~MHlerfi
October
1993
Form:
OM-138
992D
Effective
With
Serial
No.
KD461
760
OWNERS
MANUAL
RCSP-XL
'
1993
MILLER
Electric
Mtg.
Co.
Read
and
follow
these
instructions
and
all
U
Give
this
manual
to
the
operator.
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
U
For
help,
call
your
distributor
Call
your
distributor
if
you
do
not
understand
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079.
the
directions.
Appleton,
WI
54912
414-734-9821
cover
7/93
ST-139
884
PRINTED
IN
USA
MILLERS
TRUE
BLUETM
LiMITED
WARRANTY
Effective
January
1,
1992
(Equipment
with
a
aerial
number
preface
of
KC
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subjectto
the
terms
and
conditions
below,
MILLER
Electric
MIg.
Co..
Appleton,
Wisconsin,
warrants
to
its
original
retsil
purchasar
that
naw
MILLER
equipment
sold
after
the
effective
date
of
this
limited
warranty
is
free
of
de
tects
in
material
and
workmanship
at
the
time
it
Is
shipped
by
MILLER.
Tilts
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,
AIILLER
will
repair
or
replace
any
war
ranted
parts
or
components
that
tail
due
to
such
defects
In
material
or
workmanship.
MILLER
must
be
notified
in
writing
within
thIrty
(30)
days
ot
such
defect
or
tailure,
at
which
time
MILLER
will
provide
instructions
on
the
wsrranty
claim
procedures
to
be
followed.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
such
a
failure
within
the
warranty
time
periods.
Alt
warranty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
originsi
retail
purchaser,
or
one
year
after
the
equipment
is
sent
to
the
distributor.
I.
5YaarsParts3YearsLsbor
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
Lebor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
Air
Compressors
4.
1
YearParts
and
Labor
*
Motor
Driven
Guns
Process
Controllers
Water
Coolant
Systems
HF
Units
Grids
*
Spot
Welders
*
Load
Banks
SDX
Transformers
Running
Gear/Trailers
Field
Options
INOTE:
Field
options
are
covered
under
True
Blue
br
the
remaining
warranty
period
ot
the
product
they
are
installed
in.
or
for
a
minimum
of
one
year
whichever
is
greater.)
B
Months
Batteries
.
NW
go
Days
Parts
and
Labor
MIG
Guns/TIG
Torches
Plasma
Cutting
Torches
Remote
Controls
*
Accessory
Kits
Replacement
Pens
MILLERS
True
Blue~~
Limited
Warranty
shall
not
apply
to:
1.
Items
furnished
by
MILLER.
but
manufactured
by
others,
such
as
engines
or
trade
accessories.
These
items
ara
covered
by
the
manufacturers
warrsnt-y,
if
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles.
contactors
and
relays
or
parts
that
fail
due
to
normal
wear.
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
CIALIINDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENT
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shalt
be,
at
MILLERS
option:
(1)
repair:
or
(2)
replacement:
or.
where
authorized
in
writing
by
MILLER
in
appropriate
cases.
(3)
the
reasonable
cost
of
repair
or
replace
ment
at
an
authorized
MILLER
service
station;
or
(4)
payment
of
or
creditfor
me
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton.
Wisconsin,
or
FOB.
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
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
CONSEGUENTIAL
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
WARS
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
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EGUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAtMED
BY
MILLER.
Some
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
Implied
warranty
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spe
citic
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
state
to
state.
Ui.
I
5.
6.
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
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
specific
legal
righta,
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
r.
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
Seria)
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
S/g3a
TABLE
OFCONTENTS
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
General
Information
And
Safety
1
1-2.
Safety
Alert
Symbol
And
Signal
Words
1
SECTION
2-INTRODUCTION
2-1.
Description
1
SECTION
3
INSTALLATION
3-1.
Synergic
Pulse
Panel
Welding
Power
Source
Connections
1
3-2.
Synergic
Pulse
Panel
Computer
Interface
Connections
2
3-3.
Connection
For
Nonpulse
Welding
2
3-4.
Connections
For
Remote.
Pulse/Nonpulse
Control
3
3-5.
Field
Installation
Instructions
For
Synergic
Pulse
Panel
RCSP-XL
Onto
Computer
Interface
3
SECTION
4
ROBOT
PROGRAM
MODIFICATIONS
4-1.
Amendment
To
Robot
Owners
Manual
Section
4
System
Set
Up
4
4-2.
Amendment
To
Cl
Robot
Owners
Manual
Section
5
Teaching
9
SECTION
5-OPERATOR
CONTROLS
5-1.
Wire
Size
Select
Switch
And
Standard
Mode
Indicator
Light
11
5-2.
Wire
Size
Indicator
Lights
11
5-3.
Wire
Type
Select
Switch
11
5-4.
Recommended
Shielding
Gas
Indicator
Ughts
11
5-5.
No
Program
Indicator
Light
12
SECTION
6-SEQUENCE
OF
OPERATION
6-1.
Gas
Metal
Arc
Welding
(GMAW)
13
6-2.
Shutting
Down
13
SECTION
7-
MAINTENANCE
&
TROUBLESHOOTiNG
7-1.
Inspection
And
Upkeep
14
7-2.
Overload
Protection
14
7-3.
Circuit
Board
Handling
Precautions
14
7-4.
Troubleshooting
15
SECTION
8-
ELECTRICAL
DIAGRAMS
Diagram
8-1.
Circuit
Diagram
16
Diagram
8-2.
Wiring
Diagram
17
Diagram
8-3.
System
Circuit
Diagram
For
Synergic
Pulse
Panel
And
Computer
Interface
.
18
SECTION
9-
PARTS
LIST
Figure
9-1.
Main
Assembly
20
LIST
OF
CHARTS
AND
TABLES
Table
5-1.
Synergic
Pulse
Panel
Welding
Schedules
12
Table
7-1.
Troubleshooting
15
OM-138992D
10/93
SECTION
1
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
la
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
trou~Ieshooting
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
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only
by
qualified
per
sons
in
accordance
with
this
manual
and
all
safety
pre
cautions
listed
in
the
Arc
Welding
Safety
Precautions
in
the
welding
power
source
Owners
Manual.
1-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and
iden
tify
different
levels
of
hazard
and
special
instructions.
a
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
a
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
seri
ous
personal
injury
or
loss
of
life.
a
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
necessaiy
for
the
most
efficient
operation
of
this
equip
ment.
