Miller
April
1992
FORM:
OM-884B
Effective
With
Serial
No.
KC188391
MODEL:
ABB
Robot
Interface
Gas/Current
Sensing
Control
Hub
And
Spindle
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
both
this
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
Installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equip
ment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
Miller
Group
Ltd..
Compeny
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
PflINTED
IN
U.S.A
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial
number
preface
of
KC
or
newer)
This
limited
warranty
supersedes
atl
previous
MILLER
warranties
and
is
eeclusive
with
no
other
guarantees
or
warranties
eepressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
below.
MILLER
Electric
Mfg.
Co-.
Appleton,
Wisconsin,
warrants
to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
aher
the
effective
dale
of this
limited
warranty
is
free
of
de
fects
in
material
and
workmanship
at
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
repair
or
replace
any
war
ranted
parts
or
components
that
fail
duets
such
defects
in
material
or
workmanship.
MILLER
must
be
notilied
in
writing
within
thirty
(30)
days
of
such
defect
or
failure,
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
tollowed.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
such
a
failure
within
the
warranty
time
periods.
All
warranty
time
periods
start
on
the
date
that
the
equipment
w55
delivered
to
the
original
retail
purchaser.
and
are
as
follows:
t.
5
Years
Parts
3
Years
Labor
*
Original
main
power
rectifiers
2.
3
Years
Parts
and
Labor
*
Transformer/Rectifier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
*
Semi-Automatic
and
Automatic Wire
Feeders
*
Robots
3.
2
Years
Parts
and
Labor
*
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
4.
t
Year
Parts
and
Labor
Motor
Driven
Guns
Process
Controllers
Water
Coolant
Systems
HP
Units
*
Grids
*
Spot
Welders
*
Load
Banks
*
SDX
Transformers
*
Running
Gear/Trailers
*
Field
Options
(NOTE:
Field
options
are
covered
under
True
Blue~M
for
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
tsr
a
minimum
of
one
year
whichever
is
greater)
5.
6
Months
Batteries
6.
90
Days
Parts
and
Labor
MIG
Guns/Tb
Torches
Plasma
Cutting
Torches
*
Remote
Controls
*
Accessory
Kits
*
Replacement
Parts
MILLERS
True
BIuerM
Limited
Warranty
shall
not
apply
to:
Items
furnished
by
MILLER,
but
manufactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components:
such
as
contact
tips,
cutting
nozzles,
csnt
actors
and
relays.
3
Equipment
that
has
been
modified
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
for
operation
outside
of
the
specifications
for
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
of
a
warranfy
claim
covered
by
this
warranty,
the
eectusive
remedies
shall
be.
at
MILLERS
option:
(1
(repair:
or
(2)
replacement:
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases.
(3)
the
reasonable
cost
of
rnpsiror
replace
ment
at
an
authorized
MILLER
service
station:
or
(41
payment
of
or
credit
forthe
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
usn(
upon
refurn
of
the
goods
at
customers
risk
and
espense
MILLERS
option
of
repair
or
replacement
wilt
be
P.O.B
,Factory
at
Appleton,
Wisconsin,
orF.O.B.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costs
of
any
kind
will
be
allowed.
-
TO
THE
EXTENT
PERMfTTED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSfVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
LIABLE
FOR
DIRECT
INDIRECT
SPECIAL,
INCtDENTAL
OR
CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS
OP
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
OP
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVfSION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALfNG,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
PfTNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MfLLER.
Some
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
lasts.
or
the
soctusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
eeclusion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal
rights,
and
ofher
rights
may
be
available,
but
may
vary
from
state
fo
stale.
In
Canada,
legislation
in
some
provinces
provides
for
certain
addifional
warranties
or
remedies
other
than
as
staled
herein,
and
to
the
estnnt
that
they
may
not
be
waived.
the
limitationS
and
esclusiorms
ssf
out
above
may
not
apply.
This
Limited
Warranty
provides
specific
legal
righfs,
and
other
rights
may
be
available,
but
msy
vary
from
province
to
province.
<
I
K!>
:1~.
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
manufacturers
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
5/92
ERRATA
SHEET
P
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
AMENDMENT
TO
SECTION
3
INSTALLATION
Amend
Section
3-4B.
ROBOT
INTERFACE
WELDING
POWER
SOURCE
CONNECTIONS:
Output
Control
Con
nections
To
PULSTAR
a
CAUTION;
WELDING
POWER
SOURCE
will
not
respond
with
output
corresponding
to
set
value.
Be
sure
welding
power
source
main
control
board
is
modified
to
use
a
0
to
+
10
volt
command.
See
welding
power
source
Owners
Manual
for
modification
procedure.
Amend
Figure
3-9.
Voltage
Control
Board
DIP
Switch
Setting
Label
S2
Si
1
2
1
2
3
4
5
DELTAWELD
300
ON
ON ON
DELTAWELD
451
0
ON
ON
DELTAWELD
651
0
ON ON
MAXTRON
300,
400
ON ON
MAXTRON
450
ON ON
ON
XMT
200/300
ON
ON
ON
ARC
PAK35O
ON
ON
ON
SHOPMASTER
300
ON
ON ON
DIMENSION
400
ON
L\
t~
ON
PULSTAR
450
ON
Figure
3-8.
Voltage
Control
Board
DIP
Switch
Setting
Label
AMENDMENT
TO
SECTION
7-
ELECTRICAL
DIAGRAMS
DVC
SWITCH
SETTINGS
O
On
For
Optional
Soft
Start.
Turn
Off
Si
-3.
