

parts.



Shut

down

Robot

Controller,

and

disconnect

input

power

employing

lockout/ta

going

pro

cedures

before

inspecting

or

installing.

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

or

making

con

nections

inside

Robot

Control.



Transport

circuit

boards

in

proper

static

shielding

carriers

or

packages.



Perform

work

only

at

a

static-safe

work

area.

a.

Open

Robot

Control

cabinet

door

using

the

two

supplied

keys,

and

rotate

the

power

switch

han-

OM-141

182

Page

4

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Miller KF949009 Owner's manual

Brand: Miller

Model: KF949009

Category: Welding System

Type: Owner's manual

This manual is also suitable for

ROBOT PAC INTERFACE

Miller KF949009 is a Robot PAC Interface that turns a standard robot into a plasma arc cutting system. The system can be used for plasma arc cutting (PAC) or plasma arc gouging (PAG). It operates with Spectrum Matching Torch and 1250 Plasma Arc Cutter Power Supply.

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