SECTION
2INTRODUCTION
2-1.
DESCRIPTION
The
robot
Synergic
Pulse
panel
is
a
synergic
control
de
signed
to
be
used
with
the
MAXTRON
450
welding
pow
er
source,
MILLER
Computer
Interface,
and
the
robot
system.
The
unit
is
designed
for
Gas
Metal
Arc
Welding
(GMAW)
in
both
nonpulsed
and
pulsed
dc
arc
welding
modes.
The
unit
is
shipped
ready
for
pulsed
welding.
The
panel
is
considered
a
synergic
control
because
the
parameters
which
determine
arc
power
and
arc
length
are
programmed
so
that
they
can
be
adjusted
using
a
single
control
as
opposed
to
adjusting
individual
con-
trols.
If
pulse
welding,
arc
power
parameters
are
wire
feed
speed,
background
amperage,
peak
amperage,
pulse
frequency,
and
pulse
width;
arc
length
is
a
fine
tun
ing
of
pulse
frequency.
If
non-pulse
welding,
arc
power
parameters
are
wire
feed
speed,
arc
voltage,
and
induc
tance;
arc
length
is
a
fine
tuning
of
arc
voltage.
When
used
with
its
associated
equipment,
the
robot
Synergic
Pulse
panel
allows
the
operator
to
set
welding
parameters
for
optimum
welding
conditions
in
a
majority
of
situations
using
various
types
and
sizes
of
welding
wire
and
shielding
gases.
SECTION
3
INSTALLATION
3-1.
SYNERGIC
PULSE
PANEL
WELDING
POWER
SOURCE
CONNECTIONS
(Figure
3-1)
Obtain
appropriate
cords
and
make
connections
as
follows:
A.
REMOTE
14
ConnectIons
1.
Align
keyway,
insert
14-socket
plug
into
matching
receptacle
RC1
6
on
panel,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyway,
insert
14-pin
plug
into
matching
REMOTE
14
receptacle
on
welding
power
source,
and
rotate
threaded
collar
fully
clockwise.
B.
REMOTE
17
ConnectIons
1.
Align
keyway,
insert
17-socket
plug
into
matching
receptacle
RC1
7
on
panel,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyway,
insert
17-pin
plug
into
matching
REMOTE
17
receptacle
on
welding
power
source,
and
rotate
threaded
collar
fully
clockwise.
OM-138
992
Page
1
Pilot
Light
Plug
PLG1I
To
Computer
Interface
Receptacle
RCI1
-
SC-139
884
C.
Voltage
Sensing
Cable
Connection
To
Wire
Drive
Assembly
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
welding
power
source,
and
disconnect
input
power
employing
lock
out/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
1.
Align
keyways,
insert
4-socket
plug
on
end
of
Voltage
Sensing
Cable
into
receptacle
RC1
5,
and
rotate
threaded
collar
fully
clockwise.
2.
Install
and
secure
one
lead
with
ring
terminal
to
weld
cable
terminal
on
wire
drive
assembly
(see
wire
dive
assembly
Owners
Manualfor
location).
3.
Connect
remaining
lead
with
ring
terminal
to
the
workpiece.
3-2.
SYNERGIC
PULSE
PANEL
COMPUTER
INTERFACE
CONNECTIONS
(Figure
3-1)
A.
Plug
PLG14
Connections
Connect
plug
PLG1
4
from
the
panel
to
the
Voltage
Sens
ing
Receptacle
RC1
4
on
the
Computer
Interface
as
fol
lows:
align
keyway,
insert
plug,
and
rotate
threaded
col
lar
fully
clockwise.
B.
Plug
PLG11
Connections
Connect
plug
PLG1
1
from
the
panel
to
receptacle
RC1
1
on
the
Computer
Interface
as
follows:
align
keyway,
in
sert
plug,
and
rotate
threaded
collar
fully
clockwise.
3-3.
CONNECTION
FOR
NONPULSE
WELDING
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shutdown
robot
and
welding
power
source,
and
be
sure
equipment
cannot
be
accidently
energized
before
inspecting
or
installing.
This
unit
is
shipped
from
the
factory
ready
for
pulsed
welding.
If
nonpulsed
welding
is
desired,
proceed
as
fol
lows:
1.
Remove
Synergic
Panel
top
cover
and
side
pan
el.
Do
not
disconnect
wiring
harness.
2.
Locate
terminal
strip
2T
in
the
Synergic
Panel
be
low
Logic
Circuit
Board
PC2.
3.
Move
jumper
link
from
2T
terminals
B
and
C
to
2T
terminals
A
and
B.
4.
Reinstall
unit
top
cover
and
side
panel.
Voltage
Sensing
Receptacle
RC15.
Fuse
(see
SectIon
7-2)
17-Pin
Receptacle
RC17
Figure
3-1.
Synergic
Pulse
Panel
Connections
OM-138
992
Page
2
3-4.
CONNECTIONS
FOR
REMOTE
PULSE/NON-
PULSE
CONTROL
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
welding
power
source,
and
disconnect
input
power
employing
lock
out/tagging
procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
This
unit
is
shipped
from
th~
factory
ready
for
pulsed
welding.
If
selection
of
pulse/noripulse
is
desired
through
the
use
of
the
robot
Program
Module,
proceed
as
follows:
1.
The
fiber-optic
cable
that
connects
the
Robot
Control
and
Computer
Interface
contains
three
spare
leads,
two
of
which
can
be
used
for
this
con
nection.
2.
Remove
Synergic
Panel
top
cover
and
side
pan
el.
Do
not
disconnect
wiring
harness.
3.
Locate
terminal
strip
2T
in
the
Synergic
Panel
be
low
Logic
Circuit
Board
PC2
(see
Figure
9-1).
4.
Locate
extra
leads
at
fiber-optic
cable
in
the
Com
puter
Interface.
Route
leads
to
terminal
strip
2T
in
the
Synergic
Panel.
5.
Crimp
appropriate
terminals
on
leads
and
con
nect
leads
to
terminals
A
and
B
on
2T
in
the
Syn
ergic
Panel.
6.
Reinstall
unit
top
cover
and
side
panel.
7.
Open
Robot
Control
and
locate
extra
leads
from
fiber-optic
cable.
8.
