WELDING INDUSTRIES
OF
AUSTRALIA
A
DIVISION
OF
WELDING INDUSTRIES LTD
ACN
004
547
l1
l
Head
Office
and International Sales
5
Allan Street, Melrose Park
South Australia,
5039
Telephone
(08)
8276
6494
Facsimile
(08)
8276 6327
OWNERS MANUAL
FITTING INSTRUCTIONS
MODEL
NO.
AM281-0,
REV.
A
ROBOT INTERFACE
TO SUtT MILLER
S-60
SERIES WIREFEEDERS
03/98
QUALlTV WELDING PRODUCTS,
SYSTEMS
AND SERVICE
dzyH
Page
2
AM281-0
ROBOT
INTERFACE MANUAL
CONTENTS
Sec
.
1
...................
Introduction
....................................................
P.3
Sec2
...................
Equipment
......................................................
P.3
Sec.3
...................
Pre-assembly
.................................................
P.5
Sec.4
...................
Field Installation
............................................
P.6
FIG
U
RES
Fig.1
....................
Front Panel Controls
......................................
P.4
Fig.2
....................
Remote Wirefeeder Mounting
........................
P.4
Fig.3
....................
Rear Panel Modifications
...............................
P.4
Fig.4
....................
Exploded View
Of
Wirefeeder Case
..............
P.7
Fig6
....................
AM281-l0
PCB
Circuit Diagram
....................
P.9
Fig.7
....................
AM281-21 Wirefeeder Loom Assembly
.........
$.IQ
Fig.8
....................
AM281
-22
Work
Volts
Assembly
...................
P
.
11
Fig.9
....................
AM283-0 Circuit Diagram-Burnback Option
..
P.13
Fig.5
....................
AM281
-0
Circuit Diagram-Robot Interface
.....
P.8
Fig.8
....................
AM281
-23
Wiring
Loom
Diagram
..................
P
.
12
APPENDIX
Fitting Instructions for Control Detachment
Kits
to
su~t
Miller
S-60
Series wirefeeders
.
AM281-0
ROBOT
".l_""_
INTERFACE
-
MANUAL
___
Page
3
l
.INTRODUCTION
This interface kit
is
intended
for
fitting
to
MILLER
S-60
SERIES
WIREFEEDERS
for use
with
MOTOMAN
robots, in
such
a manner as
to
make them
plug
compatible
using AM281
-013
or
AM281
-018
interfaces supplied
by
WIA.
2.
EQUIPMENT
The AM281
-0/3
Package contains;
AM281-10 Miller Interface Printed Circuit Board,
'
AM281-12 Robot Isolator Printed Circuit Board,
AM283-0 Burnback Option Printed Circuit Board,
MRI
34936
Miller Control Detachment Kit 3m (loft),
AM281-20 Wirefeeder Mounting Plate,
AM281-21 Loom
Assembly,
Miller Interface,
AM281
-22
Work
Votts
Assembly,
AM281-23
Loom
Assembly, Robot YASNAC
ERC,
WIN287 Label Set,
(This)
Documentation.
The AM281-0/8 Package contains;
AM281-40
Miller
Interface
Printed Circuit
Board,
m
AM281-l2 Robot Isolator Printed Circuit Board,
AM2834 Burnback Option Printed Circuit
Board,
MRI 34937 Miller Control Detachment Kit
8m
(25ft),
AM281-20 Wirefeeder Mounting Plate,
AM281-21 Loom Assembly, Miller interface,
m
AM281 -22 Work Volts
Assembly,
It
AM281 -23
Loom
Assembly,
Robot
YASNAC
ERC,
WIN287 Label
Set,
(Phis) Documentation.
c
AM281-0
ROBOT
INTERFACE
MANUAL
MR133425
MANUAL/ROBOT REMOTE
SWITCH FITTED VOLTAGE CONTROL
IN THIS POSITION (OPTION POSITION)
WIREFEED MOTOR
AM283-0
BURNBACK
(OPTION)
FIG.
1.
FRONT PANEL CONTROLS.
WIREFEED MOTOR REMOTE COVER FITTED
MOUNTING PLATE.