A
On
For
Optional
Hot
Start.
S-150 864.0
Amend
Diagram
7-1.
Circuit
Diagram
For
Robot
Interface
(See
Page
2
on
this
Errata
Sheet)
CD
F
IC
.1
1
A
B
C
0
E
F
C
CI
J
K
L
U
IT
0
0
0
0
00
0
0
0
0
0
0
/
4
6/627212J/84J5/2/00/0/
A
6
C
D
E
F
C
H
J
K
L
U
21
0
0
0
0
0
0
Q~J~JT
0
0
0
~
~
7/
70
~p
69
52
/07
AiPEP
FACTC~Y
Ca4~CTE0
IN
POSITIUI
2
FcAC
USE
WITH
PCLSTAP.
I-CVE
J.JPER
ro
POSIT1~
I
FTP?
liVE
WITH
F~LTAWELD.
I.
MAXTPTPA
300.
C
P
0
H
F
S
C
PS
.~
V
Z
C0
SC-151
242-B
Diagram
7-1.
Circuit
Diagram
For
Robot
Interface
AMENDMENT
TO
SECTION
8
PARTS
LIST
Amend
Parts
List
as
follows:
Dia.
Part
Replaced
Mkgs.
No.
With
Description
Quantity
23-19
121
594
.
.
121
594
. .
CABLE,
interconnecting
(consisting
of)
1
152
370
. .
.
HOUSING
PLUG
&
SOCKETS,
(consisting
of)
1
079
534
CONNECTOR,
circ
skt
push-in
14-l8ga
14
079 739
CONNECTOR,
circ
clamp
str
rif
1
110
015
.
. .
CABLE,
port
No.
187/c
(order
by
ft)
lOft
141
162
. .
.
HOUSING
PLUG
&
PINS,
(consisting
of)
1
134
731
CONNECTOR,
circ
pin
push-in
14-l8ga
14
079
739
CONNECTOR,
circ
clamp
str
rlf
1
25-21
..
PCi
..
148320
..
152371
..
CIRCUIT
CARD,
voltage
control
(Effw/KC330157)
1
26-8
072
292
..
154
098
..
SHAFT,
support
spool
1
26-
Added
.
+605
941
..
WASHER,
flat
stl
.640
ID
x
1.000
OD
x
1
4ga
thk
1
26-
Added
.
+141
700
. .
RING,
retaining
ext
.625
shaft
x
.OSOthk
1
*~First
digit
represents
page
no
digits
following
dash
represent
item
no.
+Part
of
072
094
Hub
&
Spindle
Assembly.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-884B
Page
3
OM.8849
-
4
92
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
SAFETY.
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
General
Information
And
Safety
1
1-2.
Safety
Alert
Symbol
And
Signal
Words
1
SECTION
2
SPECIFICATIONS
2-1.
Description
1
SECTION
3
INSTALLATION
3-1.
Site
Selection
3
3-2.
Equipment
Installation
.3
3-3.
Gas/Current
Sensing
Control
Interconnections
4
3-4.
Robot
Interface
Welding
Power
Source
Connections
4
3-5.
Robot
Interface
Robot
Control
Unit
Connections
5
3-6.
Pulstar
Or
Deltaweld
And
Arc
Failure
Light
Terminal
Strip
Connections
7
3-7.
Welding
Wire
Installation
8
3-8.
Setting
DIP
Switches
On
Voltage
Control
Board
PCi
8
3-9.
Voltage
Control
Board
Modification
For
Early
Model
Welding
Power
Sources
9
SECTION
4
OPERATOR
CONTROLS
4-1.
Power
Switch
10
4-2.
Selector
Switch
10
4-3.
Jog
Push
Button
10
4-4.
Purge
Push
Button
10
4-5.
Voltmeter
10
4-6.
Wire
Speed
Meter
10
4-7.
Ammeter
10
4-8.
IndicatorLights
11
4-9.
Burnback
Control
ii
SECTION
5
SEQUENCE
OF
OPERATION
5-1.
Input
Signals
From
Robot
Control
Unit
11
5-2.
Output
Signals
From
Robot
Interface
11
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
6-i.
Routine
Maintenance
12
6-2.
Overload
Protection
12
6-3.
Reinstallation
Of
Hub
Assembly
13
6-4.
Display
Board
PC4
Meter
Check
14
6-5.
Circuit
Board
Handling
Precautions
15
6-6.
Troubleshooting
15
6-7.
Use
Of
Indicator
Lights
For
Troubleshooting
17
Section
No.
Page
No.
SECTION
7-
ELECTRICAL
DIAGRAMS
Diagram
7-1.
Circuit
Diagram
For
Robot
Interface
19
Diagram
7-2.
Wiring
Diagram
For
Robot
Interface
20
SECTION
8
PARTS
LIST
Figure
8-1.
Control
Box
22
Figure
8-2.
Control
Panel,
w/Components
24
Figure
8-3.
Hub
&
Spindle
Assembly
26
Figure
8-4.
Control
Box,
Gas/Current
Sensor
27
LIST
OF
CHARTS
AND
TABLES
Table
2-1.
Specifications
1
Table
6-1.
Troubleshooting
16
SECTION
1
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
1-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
A.
General
The
following
safety
alert
symbol
and
signal
words
are
Information
presented
in
this
manual
and
on
various
Ia-
used
throughout
this
manual
to
call
attention
to
and
den
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
tify
different
levels
of
hazard
and
special
instructions.
design,
installation,
operation,
maintenance,
and
/%~
This
safety
alert
symbol
is
used
with
the
signal
troubleshooting
which
should
be
read,
understood,
and
4~
words
WARNING
and
CAUTION
to
call
atten
followed
for
the
safe
and
effective
use
of
this
equipment.
tion
to
the
safety
statements.