Connect
leads
to
Robot
Control
normally-open
contacts
according
to
instructions
found
in
the
ro
bot
Owners
Manual
Section
4
System
Set-Up:
Input/Output
Terminal
Block
Connections.
9.
To
program
pulse/nonpulse
selection,
see
robot
Owners
Manual
Section
5.42.
3-5.
FIELD
INSTALLATION
INSTRUCTIONS
FOR
SYNERGIC
PULSE
PANEL
RCSP-XL
ONTO
COMPUTER
INTERFACE
(FIgures
3-1
And
3-2)
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
welding
power
source
and
ro
bot,
and
disconnect
input
power
employ
ing
lockout/tagging
procedures
before
be
ginning
this
installation.
Lockout/tagging
procedures
consist
of
removing
input
power
plug
from
receptacle,
padlocking
line
disconnect
switch
in
open
po
sition,
removing
fuses
from
fuse
box,
or
shut
ting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
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.
a
CAUTION:
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
properly
grounded
wrist
strap
BEFORE
handling
circuit
boards.
Transport
circuit
boards
in
proper
static-
shielding
carriers
or
packages.
Perform
work
only
at
a
static-safe
work
area.
INCORRECT
INSTALLATION
or
misaligned
plugs
can
damage
circuit
board.
Be
sure
that
plugs
are
properly
installed
and
aligned.
EXCESSIVE
PRESSURE
can
break
circuit
board.
Use
only
minimal
pressure
and
gentle
move
ment
when
disconnecting
or
connecting
board
plugs
and
removing
or
installing
board.
Remove
Computer
Interface
top
cover
and
side
panels.
2.
Disconnect
Synergic
Pulse
panel
wiring
harness
from
panel
Interface
circuit
board
PCi.
Remove
side
panel
from
Synergic
Pulse
panel.
Install
frame
onto
left
side
of
Computer
interface
with
sheet
metal
screws
(see
Figure
3-1).
5.
Connect
leads
25
and
27
to
terminals
T
and
U
on
the
Voltage
Control
Board
in
the
Computer
Inter
face
(polarity
is
not
important).
6.
Remove
jumper
links
between
terminals
1
TE
and
1
TF,
and
terminals
2TB
and
2TC
in
the
Computer
Interface.
7.
Make
the
following
connections
to
the
terminal
strips
in
the
Computer
Interface.
Terminal
strip
1
T
leads
must
be
routed
through
the
grommet
in
the
center
panel
of
the
Computer
Interface
to
the
right
side
of
the
unit
(see
Figure
3-2).
a.
Connect
lead
38
to
1TA.
b.
Connect
lead
39
to
1TB.
c.
Connect
lead
43
to
1TE.
d.
Connect
lead
55
to
1TF.
e.
Connect
lead
26
to
2TB.
f.
Connect
lead
45
to
2TC.
g.
Connect
lead
60
to
1TC.
h.
Connect
gray
lead
to
Computer
Interface
chas
sis
ground
terminal.
8.
Position
Synergic
Pulse
panel
side
panel
so
that
the
wiring
harness
can
be
reconnected.
Recon
nect
wiring
harness
to
PCi.
Install
side
panel
onto
Synergic
Pulse
panel.
Reinstall
Computer
Interface
right
side
panel.
Install
supplied
top
cover
onto
the
Computer
In
terface
Synergic
Pulse
panel.
3.
4.
9.
10.
11.
OM-138
992
Page
3
Communications
Board
~
Power
SuppIy.~~~
Terminal
Strip
1T~j
2T
Route
Leads
Through
This
Grommet
Right
Side
View
Of
Computer
Interface
S8-139
887-C
Figure
3-2.
Electrical
Installation
SECTION
4-
ROBOT
PROGRAM
MODVFICATIONS
IMPORTANT:
The
robot
program
must
be
changed
to
accommodate
synergic
welding.
The
following
informa
tion
pertains
to
the
robot
Owners
Manual.
4-1.
AMENDMENT
TO
ROBOT
OWNERS
MANU
AL
SECTION
4
SYSTEM
SET
UP
Before
the
Synergic
Pulse
panel
will
work,
the
robot
sys
tern
data
must
be
updated.For
Robots
with
Cl
control,
update
System
Data
4
(welding
power
source
selection)
to
SYNERGIC
according
to
instructions
in
Section
4.22.1
-
For
Robots
with
C2
control,
use
the
following
in
structions
to
change
weld
characteristics:
1)
Turn
on
Robot
Control
input
power
by
placing
the
power
switch
handle
on
the
Robot
Control
cabinet
door
in
the
ON
position,
and
the
following
displays
will
appear
as
shown:
Voltage
Control
Board
Interface
Board
Control
Board
1~0
WELCOME
TO
DIAGNOSIS
MILLER
COOPERATIVE
CONTROL
MILLER
ELECTRIC
Mfg
.
Co.
START
DIAGNOSIS
920731
08:30
OM-138
992
Page
4
2)
Press>
key
to
scroll
to
next
screen.
3)
Press
Fl
key
to
select
Parameter.
DIAGNOSIS
WE
LCOME
TO
MILLER
COOPERAT
IVE
CONTROL
92
08:
0731
30
STEP
OF
INITIAL
1,
2,
3,
4,
5,
DIAGNOSIS
T
E
AC
H
M
0
D
E
S
E
R
V
0
OF
F
T
E
ACH
E
DI
T
FILE
AL
LOT
LOCK
>
TEACH
MODE
SERVO
OFF
PA
R
M
I
E
R
C
H
E
CK
M
A
N
A
G
E S
Y
S
.
S
E
I
M
E
M
0
A
V
>
SERVO
PARAMETER
OFF
SELECT
TYPE
OF
TEACH
MODE
BY
FUNCTION
KEY
SYSTEM
SWI
TCH
WELD
I/O
AUTO
>
OM-138
992
Page
5
4)
Press>
key
to
scroll
to
next
screen.
5)
Press
F4
key
to
select
Weld
Characteristics.
6)
Use
UP/DOWN
cursor
and
DISPLAY
SELECT
keys
to
select
SYNERGIC
and
wire
size.
7)
Press
Fl
to
Register
change.