PRIOR TO MOUNTING
TO
ROBOT
ARM
MOUNTED TO AM281-20
FIG.
2.
REMOTE
WIREFEEDER MOUNTING.
MIL. SOCKET
/
32
DIA
FITTED
4
HOLES,
4
DIA
WORK
VOLTS
SCREW POST
FIG.
3.
REAR PANEL MODIFICATIONS.
~~281-o
ROBOT
“
INTERFACE
MANUAL
3.
PRE-ASSEMBLY
Disassemble wirefeeder and install
MILLER
detachment kit.
(3M
or
8M)
(Refer to
Detachment kit installation instructions
in
Miller
Power
Source Manual).
Discard original wirefeeder base plate and remount wirefeeder motor and wire
Add
necessary holes to rear panel
of
wirefeeder cabinet for addition of
MIL.
m
Remove existing screws holding Miller Option Panel and replace with Pantek
drive mechanism, and gas valve onto
AM281
-20
Base
Plate.
Socket and Volt Sense Lead terminal.
screws and PCB standoffs.
Assemble PCB’s, looms, switches, plugs etc. on bench, then install
into
wirefeeder case in sequence noted below;
1.
Fit Volt Sense wire.
2.
Fit
MIL.
socket.
3.
Fit purple cable (with Piggy back plug) to Bridge Rectifier purple
lead
terminal.
4.
Fit white cable (with
Piggy
back
plug)
to
Circuit Breaker wire
No.1
terminal.
5.
Fit
PCB’s
to appropriate standoffs.
6.
Connect Voltage Sensing Lead to quick connect terminal.
7.
Connect remaining plugs and sockets
as
per circuit diagram.
(Note
re
RC2-
Remove and discard linking plug, then fit loom connector).
Fit Remote Volts potentiometer to “Voltage
A
position
on
front panel.
Fit Burnback potentiometer
to
“Voltage
B”
position
on
front panel, and connect
lead to
RC1.
connector. (Discard linking
plug.).
Affix labels to appropriate positions.
Interface
may
now be tested. (See field installation)
Reassemble cabinet.
AM2814
ROBOT
INTERFACE
MANUAL
4.
FIELD
INSTALLATION
Install mounting plate (with wirefeeder, wire drive and gas valve) onto robot arm.
Mount wirefeeder control box in convenient position near welding power source.
m
Plug inter-connecting lead into welding power source.
Connect Volts sense lead to work side of welding power source.
Connect Detachment lead from wirefeeder drive mechanism to control box.
Set welding power source to
MIG
mode (GMAW),and External volts control.
Preliminary test;
-l,
Switch on Welding power source and wirefeeder control box.
2.
Verify JogPurge operation.
3.
Set switch
to
manual and verify wirespeed control.
4.
Verify Volts control adjusts volts indicator on welding power source.
(Note- Manual/Robot switch selects between front panel and robot
settings to Wirespeed and Arc volts.)
Connect Robot interface cable from robot
to
control box.
m
Set ManuaVRobot switch to robot position. Test each robot wirefeed function
individually, as listed below;
1. Inch forward LED4 on AM281-12
PCB
2.
Inch reverse
LE85
and LED4 on AM28142
PCB
3.
Arc
on
LED2
on
AM281-12
PCB
4.
Purge
Function not
supported
on this robot connector.
5.
Volt set point
0-1
OV
from robot indicates IO-35V on power
6.
Speed set point
0-IOV
from robot selects 0-Full speed.
(Jog
switch
source.
may be
used
to test motor operation at selected
speeds.)
operation.)
operation.)
7.
Arc active
LED6
(Most easily checked during robot
8.
Arc fail
LED7
(Most
easily checked during robot
Reassemble wirefeeder control
box.
AM281-0
ROBOT INTERFACE
MANUAL
Page
7
1
......
Gun Trigger Receptacle
RC6
2
......
ManuaVRobot Switch
3..
....
Schedule
A
Wire Speed Control R2
4
......
Schedule
A
Voltage Control R75
..
......(
Intercepted)
5
......
MIL Socket
to
Robot
7..