B.
Safety
WARNING
statements
identify
procedures
or
The
installation,
operation,
maintenance,
and
trouble-
practices
which
must
be
followed
to
avoid
seri
shooting
of
arc
welding
equipment
requires
practices
ous
personal
injury
or
loss
of
life.
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in-
CAUTION
statements
identify
procedures
or
stalled,
operated,
and
maintained
only
by
qualified
per-
practices
which
must
be
followed
to
avoid
minor
sons
in
accordance
with
this
manual
and
all
applicable
personal
injury
or
damage
to
this
equipment.
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
Safety
Rules
For
Operation
Of
Arc
Weld-
IMPORTANT
statements
identify
special
instructions
ing
Power
Source
in
the
welding
power
source
Owners
necessary
for
the
most
efficient
operation
of
this
equip
Manual.
ment.
SECTION
2
SPECIFICATIONS
Table
2-1.
Specifications
Component
Dimensions
Weight
Height
Width
Depth
Net
Ship
Robot
Interface
22-1/2in.
(572
mm)
16-1/2in.
(419
mm)
6~l/4in.*
(159
mm)
38lbs.
(17
kg)
Total
61
lbs.
(27.7
kg)
Gas/Current
Sensing
Control
4-1/2
in.
(108
mm)
5-1/2
in.
(140
mm)
10-1/2
in.
(267
mm)
5
lbs.
(2.3
kg)
SpoolSupport
Assembly+
13-3/4in.
(349
mm)
8-3/4in.
(222
mm)
8-1/2in.
(216
mm)
6Ibs.
(2.7
kg)
Add
2-1/4
in.
(57
mm)
for
brake
resistor.
+Spool
Support
without
optional
wire
reel.
*Add
7/8
in.
(22
mm)
for
front
panel
knob.
2-1.
DESCRIPTION
PULSTAR
450
welding
power
source
can
be
used
in
standard
or
pulsed
mode.
The
robot
interface
control
is.designed
to
interface
with
an
ABB
robot
and
a
DELTAWELD
series
or
PULSTAR
The
gas/current
sensing
control
contains
the
gas
valve
450
welding
power
source.
This
unit
provides
preselec-
and
current
sensing
reed
relay.
tion
and
digital
display
of
weld
volts
and
wire
feed
speed
(using
DELTAWELD
or
PULSTAR
models),
and
peak
These
components
function
with
the
robot
system
when
amperage
(using
PULSTAR
models
only).
The
using
the
Gas
Metal
Arc
Welding
(GMAW)
process.
OM-884
Page
1
ST-hg
644-B
9-7/8
in.
(251
mm)
10-1/2
in.
(267
mm)
ST-ito
320-A
Gas/Current
Sensing
Control
Overall
Dimensions
And
Mounting
Hole
Locations
Inches
Millimeters
A
21-7/8
556
B
13-3/4
349
C
3
76
D
2-1/2
63.5
E
3-1/2
88.9
F
4-1/2
114
G
10-11/16
275
ST-080
486-C
Figure
2-1.
Dimensional
Views
1/2
in.
(13
mm)
Dia.
4
Holes
5-1/2
in.
(140
mm)
in.
(89
mm)
7-3/4
in.
(197
mm)
19-1/8
in.
(486
mm)
K
16-1/2
in.
(419
mm)
4-1/2
in.
(108
mm)
II
Robot
Interface
Side
View
~~.2Hol~s
OM-884
Page
2
SECTION
3
INSTALLATION
3-1.
SITE
SELECTION
(Figure
2-1)
Select
an
installation
site
which
provides
the
following:
1.
Correct
input
power
supply
(see
unit
nameplate)
2.
Shielding
gas
supply
(if
applicable)
3.
Water
supply
(if
applicable)
4.
Adequate
ventilation
and
fresh
air
supply
5.
No
flammables
6.
A
clean
and
dry
area
7.
Proper
temperature
that
avoids
extremes
of
heat
or
cold
8.
Proper
airflow
around
unit
9.
Adequate
space
to
open
and
remove
cover
and
wrapper
for
installation,
maintenance,
and
repair
functions.
Mounting
holes
provide
the
capability
to
install
and
se
cure
the
system
components
in
a
permanent
location.
Figure
2-1
gives
overall
dimensions
and
mounting
hole
layout.
3-2.
EQUIPMENT
INSTALLATION
A.
Supplied
Equipment
The
following
equipment
is
supplied
as
standard
and
re
quires
installation
or
assembly:
1.
Weld
Control
with
Gas/Current
Sensing
Control
Cord,
Motor
Cord,
and
Voltage
Sensing
Cord
2.
Gas/Current
Sensing
Control
3.
Hub
and
Spindle
Assembly
4.
Spindle
Support
5.
25ft.
(8
m)
Weld
ControlWelding
Power
Source
Interconnecting
Cord
6.
lOft.
(3m)
Gas
Hose
B.
Equipment
Location
When
deciding
on
equipment
location,
consider
the fol
lowing:
1.
The
equipment
must
be
mounted
to
a
structure
capable
of
supporting
the
weight
of
the
equip
ment.
2.
The
lead
lengths
of
the
cords
supplied
with
the
equipment
will
limit
the
area
in
which
the
equip
ment
can
be
located.
Some
cords
can
be
ex
tended
by
using
optional
extension
cords
(check
with
welding
equipment
distributor).