Display
appears
as
follows:
TEACH
MODE
SERVO
SELECT
TYPE
OF
PARAMETER
BY
FUNCTION
KEY
OFF
SENSOR
ARC.S
AX
I
S
TEACH
TOUCH-S
W-CHARA
ML4
POWER
SOURCE
SDATA
>
GMAW
SERVO
WI
RE
OFF
REG
1ST
SYNERGIC
GTAW-1
00
G
T
AW-
3
00
USER
REG
Y
SC_ED
.035
.035
.035
MODI
F
.045
.045
.045
.045
I
STER
.062
.062
.062
.062
IT
AX
I
S
TEACH
ML4
POWER
SOURCE
SERVO
WIRE
OFF
GM
SY
GT
GT
US
Y
AW
NERG
IC
AW-
1
0
0
AW-
3 0 0
ER
REG
SC_ED
REGIST
MODIF
.035
:03:5
.035
.035
.045
.045
.045
.045
.062
.062
.062
.062
I
STER
IT
TEACH
MODE
SELECT
TYPE
BY
FUNCTION
K
SERVO
OFF
OF
PARAMETER
EY
SENSOR
ARC
S
TOUCHS
W-
C
H
ARA
SDATA
>
OM-138
992
Page
6
8)
To
check
settings,
press
F4
to
select
Weld
Characteristics
9)
Press
F2
to
check
Modify
display.
AXIS
ML4
TEACH
-
RAT
I
NG
$WTBD1
1
TYPE
ARC
POWER
OF
POWER
S
E
P
A
.
S
V
NE
R
RATING
hG
loop
PUSH
RECORD
AFTER
SETTING
10)
Press
RECORD
key
and
display
will
appear
a
s
follows:
AXIS
ML4
DISP.
REF.
TEACH
1.
20P
2.OV
2.
39P
4.OV
3.
59p
6.OV
SERVO
OFF
4,
79P
8
.OV
5.100P
lO.OV
11)
Press
the
RESET
key.
SELECT
TYPE
OF
PARAMETER
TEACH
MODE
BY
FUNCT
ION
KEY
SERVO
OFF
SYSTEM
SWI
TCH
WELD
I/O
AUTO
AXIS
ML4
TEACH
SERVO
OFF
REGIST
MOD3F
POWER
SOURCE
GMAW
SYNERGIC
GTAW-1
00
G
T
AW-
3 0
0
U
S E
R R
E
G
I
S
T
E.R
Y
SC_EDIT
.035
.035
.035
.035
WI
RE
.045
.062
.045
.062
.045
.062
.045
.062
SERVO
OFF
SOURCE
OM-138
992
Page
7
12)
To
check
settings,
use>
key
to
scroll
to
next
display.
13)
Press
F4
to
select
Weld
Characteristics.
AXIS
TEACH
-
GIC
100
300
REG
I
STER
_ED
IT
SELECT
TYPE
OF
BY
FUNCT
I
ON
KEY
TEACH
MODE
SERVO
OFF
SENSOR
ARC
~-S
PA
RAM
ET
ER
ML
4
TOUCH-S
W-CHARA
SDATA
>
POWER
SOURCE
WIRE
G.M
SY
GT
GT
US
SERVO
OFF
REGIST
MODIFY
AW
N
ER
AW
AW
ER
SC
.
035
.045
.062
.
035
.
045
.062
.
035
.045
.
062
.035
.045
.062
14)
Press
F3
to
view
scaling
of
output
voltage
for
Arc
Power
function.
WI
RE
CURRE
TEACH
MODE
>1.200
i
.
1
60A
2.300
i
.
240A
3.400i
.
310A
SERVO
OFF
4.500
i
.
400A
5.600i
500A
W.
I.
CONVERT
ON
OFF
15)
Press
RECORD
key
and
display
will
appear
as
follows:
SELECT
TYPE
OF
PARAMETER
TEACH
MODE
BY
FUNCTION
KEY
SERVO
OFF
SYSTEM
SWI
TCH
WELD
I/O
AUTO
>
16)
Press
the
RESET
key.
OM-138
992
Page
8
If
the
Synergic
Pulse
panel
WIRE
SIZE
SELECT
Switch
is
in
the
STANDARD
position,
robot
system
data
must
be
updated.
For
Robots
with
Cl
control,
update
System
Data
4
to
GMAW
according
to
instructions
in
Section
4.22.1.
For
Robots
with
C2
control,
use
above
instruc
tions
to
reset
unit
for
GMAW.
IMPORTANT:
For
Robots
with
C2
control,
see
Section
5.18
of
the
Robot
Owners
Manual
for
information
on
programming
for
synergic
welding.
4-2.
AMENDMENT
TO
Cl
ROBOT
OWNERS
MANUAL
SECTION
&
TEACHING
Amend
Section
5.12.8
Teaching
The
Arc
Start
Function
When
using
the
Synergic
Pulse
panel,
the
synergic
mode
arc
start
parameters~and
displays
differ
from
regu
lar
GMAW
welding
displays.
5.12.8
Teaching
The
Arc
Start
Function
IMPORTAN1~
Two
or
more
arc
start
functions
can
be
taught
in
series
and
only
one
arc
end
function
taught
to
end
the
welding
operation
(see
Section
5.12.9).
After
the
arc
start
function
data
is
taught,
an
asterisk
is
put
by
the
next
sequence
movement
data
taught
(linear
or
circular
arc)
to
show
that
the
movement
data
is
part
of
a
welding
function.
Welding
is
possible
within
the
range
of
linear
or
circular
arc
movement
data
only.
Welding
parameter
values
can
be
changed
in
Automatic
mode
during
the
welding
operation
by
using
the
DISPLAY
SELECT
keys
to
choose
the
desired
parameter(s)
for
value
changes.
If
the
first
sequence
movement
data
of
a
program
is
the
only
taught
data
recorded
before
entering
the
second
sequence
data,
the
display
will
appear
as
shown:
Manual
Operating
Speed
POOl
SOOl
M6
P
60
IMPORTANT:
The
display
examples
used
with
state
ments
such
as
Will
appear
as
sho
wn
maynot
match
ex
actly
with
actual
Program
Module
displays
because
of
different
program
number,
job
number,
sequence
num
ber,
line
number,
manual
operatirz.g
speed,
recorded
data,
or
moving
speed
forAutomatic
mode.
Notall
cases
can
be
given
for
actual
display
data,
and
the
examples
are
only
for
a
reference
to
supplement
instructions.
