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Millerfi
August
1994
Form:
OM-1
64
438A
Effective
With
Serial
No.
KE555371
OWNERS
MANUAL
RPH-1-500
And
RPH-1-1000
Headstock
RPT~1
000
Tallstock
U
Read
and
follow
these
instructions
and
all
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
U
Give
this
manual
to
the
operator.
For
help,
call
your
distributor
U
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
1
Axis
Headstock
Positioners
For
Robotic
Welding
Systems
Nondriven
Tailstock
For
Supporting
Long
Fixtures
Or
Parts
Requires
C2
Robot
Control
Equipped
With
External
Axis
Kit
For
Positioning
Of
Fixtures
And
Parts
Within
The
Work
Envelope
Motion
Range
Set
By
Soft
Limit
Sequential
Or
Cooperative
Operation
Capability
cover
5/94
Ref.
5T-800
519
'
1994
MILLER
Electric
Mfg.
Co.
PRINTED
IN
USA
eS
a
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial
number
preface
of
ICC
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
-
Subject
to
the
terms
and
conditions
below,
MILLER
Electric
Remote
Controls
Mtg.
Co.,
Appleton,
Wisconsin,
warrants
to
its
original
retail
purchaser
that
new
~
y,~s
MILLER
equipment
sold
after
the
effective
date
of
this
limited
warranty
Is
free
ot
de-
Replacement
Parts
lecta
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-
MILLERS
True
BIueTM
Limited
Warranty
shall
not
apply
to:
NESS.
I.
Items
fumished
by
MILLER,
but
manufactured
by
others,
such
as
engines
or
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war-
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranl~
it
ranted
parts
or
components
that
fail
due
to
such
detects
in
material
or
workmanship,
any.
MILLER
must
be
notified
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
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contact
ors
followed,
and
relays
or
pans
that
fail
due
to
normal
wear.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER.
or
equip-
event
ot
such
e
failure
within
the
warranty
time
periods.
All
warranty
time
periods
main
that
has
been
improperly
installed,
improperly
operated
or
misused
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
or
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
one
year
after
the
equipment
is
sent
to
the
distributor.
and
necessary
maintenance,
or
equipment
which
has
been
used
tor
operation
outside
of
the
specifications
for
the
equipment.
1.
5veeraParta3YearaLabor
MILLER
PRODUCTS
ARE
INTENDED
FDR
PURCHASE
AND
USE
BY
CDMMER
Onginel
main
power
rectitwra
CIAIJINDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
2.
3
Years
Pans
and
Labor
THE
USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENT.
Transformer/Rectifier
Power
Sources
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
Plasma
Arc
Cutting
Power
Sources
shall
be,
at
MILLERS
option:
(t)
repair;
or
(2)
replacement;
or,
where
authorized
in
Semi-Automatic
and
Automatic
Wire
Feeders
writing
by
MILLER
In
appropriate
cases,
(3)
the
reasonable
cost
ot
repair
or
replace-
*
Robots
ment
at
an
authorized
MILLER
service
station:
or
(4)
payment
of
or
ci
edit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
retum
ot
the
3.
2
Years
Pans
end
nj
goods
at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton.
Wisconsin,
or
FOB.
ate
MILLER
authorized
ser
Engine
Driven
Welding
Generators
vice
tacility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse-
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer
ment
for
transportation
costs
of
any
kind
will
be
allowed.
for
a
period
of
two
years.)
Air
Compressors
TO THE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES PROvIDED
HEREIN
ARE
THE SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
4.
1
Year
Parts
and
Labor
LIABLE
FOR
DIRECT,
INDIRECT.
SPECIAL,
INCIDENTAL
OR
CONSEOUENTIAL
Motor
Driven
Guns
DAMAGES
(INCLUDING
LOSS
OF
PROFR),
WHETHER
BASED
ON
CON-
Process
Controllers
TRACT,
TORT
OR
ANY
OTHER
LEGAL
THEORY.