...
.AM281
-1
0
Interface board
8
......
Circuit Breaker CBI
9
......
AM28
1-12
lsotator Board
10
....
Power Switch
SI
1
l
....
Work Volts fitted in this position
12
..,,Plug PLGI
0
and connecting cable
19
13
...
Integrated Rectifier SRI
15
...
Plug PLGS
16
...
Plug
PLG2
(Replaced
17
...
Plug PtG3 (Intercepted)
18
...
Plug
for
Burnback
19
...
Plug
PLG4
(intercepted)
20
,.
.
Motor Board PC1
21
...
Plug PLG6
22
.
.
,
Plug PLG7
23
...
Receptacle RC7
27
...
Burnback
Potentiometer
29
I
,.
Jog/Purge Switch
S2
FIG.
4.
EXPLODED
VIEW
OF
WIREFEEDER
CASE
Page
8
AM281-0
ROBOJ
INTERFACE
MANUAL
I
I
I
I
I
I
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QP
aa
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FIG.
5.
AM281.0
CIRCUIT
DIAGRAM
ROBOT
INTERFACE
-
YASNAC
ERC
TO
MILLER
S40
WIREFEEDER
AM281-0
ROBOT
INTERFACE
MANUAL
Page
9
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1H281-1
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GUflZ
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JOGSW
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2
Robotlc
Irolaror
PCB
IRRlau
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VOLTS
AMPS
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IU-laaR
P5
LEU4
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"SET
03
VCOH
4Y-
SET-VOLTS
3
+
8-10"
I
I
FIG.
6.
AM281-10 PCB
CtRCUIT
DtAGRAM
MILLER
WIREFEEDER
TO
ROBOT
Page
70
AM281-0
ROBOT INTERFACE MANUAL
,"
Y
QW
C+
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Y
om
cr
MM
cm
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QXU
2'81
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FIG.
7.
AM281-21
WIREFEEDER
LOOM ASSEMBLY
AM281-0
ROBOT
INTERFACE
MANUAL
Page
I1
RECiR
PANEL
:
LOOfl:TAB4Z
CAB516
black
8@tdM
(442
Screw
Socket
QC
FeMale
MC81-25/2
H953
FIG.
8.
AM281
-22
WORK
VOLTS
ASSEMBLY
Page
12
AM281-0
ROBOT
INTERFACE MANUAL
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CD
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m
F)
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..
dm
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CD
PI
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rd
M
a
W
K
FIG.
9.
AM281-23 WIRING
LOOM
YASNAC
ERC
AM281-0
ROBOT
INTERFACE MANUAL
Paae
13
I
X
V1
L.
VI
'.l
rc
m
cry
E
*
30
-
3
d
om
rc
lnw
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m.
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3
ZZ
03
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t
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UY
4.
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ar
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3-0
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I-
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FIG.
IO.
AM283-0
CIRCUIT
DIAGRAM
BURNBACK
OPTION
FOR
MILLER
S-60
WIREFEEDER
FIELD
INSTRUCTIONS
For
Control
Detachment
Kits
l34
936
And
134
937
In
S-60
And
S-64M
Model
Wire Feeders
January
1995
FORM:
F145
614
Use
above
FORM
number
when
ordering
extra
manuals.
Read and follow these instructions and all safety
blocks
carefully
Call your distributor
if
you
do not understand the directions.
following standard
safety
practices install
this
kit.
I
7
NOTE
D
An
S60
Model wire feeder
is
shown throughout these instructions.
A.
Removing
Control'Box
From
Base
Internal View
Of
Control Box
/'
Rear Panel
Tools
Needed:
5/8in
5/16
in
D
1/4
in
1
Shielding Gas Valve Or
Motor
Later
in
these instructions,
RC40
will
be
installed where the gas
valve is now located.
Diwnnect external gas supply
hose connected to gas valve,
if
applicable.
Remove wrapper and side panel.
Discard side panel, but keep all
hardware.
2
Hinged Front Panel
Remove screw from upper left cor-
ner, and open front panel.
3
Control
Box
Remove screws securing control
box
to
base.