If
the
arc
startfunction
data
will
be
the
next
data
recorded
after
previous
taught
data,
the
display
will
appear
as
shown:
POOl
S005
M4
Q
P
60
,
Previous
Current
Recorded
Recorded
Data
.
Data
1)
Press
the
ARC
START
key
to
teach
the
arc
start
function,
and
a
typical
display
will
appear
as
shown:
P001
S003
M4
25P
1L
039i
0.5S
IMPORTANT:
When
using
a
program
initially
pro
grammed
with
System
Data
4
set
to
GMAW,
the
Arc
Length
display
may
show
unusual
alpha-numeric
sym
bols.
The
program
needs
to
be
converted
to
SYNERG
IC.
Use
the
DISPLAY
SELECT
key
to
move
to
the
Arc
Length
parameter.
Press
the
Increase
(INC.)
or
De
crease
(DEC.)
key
to
clear
the
display
for
entry
of
valid
parameters
(5
to
+5).
2)
To
change
the
welding
parameter
values,
press
the
forward
DISPLAY
SELECT
key
for
each
weld
ing
parameter
value
until
the
appropriate
letter
(P,
S)
after
the
value
to
be
changed
flashes.
POOl
S003
M4
25;P:
1L
039
i
0.
5S
Table
5-2.
Ranges
And
Increments
Of
Arc
Start
WeldIng
Parameter
Values
Arc
power
parameters
are
wire
feed
speed,
background
amperes,
peak
amperes,
pulse
frequency,
and
pulse
width.
Arc
length
is
a
fine
tuning
of
pulse
frequency.
Welding
Parameter
Setting
Range
Increment
Arc
Power
Oto
lOOP
1
P
Arc
Length
5to+5L
1
L
Welding
Speed
4
to
234
ipm
1
ipm
Prefiow
Time
0
to
9.9
sec.
0.1
sec.
I
Arc
Power
In
Percent
I
I +
Arc
Length
Weld
ln~,~eed
Pretiow
Time
in
Seconds
t
Current
Recorded
Data
(May
Also
Be
0
Data)
OM-138
992
Page
9
3).
Enter
a
numbervalue
or
press
the
Increase
(INC.)
or
Decrease
(DEC.)
key
to
change
the
welding
parameter
value
until
the
desired
value
appears
(if
the
QUICK
INCREASE-DECREASE
key
is
pressed
at
the
same
time,
changing
of
the
data
is
performed
rapidly).
POOl
S003
M4
28P
1
L
039
i
0
.5
S
IMPORTANT:
Before
pressing
the
RECORD
key,
the
robot
axes
can
be
moved
manually
using
the
Axis
keys
to
allow
changing
axes
position
and/or
welding
gun/
torch
angle.
4)
Press
the
RECORD
key,
the
sequence
number
will
advance
one
step
to
register
the
current
data
in
the
program,
and
the
display
will
appear
as
shown:
POOl
S004
M4
Cl
AS
Amend
Section
5.12.9
Teaching
the
Arc
End
Function
When
using
the
Synergic
Pulse
panel,
the
synergic
mode
arc
end
parameters
and
displays
differ
from
regu
lar
GMAW
welding
displays.
5.12.9
TeachIng
The
Arc
End
FunctIon
When
the
arc
end
function
data
is
the
next
data
recorded
after
previous
taught
data,
the
display
will
appear
as
shown:
POOl
S005
M4
AS
*L
39i
IMPORTANT:
The
display
examples
used
with
state
ments
such
as
Will
appearas
shownmaynotmatch
ex
actly
with
actual
Program
Module
displays
because
of
different
program
number,
job
number,
sequence
num
ber,
line
number,
manual
operating
speed,
recorded
data,
or
moving
speed
forAutomatic
mode.
Not
all
cases
can
be
given
for
actual
display
data,
and
the
examples
are
only
for
a
reference
to
supplement
instructions.
1)
Press
the
ARC
END
key
to
teach
the
arc
end
func
tion,
and
a
typical
display
will
appear
as
shown:
POOl
S005
M4
18P
1L
0.2S
0.5S
I
Arc
Power
Arc
Length
Crater
Fill
Time
Postflow
Time
In
Percent
In
Seconds
In
Seconds
IMPORTANT:
When
using
a
program
initially
pro
grammed
with
System
Data
4
set
to
GMAW,
the
Arc
Length
display
may
show
unusual
alpha-numeric
sym
bols.
The
program
needs
to
be
converted
to
SYNERG
IC.
Use
the
DISPLAY
SELECT
key
to
move
to
the
Arc
-
Length
parameter.
Press
the
Increase
(INC.)
or
De
crease
(DEC.)
key
to
clear
the
display
for
entiy
of
valid
parameters
(5
to
5).
2)
To
change
the
welding
parameter
values,
press
the
forward
DISPLAY
SELECT
key
for
each
weld
ing
parameter
value
until
the
appropriate
letter
(P,
L,
5,
5)
after
the
value
to
be
changed
flashes.
POOl
S005
M4
18P
1L
0.2S
0
.5S
Table
5-3.
Ranges
And
Increments
Of
Arc
End
Welding
Parameter
Values
Arc
power
parameters
are
wire
feed
speed,
background
amperes,
peak
amperes,
pulse
frequency,
and
pulse
width.
Arc
length
is
a
fine
tuning
of
pulse
frequency.
W
elding
Parameter
Setting
Range
Increment
Arc
Power
0
to
100
P
1
P
ArcLength
5to5L
1
L
Crater
Fill
Time
0
to
9.9
sec.
0.1
sec.
Postflow
Time
0
to
9.9
sec
0.1
sec.
3)
Enter
a
numbervalue
or
press
the
Increase
(INC.)
or
Decrease
(DEC.)
key
to
change
the
welding
parameter
value
until
the
desired
value
appears
(if
the
QUICK
INCREASE-DECREASE
key
is
pressed
at
the
same
time,
changing
of
the
data
is
performed
rapidly).
POOl
S005
M4
28P
1L
0
.2S
0
.5S
IMPORTANT:.
Before
pressing
the
RECORD
key,
the
robot
axes can
be
moved
manually
using
the
Axis
keys
to
allow
changing
axes
position
and/or
welding
gun/
torch
angle.
I
Previous
Recorded
Data
I
Current
Recorded
Data
OM-138
992
Page
10
4)
Press
the
RECORD
key,
the
sequence
number
will
advance
one
step
to
register
the
current
data
in
the
program,
and
the
display
will
appear
as
shown:
POOl
SOO6
M4
AE
SECTION
5
OPERATOR
CONTROLS
5-1.