Water
Ccolant
Systems
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR-
HF
Units
RANT?,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE,
AND
ANY
Grids
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
Spot
Welders
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION.
Load
Banks
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
SDX
Transformers
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EOUIPMENT
Running
Gear/Trailers
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Field
Options
(NOTE
Field
oplions
are
covered
under
True
BIueTM
for
the
remaining
Some
states
in
the
U.S.A.
do
not
allow
limitations
ot
how
tong
an
implied
warrsnty
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
warranty
penod
of
the
product
they
are
installed
in,
or
fore
minimum
of
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
werranly
provides
spe
one
year
whichever
is
greater.)
citic
legal
nghts,
and
other
rights
may
be
available,
but
may
vary
trom
state
to
state.
5.
6
Months
Banenes
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
B.
go
Days
Pans
and
Labor
or
remedies
other
than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
and
esclusions
set
out
above
may
not
apply.
This
Limited
MIG
Guns/TIG
Torches
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
Plasma
Cutting
Torches
vary
from
province
to
province.
_~1i
RECEIVING-HANDLING
Before
unpacking
eqUipment
check
carton
for
any
damage
(hat
may
have
oCCUrrBd
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
9/93
SAFETY
GUIDELINES
A.
ROBOTIC
SAFETY
Read,
understand,
and
comply
with
all
safety
rules
at
the
beginning
of
robot
Owners
Manual
Section
1
Safety
in
addition
to
the
following
before
beginning
robotic
procedures
or
operations.
1.
KEEP
OUT
of
robot
work
envelope
when
main
power
is
on.
2.
STAY
ALERT
when
near
robot.
3.
KEEP
INFORMED
about
status
of
robot
and
general
working
conditions.
4.
HAVE
AN
EMERGENCY
STOP
BUTTON
IN
HAND
whenever
you
are
near
the
robot.
5.
UNDERSTAND
AND
BE
FAMILIAR
WITH
ROBOTIC
MOVEMENTS.
Robots
are
unique
industrial
de
vices
and
can
present
unexpected
hazards
to
personnel
because
of
their
movements.
6.
UNPREDICTABLE
ROBOT
MOTION
can
occur
in
even
the
best
designed
areas
of
operation.
7.
NEVER
stand
with
your
back
toward
the
robot.
8.
NEVER
place
yourself
between
robot
work
stations
if
more
than
one
work
station
is
used.
9.
THOROUGHLY
TRAIN
ALL
PERSONNEL
in
robot
operation
and
safety.
10.
TEST
AND
VERIFY
that
ALL
safety
devices
and
components
used
in
the
robotic
cell
are
working
properly.
11.
TURN
OFF
robot
and
welding
power
source
input
power
before
entering
work
envelope.
12.
Provide
proper
Electrostatic
Discharge
(ESD)
protection
fpr
circuit
boards
in
Robot
Control
and
Teach
Pendant.
B.
WELDING
SAFETY
Read,
understand,
and
comply
with
all
safety
rules
at
beginning
of
welding
power
source
manual
in
addition
to
the
following
before
beginning
arc
welding
operations.
1.
Prevent
electric
shock.
2.
Provide
proper
protection
from
fumes
and
gases.
3.
Protect
eyes
and
skin
from
arc
rays;
protect
ears
from
noise.
4.
Prevent
fire
and
burns
caused
by
hot
metal,
spatter,
slag,
and
arc
sparks.
5.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
and
electric
arcs.
6.
Provide
impact
protection
to
all
persons
in
the
cell.
7.
Since
magnetic
fields
from
high
currents
can
affect
pacemaker
operation,
have
wearers
consult
their
doc
tor
before
going
near
arc
welding
operations.
8.
Turn
off
robot
and
welding
power
source
input
power
before
entering
work
envelope
or
working
on
weld
ing
power
source.