Close and secure hinged front
panel.
4
Motor Compartment
Receptacle
RC40
Locate plug PLG7 in motor com-
partment, and disconnect
it
from
receptacle RC7.
Remove retaining nut from gas
valve on rear of feeder.
Slide
gas
valve
into
motor corn-
partment.
Slidecontrol boxtothe rightand re-
move from base.
1
ST.127
3%-8
I
Ref.
ST-137
224-A
- . .
-
.
-
- -
Figure
1.
Control
Box
B.
Installing
Motor
Enclosure
.,:
*.
1
-
Tools
Needed:
D
1/4,
U16
in
1
Motor Endosure
2
Motor Endosure Hardware
3
Motor Endosure
Mounting
4
Spool
Support Arm
Secure motor enclosure
to
base
with
supplied 10-32
x
W8
in
self-
tapping screws. Install endosure
with
gas valve and receptacle
holes
towards
spool
support arm
5
Receptade RC37
6
Plug PLG33
PLG33
and RC37 are a supplied
wiring harness.
Install RC37
in
hole
as
shown, and
secure
with
supplied 8-32
x
5/8
in
self-tapping mews
7
PlugPLG7
ConnectPLG33
to
PLG7located in
control
box
motor compartment
8
Existing
Gas
Valve
install
gas valve
with
friction
termi-
nals
facing
in
as
shown.
9
Side Panel
10
Side Panel Hardware
install
panel and secure with
supplied hardware.
Holes
(see
Figure
l,
No.
4).
ST-l45
685-8
Figure
2.
installing
Motor
Enclosure
F145
61
4
Page
2
.
I
.
.
.:-
..
.
..
.,
.
..
,.,..
'.
.I.
. . .
..
..
.i*..
. ....._.
.
...
C.
Relocating
The
Control
Box
NOTE
D
When relocating control
box, place
it
in
an
upright
position,
just
like
it
was instal/&
to
the
base.
Do
not
place
control
box
upside
down,
or
in
a
vertical
pOSitiOn.
Locate supplied wiring harness
consisting of plug PLG39 and re-
ceptade
RC40.
Connect PLG39 to
RC7,
located
in
control
box
motor
compartment (see Figure
1,
No.4).
Install
RC40
into control
box
rear
panel opening, using hole where
gas valve. was removed (see
Figure
1,
NO.
1).
Secure
RC40
with
supplied
8-32
x
5/8
in self-tapping
screws.
i
1
I
Tools Needed:
p
114 in
1
Rubber Grommets
2
Angle Feet
Install
grommets into one of the
angle feet as shown.
I
I
3
Side Panel
\
Locate correct side panel
(two
are
supplied, one for
S40
Models and
one for
S-"
Models)
1
.
Use
existing hardware to secure
angle foot and side panel
to
control
box.
Install
remaining grommets into re-
maining angle foot as shown.
Install wrapper and angle
foot;
use
existing hardware to secure angle
foot and wrapper to control box.
ST-l45
881
Figure
3.
Installation
Of
Angle Feet
D.
Final Connections
This
kil
contains
fwo
identical extension
cods.
One
is
a
tigger
extension cord, and the other
isforusewManoptimdreedrelay.lfunitdoes
not
have
a reed
relax
discard one cord.
I
4
1
Detachment
Cord
Connect
one
end of supplied de-
tachment cord to
RC37
(see
Figure
2,
No.
5),
connect remain-
ing end
of
cord to
RC40
(see
Fgure
1,
No.
1).
Makeconnections
as
follows: align keyway, insert
plug, and tighten threaded collar.
2
Gun Trigger Plug
3
Trigger Extension Cord
4
Trigger Receptacle
Connect one end
of
cord
to
gun
trigger plug, connect remaining
end
of
cord
to Trigger Receptacle.
Make connections as follows: align
keyway, insert plug,
and
tighten
threaded collar.
5
Reed
Relay
6
Receptacle
RC70
If
unit is equipped with an optional
reed
relay, locate supplied exten-
sion cord and connect one end
of
cord
to reed relay plug
PLG70,
and
connect remaining end to
RC70
as
follows:
align keyway, insert plug,
and
tighten threaded collar.