WIRE
SIZE
SELECT
SWITCH
AND
STAN
DARD
MODE
INDICATOR
LIGHT
The
WIRE
SIZE
SELECT
Switch
and
the
WIRE
TYPE
SELECT
Switch
set
the
output
range
of
the
welding
pow
er
source
and
robot
wire
drive
~or
the
specific
type
and
size
of
wire
chosen.
Together,
the
switches
determine
the
relationship
of
the
various
arc
power
parameters.
If
the
unit
is
operated
in
a
pulse
condition,
arc
power
pa
rameters
are
wire
feed
speed,
background
amperes,
peak
amperes,
pulse
frequency,
and
pulse
width.
Arc
length
is
a
fine
tuning
of
pulse
frequency.
If
the
unit
is
operated
in
a
nonpulse
condition,
arc
power
parameters
are
wire
feed
speed,
arc
voltage,
and
induc
tance.
Arc
length
is
a
fine
tuning
of
arc
voltage.
When
the
WIRE
SIZE
SELECT
Switch
is
placed
in
the
STD
position,
the
STANDARD
MODE
Indicator
Light
will
come
on,
indicating
that
the
Synergic
Pulse
panel
is
in
standard
mode
and
cannot
be
used
to
set
the
output
pa
rameters
for
the
welding
power
source
or
robot
wire
drive.
When
the
control
is
in
standard
mode,
the
robot
needs
to
be
reset
to
the
GMAW
mode
through
System
Data
4.
IMPORTANT:
Position
the
WIRE
SIZE
SELECT
Switch
in
the
.045
position
when
welding
with
.047
in.
diameter
welding
wire.
5-2.
WIRE
SIZE
INDICATOR
LIGHTS
(Figure
5-1)
The
top
light
indicates
whether
the
unit
is
set
to
pulse
(light
on)
or
is
in
STD
(light
off).
The
remaining
lights
turn
Standard
Mode
Indicator
Light
Wire
Type
Selector
No
Program
Indicator
Light
on
when
the
corresponding
wire
size
is
selected
by
the
WIRE
SIZE
SELECT
switch.
5-3.
WIRE
TYPE
SELECT
SWITCH
(Figure
5-1)
The
WIRE
TYPE
SELECT
Switch
is
functional
when
the
WIRE
SIZE
SELECT
Switch
is
not
in
STD.
The
WIRE
TYPE
SELECT
Switch
and
the
WIRE
SIZE
SELECT
Switch
set
the
output
range
of
the
welding
power
source
and
robot
wire
drive
for
the
specific
type
and
size
of
wire
chosen.
Together,
the
switches
determine
the
relation
ship
of
the
various
arc
power
parameters.
If
the
unit
is
operated
in
a
pulse
condition,
arc
power
pa
rameters
are
wire
feed
speed,
background
amperes,
peak
amperes,
pulse
frequency,
and
pulse
width.
Arc
length
is
a
fine
tuning
of
pulse
frequency.
If
the
unit
is
operated
in
a
nonpulse
condition,
arc
power
parameters
are
wire
feed
speed,
arc
voltage,
and
induc
tance.
Arc
length
is
a
fine
tuning
of
arc
voltage.
5-4.
RECOMMENDED
SHIELDING
GAS
INDICA
TOR
LIGHTS
(Figure
5-1)
The
RECOMMENDED
SHIELDING
GAS
Indicator
Lights
represent
the
types
of
shielding
gases
recom
mended
for
use
with
the
Synergic
Pulse
panel.
The
panel
is
programmed
to
select
the
shielding
gas
that
will
provide
optimum
welding
conditions
in
a
majority
of
situ
ations
for
the
type
and
size
of
wire
selected
on
the
WIRE
SIZE
SELECT
and
WIRE
TYPE
SELECT
switches.
Wire
Size
Indicator
Light
Wire
Size
Selector
Switch
Recommended
Shielding
Gas
Indicator
Lights
SB-139
885.A
Figure
5-1.
Operator
Controls
OM-138
992
Page
11
After
selecting
the
wire
size
and
type,
the
indicator
light
for
the
recommended
shielding
gas
will
come
on.
If
a
light
does
not
come
on,
and
the
NO
PROGRAM
Indica
tor
light
does
not
come
on,
refer
to
Table
5-1
for
the
rec
ommended
shielding
gas.
If
the
NO
PROGRAM
Indicator
Light
comes
on
with
or
without
a
RECOMMENDED
SHIELDING
GAS
Indicator
Light,
reselect
the
wire
type
and
size
to
be
used
(see
Sections
5-1
and
5-3).
5-5.
NO
PROGRAM
INDICATOR
LIGHT
(Figure
5-1)
The
Synergic
Pulse
panel
has
been
programmed
to
pro
vide
optimum
welding
conditions
in
a
majority
of
situa
tions
using
various
types
and
sizes
of
welding
wire
and
various
shielding
gases.
The
NO
PROGRAM
Indicator
Light
allows
the
operator
to
determine
if
the
unit
has
been
programmed
for
the
conditions
set
by
the
WIRE
TYPE
SELECT
and
WIRE
SIZE
SELECT
switches.
If
the
NO
PROGRAM
Indicator
light
comes
on,
the
control
is
not
programmed
for
the
conditions
set
by
the
two
switches;
therefore,
it
will
be
necessary
to
reselect
the
type
and
size
of
wire
to
be
used.
IMPORTANT:
Use
of
a
nonrecommended
shielding
gas
could
change
weld
characteristics.
Table
5-1.
Synergic
Pulse
Panel
Welding
Schedules
PULSE
WELDING
The
Synergic
Pulse
panel
is
not
programmed
for
type
and
size
of
welding
wire
indicated.
DEFINITION
OF
TABLE
5-1
DATA
Wire
Type:
STL1
=
Mild
Steel
(Used
with
CO2
shielding
gas
for
short
circuit
welding
from
minimum
to
maximum
wire
feed
speed.)
STL2
=
Mild
Steel
(In
PULSE
mode,
STL2
is
used
with
98
Ar/2
02
shielding
gas
for
pulse
spray
welding
from
minimum
to
maximum
wire
feed
speed.