TABLE
OF
CONTENTS
SECTION
1
SAFETY
INFORMATION
.
1
SECTION
2-
SPECIFICATIONS
1
2-1.
Load
Moment
Charts
2
2-2.
Calculating
Load
Moment
3
2-3.
Weld
Current
Capacity
4
SECTION
3
INSTALLATION
5
3-1.
Selecting
A
Location
And
Moving
Positioner
5
3-2.
Positioner
Connections
8
3-3.
Absolute
Offset
Adjustment
Of
Positioner
Axis
8
3-4.
Setting
Soft
Limit
Range
22
SECTION
4OPERATION
25
4-1.
Positioner
Components
26
4-2.
Method
Of
Entering
Simultaneous
Or
Cooperative
Motion
Data
26
4-3.
Teaching
Simultaneous
Motion
Data
30
4-4.
Teaching
Cooperative
Motion
Data
57
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
73
5-1.
Routine
Maintenance
73
5-2.
Overrun
Protection
73
5-3.
Positioner
Lubrication
74
5-4.
Carbon
Tip
Inspection
74
SECTION
6-
ERROR CODES
75
6-1.
Error
Codes
Information
75
SECTION
7
ELECTRICAL
DIAGRAMS
84
SECTION
8
PARTS
LIST
84
Figure
8-1.
RPH-1
-500
86
Figure
8-2.
RPH-1-1000
88
OM-164438A-8/94
SECTION
1
SAFETY
INFORMATION
Read
all
safety
messages
throughout
this
manual.
Obey
all
safety
messages
to
avoid
injury.
Learn
the
meaning
of
WARNING
and
CAUTION.
Figure
1-1.
Safety
Information
SECTION
2-
SPECIFICATIONS
Table
2-1.
Positioners
modl.1
2193
Specification
Description
Maximum
Load
RPH-1-500:
1102
lb
(500
kg);
RPH-1-1000:
2205
lb
(1000
kg)
Rotating
Speed
RPH-1-500:
8
rpm
(48/sec);
RPH-1-1000:
4
rpm
(24/sec)
Rotation
Load
Moment
RPH-1-500:
11570
lbft2/s2
(490
N.m
(50
kgf.m*fl;
RPH-1-1000:
23144
lb
tt2/s2
(980
N.m
(100
kgf.m])
Rotating
Repeatability
+0.008
in
(+0.2
mm)
At
19.7
in
(500
mm)
From
Center
Center
Of
Gravity
Eccentric
3.9
in
(100
mm)
at
maximum
load
Center
Of
Gravity
Height
19.7
in
(500
mm)
at
maximum
load
Maximum
Rotation
–10
Turns
(–3600)
Rotating
Motor
850
W
AC
Servo
Motor
Stop
Position
For
Rotating
Any
Position
Position
Detection
Encoder
Welding
Power
Rating
500
Amperes
At
60%
Duty
Cycle
Ambient
Temperature
And
Humidity
32
To
122
F
(0
To
50
C);
20%
To
80%
RH
(Without
Condensation)
Overall
Dimensions
See
Figure
3-2
Weight
441
lb
(200
kg)
Units
in
gravitational
system.
1
2
___
:
2
ELECTRIC
SHOCK
can
kIII.i
Do
not
touch
live
electrical
parts.
DIsconnect
input
power
betore
4
Installing
or
servicing.
4A
CAUTION
/
5
MOVING
PARTS
can
Injure.
Keep
away
from
moving
parts.
Keep
all
panels
and
covers
closed
when
operating.
1
Safety
Alert
Symbol
2
Signal
Word
WARNING
means
possible
death
or
serious
injury
can
happen.
CAUTION
means
possible
minor
injury
or
equipment
damage
can
happen.
3
Statement
Of
Hazard
And
Result
6
a
WARNING
NOTE
~
READ
SAFETY
BLOCKS
at
start
01
SectIon
3-1
before
proceedIng.
Turn
Off
switch
when
using
high frequency.