3.
The
interconnecting
cords
must
be
routed
so
that
they
are
not
caught,
pinched,
or
strained
during
welding
operations.
4.
One
weld
output
cable
must
be
routed
to
the
Gas/
Current
Sensing
control.
5.
Welding
wire
must
be
routed
so
that
it
does
not
contact
the
weld
control
or
any
other
grounded
equipment.
C.
Equipment
Installation
Obtain
appropriate
mounting
brackets
or
adapter
plates
as
necessary
and
mounting
hardware.
Prepare
struc
ture
for
equipment
installation.
Secure
weld
control,
Gas/Current
Sensing
control,
and
all
other
equipment
onto
structures
in
the
welding
area.
D.
Hub
Installation
(Figure
3-1)
The
hub
assembly
is
supplied
with
the
robot
interface.
Remove
the
hub
assembly
from
the
shipping
carton,
and
install
it
as
follows:
1.
Remove
hex
nut
from
end
ofhub
support
shaft.
2.
Align
keyway
and
insert
hub
support
shaft
through
selected
hole
in
hub
support.
Hole
selec
tion
in
hub
support
depends
on
wire
spool
size.
Be
sure
the
brake
washers
are
properly
seated
in
the
hub.
3.
Reinstall
hex
nut
onto
support
shaft.
Tighten
hex
nut
until
a
slight
drag
is
felt
while
turning
hub.
4.
Install
welding
wire
according
to
Section
3-7.
~etainIng
Ring
srake
Washer
Hub
Assembly
Hub
Support
Hex
Nut
ST.126
870
Figure
3-1.
Hub
Assembly
Installation
OM-884
Page
3
3-3.
GAS/CURRENT
SENSING
CONTROL
INTER
CONNECTIONS
(Figures
3-2,
3-3
And
3-4)
A
WARNING:
ELECTRIC
SHOCK
can
kill.
______
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
in
terconnections.
Lockout/tagging
procedures
consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
There
are
several
cords
supplied
for
gas/current
sens
ing
control
interconnections.
Examine
and
select
the
proper
cord
for
the
following
connections.
2.
Align
keyways,
insert
16-pin
Amp
plug
into
matching
receptacle
RC16
on
gas/current
sens
ing
control,
and
rotate
threaded
collar
fully
clock
wise.
B.
Gas/Current
Sensing
Control
Motor
Connec
tions
Align
keyways,
insert
14-pin
plug
from
motor
cord
into
matching
receptacle
RC7
on
gas/current
sensing
con
trol,
and
rotate
threaded
collar
fully
clockwise.
C.
Weld
Cable
Connections
For
Electrode
Positive/Reverse
Polarity,
route
cable
from
welding
power
source
POSITIVE
weld
output
ter
minal,
through
the
gas/current
sensing
control,
to
the
wire
drive
assembly,
and
connect
cable
to
weld
cable
terminal
(see
Motor/Drive
Assembly
Owners
Manual
for
location).
D.
Gas
Connections
Figure
3-2.
Right
Side
View
A.
Robot
Interface
Gas/Current
Sensing
Control
Connections
1.
Align
keyways,
insert
14-pin
Amp
plug
into
matching
receptacle
RC9
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
Connect
hose
from
gas
regulator/flowmeter.
(customer
supplied)
at
gas
source
to
IN
fitting
on
gas/current
sens
ing
control.
Connect
gas
hose
from
wire
drive
assembly
to
fitting
on
gas/current
sensing
control.
The
gas
flow
must
be
accurately
controlled
by
a
regulator/flowmeter
at
the
source.
3-4.
ROBOT
INTERFACE
-
WELDING
POWER
SOURCE
CONNECTIONS
(Figures
3-3,
3-4,
And
3-5)
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/ta
gging
procedures
before
making
in
terconnections.
Lockout/tagging
procedures
consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
There
are
several
cords
used
for
interconnections
be
tween
the
robot
interface
and
welding
power
source.
Ex
amine
and
select
the
proper
cord
for
the
following
con
nections.
A.
Arc
Sensing
Connections
1.
Align
keyway,
insert
four-socket
Amphenol
plug
into
matching
receptacle
RC12
on
robot
inter
face,
and
rotate
threaded
collar
fully
clockwise.
2.
Connect
lead
with
ring
terminal
to
welding
power
source
POSITIVE
weld
output
terminal
as
shown
on
Figure
3-4.
3.
Connect
lead
with
clamp
to
welding
power
source
NEGATIVE
weld
Output
terminal.
00000
)0000(
00000
)0000(
00000
)0000(
00000
)0000(
00000
)0000(
00000
)0000(
0
0~0
0
0
~
0
00000
Gas/Current
Sensing
Control
Receptacle
RC9.
115
Volts
AC/Contactor
Control
Receptacle
RC13
Including
Output
Control
For
DELTAWELD
Models
Strain
Relief
Welding
Power
Source
Interface
Receptacle
RCI7
Arc
Sensing
Receptacle
RC12
OM-884
Page
4
C.
115
Volts
AC/Contactor
Control
Connection
And
DELTAWELD
Output
Control
Connection
I.
Align
keyway,
insert
14-socket
plug
into
matching
receptacle
RC13
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyway,
insert
14-pin
plug
into
matching
re
ceptacle
on
welding
power
source,
and
rotate
thread
collar
fully
clockwise.
3.
Place
welding
power
source
OUTPUT
(CON
TACTOR)
switch
in
the
REMOTE
14
position.
4.