In
NON-
PULSE
mode,
STL2
is
used
with
75
Ar/25
CO2
shielding
gas
for
short
circuit
welding
from
minimum
to
maximum
wire
feed
speed.)
NI
=
High
Nickel
Alloy
SS1
=
Stainless
Steel
(In
PULSE
mode,
SS1
is
used
with
98
Ar/2
02
shielding
gas
for
spray
transfer
welding
from
minimum
to
maximum
wire
feed
speed.
In
NON-
PULSE
mode,
SS1
is
used
with
Tn-Mix
shielding
gas
for
short
circuit
transfer
welding
from
minimum
to
maximum
wire
feed
speed.)
SS2
=
Stainless
Steel
(SS2
is
used
with
98
Ar/2
02
shielding
gas
for
spray
transfer
welding
from
minimum
to
maximum
wire
feed
speed.)
ALl
=
4043
Aluminum
Wire
Type
STL1
STL2
NI
S51
SS2
ALl
AU
SI
BR
CUST.
030
*
*
*
* *
*
*
*
.035
*
98Ar/2
02
75ArI25
HE
98ArI2
02
*
Ar
Ar
Ar
.045
98Ar/2
02
75Ar/25
HE
98Ar/2
02
*
Ar
Ar
Ar
98An/2
2
.062
*
*
*
Ar
Ar
*
NON
PULSE
WELDING
Wire
Type
STL1
STL2
NI
SS1
SS2
ALl
AU
SI
BR
CUST.
.030
CO2
75An/25
CO2
SPCL
98An/2
02
* * *
.035
CO2
75Ar/25
CO2
SPCL
98Ar/2
02
Ar
Ar Ar
*
.045
CO2
75An/25
CO2
*
SPCL
98ArI2
02
Ar
Ar
*
CO2
.062
*
*
*
*
Ar
Ar
*
*
OM.138
992
Page
12
AL2
5356
Aluminum
Shielding
Gas:
-
SI
BR
=
Silicon-Bronze
CO2
=
Carbon
Dioxide
*CUST
=
Position
usually
reserved
for
program-
75
Ar/25
CO2
=
75%
Argon
ming
a
welding
schedule
not
included
in
25%
Carbon
Dioxide
thestandardprogrammingoftheunit.At
SPCL
=
Tn-Mix:
90%
Helium
this
time,
the
welding
schedule
pro-
7.5%
Argon
grammed
for
this
position
is
as
follows:
2.5%
Carbon
Dioxide
*puLsEwelding
=
.045409flux-cored
AR
=
Argon
stainless
steel
welding
wire
98
Ar/2
02
=
98%
Argon
*NONPULSE
Welding
=
.045
AWS
2%
Oxygen
class
E71T-1
flux-cored
welding
wire
~75Ar/25HE
=
75%
Argon
25%
Helium
~This
shielding
gas
is
not
included
on
nameplate
of
the
Synergic
Pulse
panel.
SECTION
6-
SEQUENCE
OF
OPERATION
a
WARNING:
ELECTRIC
SHOCK
can
kill;
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
MOVING
PARTS
can
cause
serious
injury;
can
affect
pacemaker
operation.
IMPROPER
AIRFLOW
AND
EXPOSURE
TO
Wearers
should
consult
their
doctor
before
ENVIRONMENT
can
damage
internal
parts.
going
neararc
welding,
gouging,
or
spot
weld-
Do
not
touch
live
electrical
parts.
ing
operations.
Keep
all
covers
and
panels
in
place
while
See
Arc
Welding
Safety
Precautions
in
the
weld
operating.
ing
power
source
Owners
Manual
for
basic
Do
not
touch
welding
wire
oranymetal
part
in
welding
safety
information.
contact
with
it
while
welding.
The
welding
wire
and
all
metal
parts
in
contact
with
it
carry
weld
output
when
the
welding
power
6-1.
GAS
METAL
ARC
WELDING
(GMAW)
source
contactor
is
energized.
1.
Install
and
connect
robot
system
according
to
its
Warranty
is
void
if
any
of
the
equipment
is
open-
Owners
Manuals.
ated
with
any
portion
of
the
outer
enclosure
removed.
2.
Connect
panel
according
to
Section
3.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
3.
Position
WIRE
SIZE
SELECT
Switch
for
size
wire
hearing,
used
(see
Section
5-1).
Wear
correct
eye,
ear,
and
body
protection.
4.
Position
WIRE
TYPE
SELECT
Switch
for
type
FUMES
AND
GASES
can
seriously
harm
wire
used
(see
Section
5-3).
your
health.
Keep
your
head
out
of
the
fumes.
5.
Place
welding
power
source
front
panel
adjust-
Ventilate
to
keep
from
breathing
fumes
and
ment
control(s)
to
the
maximum
setting.
gases.
6.
Turn
on
shielding
gas
at
its
source.
If
ventilation
is
inadequate,
use
approved
breathing
device.
7.
Energize
robot
system.
WELDING
WIRE
can
cause
puncture
8.
Begin
welding.
wounds.
Do
not
point
gun
toward
any
part
of
the
body,
6-2.
SHUTTING
DOWN
any
conductive
surface,
or
other
personnel.
HOT
METAL,
SPATTER,
AND
SLAG
can
1.
Stop
welding.
cause
fire
and
burns.
2.
Shut
down
robot
system.
Watch
for
fire.
Keep
a
fire
extinguisher
nearby,
and
know
3.
Turn
off
shielding
gas
at
the
source.
how
to
use
it.
Do
not
use
near
flammable
material,
WARNING:
HIGH
CONCENTRATION
OF
SHIELDING
GAS
can
harm
health
or
kill.
Allow
work
and
equipment
to
cool
before
handling.
Shut
off
gas
supply
when
not
in
use.
OM-138
992
Page
13
SECTION
7
MAINTENANCE
&
TROUBLESHOOTING
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.
7-1.
INSPECTION
AND
UPKEEP
Usage
and
shop
conditions
will
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
robot
and
welding
power
source,
and
disconnect
input
power
employing
lock
out/tagging
procedures
before
inspecting,
maintaining,
or
servicing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
MOVING
PARTS
can
cause
serious
injury.
Keep
away
from
moving
parts.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
servicing.
Maintenance
and
troubleshooting
to
be
per
formed
only
by
qualified
persons.
1.