4
Safety
Instructions
To
Avoid
Hazard
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
Read
safety
blocks
for
each
sym
bol
shown.
7
NOTE
Special
instructions
f
or
best
oper
ation
not
related
to
safety.
1
OM-164
438
Page
1
2-1.
Load
Moment
Charts
The
load
moment
charts
show
the
weight
and
location
of
a
load
on
the
positioners.
1
Eccentncity
Of
Height
Center
Of
Gravity
2
Eccentricity
Of
Radius
Center
Of
Gravity
3
Gravitational
Force
RPH-1
-500
Model
Height
Of
The
Center
Of
Gravity
And
Mass
Of
Maximum
Load
19.7
in
(500
mm)l
23.6
in
(600
mm)
]
1102
lb
(500
kg)
920
lb
(417
kg)
787
lb
(357
kg)
689
lb
(313
kg)
613
lb
(278
kg)
551
lb
(250
kg)
27.6
in
(700
mm)
31.5
in
(800
mm)
35.4
in
(900
mm)
39.4
in
(1000mm)
Eccentricity
Of
Radius
Of
The
Center
Of
Gravity
And
Mass
Of
Maximum
Load
RPH-1
-1000
Model
3.9
in
(100
mm)l
2205
lb
(1000
kg)
7.9
in
(200
mm)
1102
lb
(500
kg)
11.8
in
(300
mm)
735
lb
(333
kg)
15.7
in
(400
mm)
I
549
lb
(250
kg)
19.7
in
(500
mm)
1441
lb
(200
kg)
23.6
in
(600
mm)
368
lb
(167
kg)
Height
Of
The
Center
Of
Gravity
And
Mass
Of
Maximum
Load
Eccentricity
Of
Radius
Of
The
Center
Of
Gravity
And
Mass
Of
Maximum
Load
Figure
2-1
-
Load
Moment
Charts
Ref.
ST-800
518
1
549
lb
(250
kg)
368
lb
(167
kg)
267
lb
(125
kg)
220
lb
(100
kg)
184
lb(83
kg)
27.6
in
(700
mm)
31.5
in
(800
mm)
19.7
in
(500
mm)l
2205
lb
(1000
kg)
23.6
in
(600
mm)
1837
lb
(833
kg)
11574
lb
(714
kg)
1378
lb
(625
kg)
1225
lb
(556
kg)
11102
lb
(500
kg)
35.4
in
(900
mm)
::~
39.4
in
(1000
mm)
0
OM-164
438
Page
2
2-2.
Calculating
Load
Moment
N
OTE
~
Load
moment
of
the
axis
must
be
within
the
limit
of
the
mass
for
the
maximum
load.
The
equation
for
calculating
the load
moment
is
as
follows:
(Load
moment
1)
=
(Mass
of
load)
x
(Gravitational
acceleration)
x
(Center
of
gravity
eccentricity)
Any
external
load
applied
to
the
original
load
must
be
calculated
for
the
axis
as
follows:
(Load
moment
2)
=
(Mass
of
load)
x
(External
force
eccentricity)
Total
axis
load
moment
=
Load
moment
1
+
Load
moment
2
For
example,
calculate
the
load
moment
for
the
RPH-1-500
using
the
conditions
as
follows:
Mass
of
load
=
661.4
lb
(300
kg)
Eccentricity
of
height
center
of
gravity
=
7.9
in
(200
mm)
Eccentricity
of
radius
center
of
gravity
=
3.9
in
(100
mm)
No
external
force
Load
moment
Ml
=
661.4
lb
x
32
ftls2
x
.328
ft
(300
kg
x
9.8
rn/s2
x
0.1
m)
Ml
=
69421b
ft2/s2
(294
N
m)
This
value
is
less
than
the
11570
lb
ft2/s2
(490
N
m)
load
moment
limit
for
the
axis.