For
DELTAWELD
units,
place
welding
power
source
VOLTAGE
switch
in
the
REMOTE
14
posi
tion.
Figure
3-4.
Arc
Sensing
Lead
And
Weld
Cable
35.
ROBOT
INTERFACE
ROBOT
CONTROL
Locations
UNIT
CONNECTIONS
(Figures
3-2,
3-3,
And
B.
Output
Control
Connections
To
PULSTAR
Align
keyway,
insert
1
0-socket
plug
into
matching
receptacle
RC15
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyway,
insert
10-pin
plug
into
matching
re
ceptacle
on
welding
power
source,
and
rotate
threaded
collar
fully
clockwise.
3.
Place
welding
power
source
VOLTAGE
switch
in
the
REMOTE
10
position.
Weld
Cables
Arc
Failure
Connection
In
Robot
Control
Unit
Electrode
(Welding
Wire)
cord
Wire
Drive
Assembly
Positive
Weld
Output
Terminal
On
Power
Sour
Figure
3-3.
Interconnection
Diagram
For
PULSTAR
Welding
Power
Source
S
0290
Lock
Nut
Arc
Sensing
Lead
Ring
Terminal
Location
STI21
083.A
3-4)
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
in
terconnections.
Lockout/tagging
procedures
Consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
OM-884
Page
5
Robot
Interface
Connections
To
Robot
Control
Unit
Arc
Failure
Connection
In
Robot
Control
Unit
Shielding
Gas
Supply
Electrode
(Welding
Wire)
Ref.
S-0290
Figure
3-5.
Interconnection
Diagram
For
DELTAWELD
Welding
Power
Source
1.
Obtain
a
proper
Cord
and
24-socket
Amphenol
plug
(not
supplied).
2.
Connect
conductors
at
one
end
of
cord
to
appro
priate
sockets
in
plug.
3.
Align
keyway,
insert
24-socket
plug
into
matching
receptacle
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
4.
Route
and
connect
conductors
at
remaining
end
of
cord
to
the
robot
control
unit.
The
input
and
output
signals
at
the
sockets
of
receptacle
AC
17
by
means
of
the
robot
interface
control
circuitry
are
as
follows:
Socket
A:
Provides
connection
to
2TA;
for
customer
use.
Socket
B:
Current
Detect
output
to
robot
control
unit
with
respect
to~Socket
D;
isolated
CR1
con
tacts
rated
1A
at
120
VAC.
Socket
D:
Current
Detect
output
to
robot
control
unit
with
respect
to
Socket
B;
isolated
CR1
con
tacts
rated
at
1A
at
120
VAC.
Socket
E:
Contactor
Control;
+24
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
J
(Circuit
Common).
Socket
F:
Jog
Forward;
+24
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
J
(Circuit
Common).
Socket
G:
Gas
Control;
+24
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
J
(Circuit
Common).
Socket
H:
Wire
Stick
Check;
+24
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
J
(Circuit
Common).
Socket
J:
Circuit
Common
for
Sockets
E,
F,
G,
and
H;
all
circuit
voltages
referenced
to
this
point.
Socket
K:
Jog
Forward;
momentary
contact
output
to
robot
control
unit
with
respect
to
Socket
0
(Digital
Common).
Socket
L:
Set-Up
and
Weave
Set-Up
output
to
robot
control
unit
with
respect
to
Socket
0
(Digital
Common).
Socket
M:
Weave
Set-Up
output
to
robot
control
unit
with
respect
to
Socket
Q
(Digital
Common).
Socket
N:
Wire
Stick
Signal
output
to
robot
control
unit
with
respect
to
Socket
Q
(Digital
Common);
indicates
wire
is
stuck
to
work;
isolated
CR2
contacts
rated
1A
at
120
VAC.
Socket
P:
Weld
Standby
output
to
robot
control
unit
with
respect
to
Socket
0
(Digital
Common);
indicates
robot
interface
is
in
standby;
iso
lated
CR5
contacts
rated
3A
at
120
VAC.
Socket
0:
Digital
Common
for
Sockets
K,
L,
M,
N,
and
P.
Socket
R:
+
Peak
Amps;
0-10
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
S
(analog
common)
equals
0-500
amperes
dc
output.
Robot
Interface
Weld
cables
Motor
Control
Cord
Wire
Drive
Assembly
OM-884
Page
6
To
Voltage
Source
115VAC,
24VAC,
24VDC)
Weld
Alarm
Terminal
If
So
Equipped
If
operation
with
a
DELTAWELD
welding
power
source
is
desired,
reconnect
jumper
link
between
2TG
and
2TH
on
terminal
strip
2T.
B.
Arc
Failure
Light
Connections
(Figure
3-7)
a
WARNING:
Read
and
follow
safety
informa
tion
at
beginning
of
Section
3-6
before
pro
ceeding.
The
ARC
FAILURE
light
on
the
robot
interface
front
pan
el
is
turned
on
and
off
by
a
signal
from
the
robot
control
unit.
Obtain
proper
length
of
18
gauge/2-conductor
cord
for
this
connection,
and
proceed
as
follows:
1.
For
robot
control
units
when
24
vdc
is
used
(Fig
ure3-7):
a.
Route
cord
through
strain
relief
on
right
side
panel
of
robot
interface,
and
make
proper
con
nections
to
1TL
and
1TM.
b.
Route
and
connect
remaining
end
of
cord
to
weld
alarm
terminal
and
ground
connection
at
the
robot
control
unit.
c.
Connect
+24
vdc
to
common
relay
contact
ter
minal.