Inspect
all
interconnecting
cords
for
damage
to
or
breaks
in
the
insulation
jacket,
particularly
at
the
plugs.
Repair
or
replace
the
cord(s)
as
necessary.
2.
Remove
grease
and
dirt
from
components
and
moisture
from
electrical
parts
and
cables.
7-2.
OVERLOAD
PROTECTION
a
WARNING:
ELECTRIC
SHOCK
can
kIll.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
welding
power
source,
and
disconnect
input
power
employing
lock
out/tagging
procedures
before
inspecting,
maintaining,
or
servicing.
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).
Fuse
Fl
protects
the
unit
from
overload.
If
fuse
Fl
should
open,
the
Synergic
Pulse
panel
would
not
func
tion.
To
replace
fuse
Fl,
proceed
as
follows:
1.
Depress
and
rotate
fuse
holder
cover
counter
clockwise.
2.
Pull
out
fuse
with
cover
when
fuse
holder
cover
is
free.
3.
Insert
new
fuse
into
fuse
holder
cover.
4.
Install
new
fuse
with
fuse
holder
cover
back
into
unit.
5.
Depress
and
rotate
fuse
holder
cover
clockwise
until
cover
is
secure.
7-3.
CIRCUIT
BOARD
HANDLING
PRECAUTIONS
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
welding
power
source,
and
disconnect
input
power
employing
lock
out/tagging
procedures
before
inspecting,
maintaining,
or
servicing.
Lockout/tagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
CAUTION:
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
properly
grounded
wrist
strap
BEFORE
handling
circuit
boards.
Transport
circuit
boards
in
proper
static-
shielding
carriers
or
packages.
Perform
work
only
at
a
static-safe
work
area.
INCORRECT
INSTALLATION
or
misaligned
plugs
can
damage
circuit
board.
Be
sure
that
plugs
are
properly
installed
and
aligned.
EXCESSIVE
PRESSURE
can
break
circuit
board.
Use
only
minimal
pressure
and
gentle
move
ment
when
disconnecting
or
connecting
board
plugs
and
removing
or
installing
board.
IMPORTANT:
The
circuit
boards
in
this
unitInterface
Circuit
Board
PCi,
Logic
Circuit
Board
PC2,
and
Memory
Circuit
Board
PC3are
installed
stacked
on
top
of
each
other
on
the
inside
of
the
operator
control
paneL
PC2
is
at
the
bottom
of
the
stack
(closest
to
the
operator
control
panel)
,
PC3
is
in
the
middle,
and
PCi
is
at
the
top
of
the
stack.
OM-138
992
Page
14
7-4.
TROUBLESHOOTING
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
welding
power
source.
and
disconnect
input
power
employing
lock
out/tagging
procedures
before
inspecting,
maintaining,
or
servicing.
Lockoutltagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect-
-
ing
device.
Troubleshooting
of
internal
parts
to
be
per
formed
only
by
qualifier]
persons.
It
is
assumed
that
proper
installation
has
been
made
ac
cording
toSection
3
of
this
manual,
the
operator
is
famil
iar
with
the
function
of
controls,
the
unit
was
working
properly,
and
that
the
trouble
is
not
related
to
the
welding
process.
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
unit.
Use
this
chart
in
conjunction
with
the
circuit
diagram
while
performing
troubleshooting
procedures.
If
the
trouble
is
not
remedied
after
performing
these
proce
dures,
the
nearest
Factory
Authorized
Service
Station/
Service
Distributor
should
be
contacted.
In
all
cases
of
equipment
malfunction,
the
manufacturers
recommen
dations
should
be
strictly
followed.
Table
7-1.
Troubleshooting
TROUBLE
PROBABLE
CAUSE
REMEDY
No
weld
output.
POWER
Switch
on
welding
power
source
in
OFF
position.
Place
POWER
Switch
on
welding
power
source
in
ON
position.
Fuse(s).
Check
fuse
on
Computer
Interface
and
Synergic
Pulse
panel.
Replace
necessary
parts.
Welding
gun.
See
welding
gun
Owners
Manual.
No
control
of
weld
output.
Control
cords
not
secure.
Secure
all
connections
between
Synergic
Pulse
panel,
Computer
Interface,
welding
power
source,
and
wire
drive
assembly.
Voltage
Sensing
Cable
connec-
tions.
Check
routing
of
voltage
sensing
cable
and
se
cure
connections.
Work
connection
loose
or
in-
complete
due
to
rust,
paint,
etc.,
on
surface
of
workpiece.
Check
work
connection
for
good
metal-to-metal
contact.
Synergic
Pulse
panel
not
pro-
grammed
for
weld
conditions
set
by
WIRE
SIZE
SELECT
and
WIRE
TYPE
SELECT
switches
(NO
PROGRAM
Indicator
light
will
be
on.)
Reselect
wire
type
and
wire
size
to
be
used.
Computer
Interface.
See
Computer
Interface
Owners
Manual.
Synergic
Pulse
panel
controls
not
functional.
Interface
Circuit
Board
PCi
See
Section
7-3
and
contact
nearest
Factory
Au-
thorized
Service
Station/Service
Distributor.
Memory
Circuit
Board
PC3.
See
Section
7-3
and
contact
nearest
Factory
Au
thorized
Service
Station/Service
Distributor.
Logic
Circuit
Board PC2.
See
Section
7-3
and
contact
nearest
Factory
Au
thorized
Service
Station/Service
Distributor.
Erratic
weld;
incorrect
weld
characteristics.
Incorrect
settings
on
WIRE
TYPE
SELECT
and/or
WIRE
SIZE
SELECT
switches.
Reselect
wire
type
and
wire
size
to
be
used.
Incorrect
arc
length.
Adjust
ARC
LENGTH
control
on
the
robot
Pro
gram
Module.
Voltage
Sensing
Cable
connec-
tions.
Check
routing
of
voltage
sensing
cable
and
se
cure
connections.
Work
connection
loose
or
in-
complete
due
to
rust,
paint,
etc.,
on
surface
of
workpiece.
Check
work
connection
for
good
metal-to-metal
contact.
OM-138
992
Page
15
SECTION
8
ELECTRICAL
DIAGRAMS
1~
~.0
1~
th
Cl)
0
z
E
ci
(0
0
U
1~
C.)
E
(0
ci
(0
0
e
C.,
1~
E
Cu
I
a)
(0
0
OM-138
992
Page
16
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