M2
=
7.9
in
(200
mm)
(eccentricity
of
height
center
of
gravity
for
the
load)
7.9
in
(200
mm)
<
19.7
in
(500
mm)
(max.
eccentricity
of
height
center
of
gravity
for
positioner)
Ml
and
M2
are
within
the
allowable
limits
of
the
RPH-1-500
model
headstock
positioner.
If
an
external
force
is
applied
to
the
load
as
shown
in
Figure
2-2,
the
calculation
is
as
follows:
(Mass
of
load)
x
(Height
of
center
of
gravity
2])
+
(External
force)
x
(Height
to
external
force
acting
point
3])
The
results
of
the
above
calculation
must
be
less
than
1102
lb
(500
kg)
(Mass
of
max.
load)
x
19.7
in
(0.5
m)
(Max.
height
of
center
of
gravity)
that
are
the
specifications
for
the
RPH-1
-500
model
headstock
positioner.
Eccentricity
Of
Radius
Center
Of
Gravity
Eccentricity
Of
Height
Center
Of
Gravity
Height
Of
External
Force
Contact
Point
Eccentricity
Of
Height
For
Contact
Point
Of
External
Force
Ref.
ST-800
522
Figure
2-2.
Example
Of
External
Force
Applied
To
Load
OM-164
438
Page
3
2-3.
Weld
Current
Capacity
£~
CAUTION
EXCEEDING
WELD
CURRENT
CAPACITY
will
damage
unit.
Do
not
exceed
indicated
weld
current
capacity.
The
weld
current
capacity
is
a
maximum
current
and
a
percentage
of
time
that
welding
can
be
performed
on
the
unit
within
a
ten
minute
period
without
causing
overheating
or
damage.
The
rated
weld
current
capacity
for
these
units
is
500
amperes
and
60%
allowing
welding
6
minutes
out
of
every
10
minutes
at
rated
load.
If
the
welding
amperes
decrease,
the
percentage
of
time
for
welding
increases.
The
percentage
of
weld
time
is
calculated
as
follows:
Actual
weld
time
(mm
0.6
(60%)
Reference
weld
time
(10 mAn)
If
welding
is
lowered
to
less
than
the
rated
500
amperes,
the
percentage
of
weld
time
is
calculated
as
follows:
Percentage
of
weld
time
=
(
current)2
x
Percentage
of
time
at
rated
load
(Operating
current)2
For
example,
if
the
welding
amperage
is
350
amperes,
the
percentage
of
weld
time
is
determined
as
follows:
Percentage
of
weld
time
=
(
x
0.6
=
1.2
(120%)
(350)2
Because
the
percentage
is
over
100%,
welding
can
be
performed
continuously.
If
more
than
one
welding
power
supply
is
used
with
the
positioner,
the
operating
currents
are
added
together
as
follows:
Percentage
of
weld
time
=
(
current)2
x
Percentage
of
time
at
rated
load
(Operating
currenti
+
Operating
current2)2
For
example,
if
2
power
sources
are
each
supplying
welding
amperage
of
300
amperes,
the
percentage
of
weld
time
is
determined
as
follows:
Percentage
of
weld
time
=
(
x
0.6
=
0.41
(41%)
(300
+
300)2
So
duty
cycle
within
a
ten
minute
period
would
be
4.1
minutes
of
welding
and
5.9
minutes
of
nonwelding.
warn7.r
2/92
OM-164
438
Page
4
SECTION
3-
INSTALLATION
3~1.
Selecting
A
Location
And
Moving
Positioner
a
WARNING
FIRE
OR
EXPLOSION
can
result
from
FALLING
EQUIPMENT
can
cause
placing
unit
on,
over,
or
near
corn-
serious
personal
Injury
and
equipment
bustible
surfaces.
damage.
Do
not
locate
unit
on,
over,
or
near
combustible
Use
lifting
eyes
to
lift
unit
only.
surfaces.
Use
equipment
of
adequate
capacity
to
lift
the
unit.