Robot
Control
Unit
Robot
Interface
Socket
S:
Peak
Amps;
analog
common
for
Socket
A
(+
Peak
Amps).
Socket
W:
Wire
Feed
Speed;
analog
common
for
Socket
X
(+
Wire
Feed
Speed).
Socket
X:
+
Wire
Feed
Speed;
0-10
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
W
(analog
common)
equals
0-1
000
1PM.
Socket
Y:
Arc
Volts;
analog
common
for
Socket
Z
(+
Arc
Volts).
Socket
Z:
+
Arc
Volts;
0-10
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
Y
(analog
common)
equals
0-50
volts
dc
output.
IMPORTANT:
The
remaining
sockets
in
the
receptacle
are
not
used.
S.0291
Figure
3-6.
Front
View
Of
24-Socket
Amphenol
Receptacle
With
Socket
Designations
3-6.
PULSTAR
OR
DELTAWELD
AND
ARC
FAIL
URE
LIGHT
TERMINAL
STRIP
CONNEC
TIONS
4~
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
in
terconnections.
Lockout/tagging
procedures
consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
There
are
two
terminal
strips
inside
the
robot
interlace
for
control
connections.
Loosen
screws
on
strain
relief
on
unit
right
side
panel
if
applicable,
open
front
panel
ac
cess
door,
and
locate
appropriate
terminal
strip
for
con
nections.
Tighten
screws
on
strain
relief
if
necessary,
and
close
and
secure
front
panel
access
door
when
pro
cedure
is
finished.
A.
Jumper
Link
Reconnection
For
DELTAWELD
Welding
Power
Source
a
WARNING:
Read
and
follow
safety
informa
tion
at
beginning
of
Section
3-6
before
pro
ceeding.
The
jumper
link
connected
between
2TH
and
2TJ
on
ter
minal
strip
2T
is
shipped
from
the
factory
for
operation
with
a
PULSTAR
450
welding
power
source.
Common
Terminal
If
So
Equipped
+24VDC
Weld
Alarm
Terminal
So
Equipped
1
TM
Robot
Control
Unit
Common
Terminal
If
So
Equipped
Isolation
Relay
CR1
Robot
Control
Robot
Interface
CR1
ITL
#24VDC
~O--j
~O
Arc
Failure
1TM
Indicator
Light
S~O292
Figure
3-7.
Arc
Failure
Light
Connections
OM-884
Page
7
2.
For
robot
control
units
when
115
or
24
vac,
or
24
vdc
is
used
(Figure
3-7):
a.
Route
cord
through
strain
relief
on
right
side
panel
of
robot
interface,
and
make
proper
con
nections
to
1TL
and
1TM.
b.
Obtain
a
115
or
24
vac,
or
24
vdc
isolation
relay
CR1,
and
instalLinto
robot
control.
c.
Route
and
connect
remaining
end
of
cord
to
one
side
of
the
normally-open
robot
control
relay
contact
and
ground.
d.
Connect
+24
vdc
to
remaining
side
of
normally-
open
robot
control
relay
contact.
e.
Connect
a
lead
from
one
side
of
robot
control
coil
to
weld
alarm
terminal.
f.
Connect
proper
voltage
source
(115
vac,
24
vac,
or
24
vdc)
between
common
terminal
and
remaining
side
of
robot
control
relay
coil.
3-7.
WELDING
WIRE
INSTALLATION
A.
Installation
Of
Spool-Type
Wire
(Figure
3-8)
1.
Remove
retaining
ring.
2.
Slide
spool
of
wire
onto
hub
so
that
wire
feeds
off
bottom
of
spool.
3.
Rotate
spool
until
hole
in
spool
aligns
with
pin
in
hub.
Slide
spool
onto
hub
until
it
seats
against
back
flange
of
the
hub.
4.
Reinstall
retaining
ring
onto
hub.
B.
Installation
Of
Optional
Wire
Reel
And
Reel-
Type
Wire
(Figure
3-8)
1.
Remove
retaining
ring
and,
if
applicable,
wire
reel
assembly
from
hub.
2.
Lay
wire
reel
assembly
flat
on
a
table
or
floor.
3.
Remove
spanner
nut
from
wire
reel
assembly.
4.
Remove
wire
retainer,
and
install
wire
onto
wire
reel.
Be
sure
that
wire
feeds
off
bottom
of
reel.
5.
Reinstall
wire
retainer
and
spanner
nut
onto
wire
6.
Slide
wire
reel
assembly
onto
hub,
and
rotate
as
sembly
until
hub
guide
pin
is
seated
in
reel.
7.
Reinstall
retaining
ring
onto
hub.
C.
Adjustment
Of
Hub
Tension
(Figure
3-1)
Check
the
hub
tension
by
slowly
rotating
the
wire
spool
or
reel.
The
wire
should
unwind
freely,
but
hub
tension
should
be
sufficient
to
keep
wire
taut
and
prevent
back
lash
when
the
wire
feed
stops.
If
adjustment
is
required,
loosen
or
tighten
the
hex
nut
on
the
end
of
the
hub
sup
port
shaft
accordingly.
ST.127
308
Figure
3-8.
Optional
Wire
Reel
And
Reel-Type
Wire
Installation
3-8.
SETTING
DIP
SWITCHES
ON
VOLTAGE
CON
TROL
BOARD
PCi
(Figure
3-9)
a
CAUTION:
INCORRECT
DVC
BOARD
DIP
SWITCH
POSITION
can
cause
equipment
malfunction.