STSOO
281
Figure
4.
Final Connections
F145 614
Page
3
L
Dia
.
Part
Mkgs
.
No
.
Description
Quantity
Kit,
Control Detachment
Single
(Field)
134936 134937
............
145338
...
ANGLE.foot.;
...................................................
2
.....
2
............
135
414
...
LEAD
ASSY. elect (consisting
of)
..................................
1
.....
1
..
PLG39
...
115 092
....
CONNECTOR
&
SOCKETS. (consisting
of)
.......................
1
.....
1
...
RC40
...
047 637
....
CONNECTOR
&
SOCKETS. (consisting
of)
.......................
1
.....
1
.............
......
...............................
.....
113
746 CONNECTOR. rect
skt
24-1 8ga 8
8
079
534
CONNECTOR. circ
skt
push-in 14-1 8ga
14 14
.....
:
......
048 144
....
CONNECTOR. circ pin plug keying
..............................
2
.....
2
159 995
...
LEAD ASSY. elec (consisting
of)
1 1
............
......
........................
...
............
..................................
.....
..
PLG33
..
135 409
....
CONNECTOR
&
PINS. (consisting
of)
............................
1
.....
1
.............
114
656
......
CONNECTOR. rect pin 24-18ga
...............................
8
.....
8
...
RC37
...
047 637
....
CONNECTOR
&
SOCKETS. (consisting
of)
.......................
1
.....
1
............
079
534
......
CONNECTOR. circ
skt
push-in 14-18ga
........................
14
...
14
............
048 144
....
CONNECTOR. circ pin plug keying
..............................
2
.....
2
...........
+l45 336
...
ENCLOSURE. fronthoplrear
......................................
1
.....
1
............
139 596
...
PANEL. side lower (used with
S-60
Models only)
....................
1
.....
1
............
155 261
...
PANEL. side lower (used with S-60M Models only)
..................
1
.....
1
............
045 358
...
CABLE. trigger (consisting
of)
.....................................
2
.............
113 24.4
...
CABLE. trigger (consisting of)
.............................................
2
............
080
328
....
CONNECTOR w/SOCKETS. (consisting
of)
.......................
1
.....
1
............
079
534
......
CONNECTORl circ
skt
push-in 14-18ga
........................
4
.....
4
............
079 531
....
CONNECTOR. circ clamp str
rlf
sz
11
............................
2
.....
2
............
604
571
....
CABLE. port
No
.
18 4/c (order by
ft)
............................
13ft
...
28ft
............
079 878
....
CONNECTOR
&
PINS.
(consisting
of)
............................
1
.....
1
............
079
535
.......
CONNECTOR. circ pin push-in 14-18ga
.........................
4
.....
4
............
160 579
...
CABLE. interconnecting (consisting
of)
.............................
1
............
160
578
...
CABLE. interconnecting (consisting
of)
.....................................
1
............
047 636
....
CONNECTOR
&
PINS.
(consisting
of)
............................
2
.....
2
............
079 535
......
CONNECTOR. circ pin push-in 14-18ga
........................
14
...
14
............
079 739
....
CONNECTOR. circ clamp str rlf
sz
17-20
..........................
2
.....
2
............
163 51 9
....
CABLE. port
No
.
18/14 8/c (order by
ft)
..........................
11
ft
...
25ft
............
134
327
...
LABEL. warning general precautionary
.............................
1
.....
1
.............
604
311
...
GROMMET.
rbr
.
250
ID
x
.
375mtg hole
............................
4
.....
4
............
082 193
...
SCREW. slftpg hexhd 10-32
x
.
375
................................
4
.....
4
............
602 145
...
SCREW. 8-32
x
.
625
hexwhd slt std
...............................
8
.....
8
............
604 804
...
SCREW. sh met hexwhd
No
.
8
x
.
375
..............................
5
.....
5
............
...................................................
.....
145
337
...
COVER. side
1 1
+When
ordering a component originally displaying a precautionary label. the label should
also
be
ordered
.
F145
614
Page
4
/