Do
not
install
unit
near
flammables.
owamIl.r
3d93
The
location
and
installation
method
are
very
important
for
providing
reliable
operation
of
the
positioner.
Environmental
conditions
can
have
a
direct
affect
on
the
service
life
of
the
positioner
and
associated
equipment.
Operating
precision
of
the
positioner,
such
as
positioning
and
interpolation
functions,
depend
significantly
on
the
condition
of
the
supporting
foundation.
The
foundation
should
have
enough
strength
to
not
only
withstand
the
static
load,
but
forces
from
acceleration
and
deceleration
during
positioner
operation.
Follow
all
safety
instructions
in
this
manual
and
Section
1
Safety
in
the
robot
Owners
Manual
when
preparing
to
install
or
operate
the
positioner
and
robotic
equipment.
When
selecting
a
site
for
installing
the
positioner,
check
the
area
for
conditions
as
follows:
1.
Climate
control
in
the
site
area
should
be
within
a
temperature
range
between
32
to
122
F
(00
to
50
C)
and
relative
humidity
below
80%.
Do
not
choose
an
area
that
is
exposed
to
direct
sunlight
2.
Provide
proper
lighting
at
site
3.
The
site
area
should
be
relatively
free
of
dust,
dirt,
moisture,
and
other
harmful
contaminants
4.
Provide
proper
ventilation
for
arc
welding
applications
5.
The
site
area
must
be
free
of
flammable
and
corrosive
gases
and
liquids
6.
Provide
proper
fire
protection
at
the
site
7.
Avoid
any
area
that
is
near
a
source
of
continuous
vibration
8.
Avoid
areas
near
equipment
that
produces
output
in
the
radio
frequency
range
such
as
high-frequency
arc
start
ers,
plasma
welding
or
cutting
equipment,
etc.,
where
noise
interference
can
affect
positioner
operation.
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Disconnect
cords
and
cables
BEFORE
moving
unit.
FUMES
can
be
hazardous;
LACK
OF
FRESH
AIR
AND
PROPER
VEN
TILATION
can
be
harmful.
Do
not
breathe
welding
fumes.
Place
unit
only
where
there
is
a
good
fresh
air
supply
and
proper
ventilation.
2
1
RPH-1.500,
RPH-1-1000,
And
RPT-1000
2
Cables
Or
Straps
Use
cables
or
straps
of
same
length
(40
in
(1000
mm]
or
longer)
and
rated
for
1000
lb
(500
kg)
or
greater.
ST~8OO
517
Figure
3-1.
Transporting
Positloner
OM-164
438
Page
5
17.9in(455i
Figure
3-2.
RPH-1
-500,
RPH-1
-1
000,
And
RPT-1
000
Models
Overall
Dimensions
And
Rotating
Plate
Surface
MountIng
Hole
Layout
12.6
in
(320mm
15.9
in
1(405
mm)
Work
Weld
Motor/Encoder
Cable
Connection
Connections
7.9
mm
I
mm)
M16
(Depth
1.0
in
(26
mm))
(8
Holes)
20.1
in
(510
mm)
~
I~cz
18.1
in
(460
mm)
~l
0.5
in
(12
mm)
Dia.
(Depth
0.8
in
20
mm))
(2
Holes)
T
/
/
0.7
in
(18
mm)
Dia.
(4
Holes)
SB-156
917-A
OM-164
438
Page
6
-n
C
-I
m
ru
0
0
C
a.
C)
0
m
C,
0
In
0
0
0
-I.
cn
CD
CD
3
C,
0
3
0
ID
CD
(n
DO
NOT
mount
anything
to
robot
control
cabinet.
Input
Power
Supply
U
Line
Disconnect
Switch
Box
~~Existing
For
Input
Power
To
Fixture
input
Power
Positioning
And
Peripheral
Equipment
Supply
Ground
=
Use
Proper
Size
Input
And
Ground
Conductors
For
The
Input
Power
Supply
Line
Voltage
/
Make
Separate
Equipment
Earth
Ground
Using
A
Minimum
Of
No.