DVC
DIP
switch
is
factory
set
for
operation
with
Deltaweldfi
451
welding
power
source.
See
Figure
3-9
for
DVC
DIP
switch
setting
when
using
another
welding
power
source.
DIP
switch
Si
and
S2
on
voltage
control
board
PCi
al
low
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
Delta-
weldfi
451
to
another
welding
power
source,
proceed
as
follows:
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
wire
feeder,
and
disconnect
in
put
power
em
ploying
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.
Transport
circuit
boards
in
proper
static
shielding
carriers
or
packages.
Perform
work
only
at
a
static-safe
work
area.
1.
Loosen
screw
securing
front
access
door
on
weld
control,
and
open
door.
2.
Locate
voltage
control
board
PCi
in
left
portion
of
component
mounting
panel
inside
weld
control.
reel.
OM-884
Page
8
DVC
SWITCH
SETTINGS
S2
Si
1
2
1
2
3
4
5
DELTAWELD
300
ON
ON
ON
DELTAWELD
451
0
ON
ON
DELTAWELD
651
0
ON
ON
MAXTRON
300,
400
ON
ON
MAXTRON
450
ON
ON ON
XMT
200/300
ON ON ON
ARC
PAK
350
ON
ON
ON
SHOPMASTER
300
ON
ON
ON
DIMENSION
400
ON
A
A
ON
O
On
For
Optional
Soft
Start.
Turn
Off
Si
-3.
A
On
For
Optional
Hot
Start.
S-150
864-A
Figure
3-9.
Voltage
Control
Board
DIP
Switch
Setting
Label
3.
Set
position
of
DIP
switches
Si
and
S2
according
to
label
inside
unit
and
Figure
3-9
for
appropriate
welding
power
source.
4.
Close
and
secure
front
access
door.
3-9.
VOLTAGE
CONTROL
BOARD
MODIFICA
TION
FOR
EARLY
MODEL
WELDING
POWER
SOURCES
(Figure
3-10)
If
the
weld
control
unit
is
to
be
used
with
an
early
model
Deltaweld
450
or
650
welding
power
source
prior
to
seri
al
number
JJ400026,
proceed
as
follows:
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
wire
feeder;
and
disconnect
input
power
em
ploying
lockout/tagging
procedures
before
making
circuit
board
modifications.
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
discon
necting
device.
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
properly
grounded
wrist
strap
BE
FORE
handling
circuit
boards.
Transport
circuit
boards
in
proper
static-
shielding
carriers
or
packages.
Perform
work
only
at
a
static-safe
work
area.
1.
Loosen
screw
securing
front
access
door
on
weld
control,
and
open
door.
2.
Locate
voltage
control
board
PCi
in
left
portion
of
component
mounting
panel
inside
weld
control.
3.
Mark
and
disconnect
leads
from
voltage
control
board
PCi.
4.
Mark
and
disconnect
plugs
from
PCi.
5.
Note
position
of
circuit
board
and
remove
from
unit.
6.
Place
circuit
board
on
a
stationary
work
surface
so
that
component
side
is
facing
up.
7.
Locate
jumpers
Ji
thru
J8
on
surface
of
board
(see
Figure
3-10).
8.
Use
a
sharp
tool
to
remove
sealant
coating
from
all
jumper
locations,
and
remove
foil
jumper
be
tween
pads
at
J2,
J4,
J6,
and
J8.
9.
Apply
a
small
amount
of
solder
to
bridge
the
foil
pads
at
jumper
Ji,
J3,
J5,
and
J7.
10.
Apply
a
sealant
coating
over
all
jumper
locations.
ii.
Reinstall
circuit
board
into
unit
in
its
original
posi
tion.
12.
Reconnect
marked
leads
and
plugs
to
appropri
ate
locations.
13.
Close
and
secure
front
access
door.
OM-884
Page9
Jumper
Jumper
J2
JI
Jumper
13
Figure
3-10.
Jumper
Locations
On
Voltage
Control
Board
PCi
SECTION
4
OPERATOR
CONTROLS
R&.
SD-i
49
322
4-1.
POWER
SWITCH
(Figure
4-1)
Placing
the
POWER
switch
in
the
ON
position
energizes
the
robot
interface.
The
interface
must
be
on
for
the
ro
bot
to
weld.
Placing
the
POWER
switch
in
the
OFF
posi
tion
shuts
down
the
interface.
4-2.
SELECTOR
SWITCH
(Figure
4-1)
The
SELECTOR
switch
has
three
positions:
RUN,
SET
UP,
and
SET-UP
WEAVE.
Consult
robot
Owners
Manu
al
or
robot
manufacturer
for
SELECTOR
switch
func
tions.
4-3.
JOG
PUSH
BUTTON
(Figure
4.1)
The
JOG
push
button
is
a
momentary-contact
switch.
Consult
robot
Owners
Manual
or
robot
manufacturer
for
JOG
push
button
function.
4-4.
PURGE
PUSH
BUTTON
(Figure
4.1)
The
PURGE
push
button
is
a
momentary-contact
switch.
This
switch
energizes
the
gas
solenoid
and
purges
the
shielding
gas
line
of
the
gun.
The
PURGE
push
button
allows
the
flow
meter
to
be
adjusted
without
energizing
the
welding
circuit.
4-5.
VOLTMETER
(Figure
4-1)
The
voltmeter
displays
weld
voltage
to
the
nearest
tenth
of
a
volt
while
welding
and
preset
voltage
while
idling.
4-6.
WIRE
SPEED
METER
(Figure
4-1)
The
wire
speed
meter
displays
preset
wire
feed
speed
to
the
nearest
inch
per
minute
while
welding
and
idling.
Ac
tual
and
preset
wire
feed
speed
are
the
same
due
to
the
wire
feed
speed
feedback
circuit.
4-7.
AMMETER
(Figure
4-1)
The
ammeter
displays
weld
peak
amperage
to
the
near
est
ampere
while
welding
and
preset
peak
amperage
while
idling.
Jumper
Jumper
Jumper
Jumper
J8
J7
J6
J5
OM-884
Page
10
Fuse
(See
Section
6-2)
4-8.
INDICATOR
LIGHTS
(Figure
4-1)
There
are
five
indicator
lights
on
the
interface.
These
are
visual
indications
of
various
process
functions.
The
GAS
light
turns
on
when
the
gas
valve
is
energized
to
indicate
shielding
gas
flow.
The
CONTACTOR
light
turns
on
when
the
welding
pow
er
source
contactor
is
energized
to
indicate
that
weld
output
is
available.
The
WIRE FEED
light
turns
on
when
the
wire
drive
motor
is
energized
to
indicate
that
wire
is
feeding.
The
CURRENT
light
turns
on
when
the
current
detect
relay
is
energized
to
indicate
that
an
arc
is
established.
The
ARC
FAILURE
light
turns
on
only
when
properly
connected
according
to
instructions
in
Section
3-6,
and
there
is
an
arc
outage
while
welding.
4-9.
BURNBACK
CONTROL
Burnback
is
provided
by
potentiometer
R32
on
Interface
Circuit
Board
PC3
inside
the
unit.
The
burnback
circuitry
in
this
unit
keeps
the
welding
wire
from
sticking
to
the
workpiece
after
the
arc
is
extin
guished.
This
circuitry
keeps
weld
output
on
the
welding
wire
from
0
to
0.25
seconds
after
the
wire
has
stopped
feeding.
This
delay
action
permits
the
welding
wire
to
Ref.
ST.119
645-A
burn
back
to
a
point
where
it
neither
sticks
to
the
work-
piece
or
the
contact
tube.
To
adjust
burnback
time
pro
ceed
as
follows:
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
ins
pect
ing
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
discon
necting
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.
Open
front
access
door
on
weld
control
and
lo
cate
PC3.
2.
Locate
potentiometer
R32
in
upper
left
corner
of
PC3.
3.
Rotate
R32
clockwise
to
increase
burnback
time.
4.
Close
and
secure
front
access
door.
SECTION
5
SEQUENCE
OF
OPERATION
5-1.
INPUT
SIGNALS
FROM
ROBOT
CONTROL
UNIT
(Figure
5-1)
The
robot
interface
receives
input
signals
for
contactor
control,
gas
control,
jog,
welding
volts,
wire
speed
(using
DELTAWELD
or
PULSTAR
models),
and
peak
current
(using
PULSTAR
models
only).
It
also
receives
a
signal
to
initiate
a
check
to
see
if
the
wire
is
stuck
to
the
work-
piece
at
the
end
of
the
weld.
5-2.
OUTPUT
SIGNALS
FROM
ROBOT
INTER
FACE
(Figure
5-1)
The
robot
interface
sends
output
signals
to
the
robot
control
unit
for
current
sense,
wire
stuck,
and
weld
standby.
Gas
Indicator
Light
Contactor
Indicator
Light
Wire
Feed
Current
Indicator
Arc
Failure
Jog
Push
Indicator
Light
Light
Indicator
Light
Button
Switch
Figure
4-1.
Front
Panel
Controls
OM-884
Page
11
Wire
Feed
Speed
0-IOV
=
0-1000
1PM
Output
Volts
0-1OV
=
0-50V
Robot
Control
Unit
To
Computer
Intertace
Computer
Interface
To
Robot
Control
Unit
Peak
Amps
0-1OV
=
0.500
Amps
Output
Gas
Control
Contactor
Control
Jog
Fwd.
Wire
Stuck
Check
~o~
]
Power
On,
Standby
Current
Detect
~Wire
Stuck
Output
Voltage
Shielding
Gas
Wire
Feed
Figure
5-1.
Input
And
Output
Signal
Timing
Chart
ST-094
382-e
SECTION
6
MAINTENANCE
&
TROUBLESHOOTING
6-1.
ROUTINE
MAINTENANCE
IMPORTANT:
Every
six
months
inspect
the
labels
on
this
unit
for
legibility.
All
precautionary
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
Parts
List
for
part
number
of
precautionary
labels.
Usage
and
shop
conditions
determine
the
frequency
and
type
of
maintenance.
At
minimum,
inspect
equip
ment
every
three
months
as
follows:
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
inspect
ing,
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.
MOVING
PARTS
can
cause
serious
injury.
Keep
away
from
moving
parts.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
servicing.
Maintenance
to
be
performed
only
by
qualified
persons.
1.
Repair
or
replace,
as
required,
all
hose
and
cable;
give
particular
attention
to
frayed
and
cracked
insu
lation
and
areas
where
it
enters
equipment.
2.
Remove
grease
and
grime
from
components;
mois
ture
from
electrical
parts
and
cable.
6-2.
OVERLOAD
PROTECTION
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
inspect
ing,
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.
INCORRECT
FUSE
can
damage
unit.
Use
only
replacement
fuse
of
same
size,
type,
and
rating
(see
Parts
List).
A.
Wire
Drive
Motor
Circuit
Breaker
CB1
(Figure
4-1)
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
motor
would
stop.
Normal
Abnormal
OM-884
Page
12
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