3
Gauge
Copper
Braided
Cable
That
Provides
A
Resistance
Value
Less
Than
100
Ohms
Between
The
Component
Connection
And
The
Ground
Wire
Use
Proper
Size
Input
And
Ground
Conductors
For
The
Input
Power
Supply
Line
Voltage;
If
Using
Conduit,
isolate
It
From
Robot
Control
Cabinet
Insulating
Liner
Strips
Under
Both
Support
Channels
3-2.
Positioner
Connections
£~
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
making
any
weld
output
connections.
Figure
3-4.
Connections
To
Positioner
3-3.
Absolute
Offset
Adjustment
Of
Positioner
Axis
swaml2.1
2193
Absolute
offset
adjustment
is
the
process
of
correcting
absolute
encoder
data
in
the
Robot
Control
memory
to
match
the
position
of
the
external
axes.
This
procedure
is
necessary
for
any
of
the
following
cases:
1.
After
installation
of
robot
system
components
(see
Section
3
Installation
in
robot
Owners
Manual
and
external
axes
installation
instructions)
2.
After
memory
initialization
3.
After
motor
replacement
or
repair
work
that
required
disconnecting
the
plug
for
encoder
cord
at
the
motor
(see
Section
7
Disassembly
And
Repair
in
robot
Owners
Manual)
4.
After
repair
work
that
required
disconnect
CN2
and/or
CN3
cable
plugs
from
the
servo
control
(SCON)
boards,
Interlock
board,
or
manipulator
(see
Section
9
Electrical
Troubleshooting
in
robot
Owners
Manual)
5.
Alarm
Al
0503
xxxx
appears
on
the
Teach
Pendant
display
(alarm
message
due
to
inoperative
charging
circuit
inside
Robot
Control;
see
Section
9
Electrical
Troubleshooting
in
robot
Owners
Manual)
6.
Alarm
Al
1103
xxxx
appears
on
the
Teach
Pendant
display
(alarm
message
due
to
the
absolute
encoder
data
not
being
received
by
the
Robot
Control)
7.
Alarm
A5060l
xxxx
appears
on
the
Teach
Pendant
display
(alarm
message
because
the
absolute
offset
adjust
ment
was
not
accomplished
after
memory
initialization).
1
Work
Weld
Cable
Terminal
Connect
work
weld
cable
from
welding
power
source
to
terminal
on
positioner.
2
Motor/Encoder
Connectors
Connect
motor/encoder
cord
from
Robot
Control
to
connectors
at
positioner.
Tools
Needed:
~
17mm
Ret.
ST-800
519
OM-164
438
Page
8
A.
Absolute
Reset
Certain
conditions
require
the
absolute
reset
procedure
be
performed
to
clear
encoder
data
in
the
Robot
Control
memory.
These
conditions
are
as
follows:
1.
Robot
Control
power
not
turned
on
for
10
days
or
longer
2.
Encoder
batteries
disconnected
inside
Robot
Control
3.
Encoder
cable
disconnected
between
Robot
Control
and
the
robot
or
peripheral
equipment
4.
Cable
disconnected
between
SCON
board
and
servodriver
inside
Robot
Control.
If
none
of
these
conditions
apply,
perform
the
absolute
off
set
adjustment
procedure
according
to
Section
B;
however,
if
any
of
the
conditions
do
apply,
perform
the
absolute
reset
as
follows:
N
OTE
~
Servo
motor
assemblies
for
external
axes
contain
electromagnetic
brakes
preventing
the
axes
from
moving
when
servo
power
is
off
The
position
of
these
axes
can
only
be
changed
using
the
Axis
keys
when
servo
power
is
on.
5.
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:
WELCOME
TO
DIAGNOSIS
MILLER
COOPERATIVE
CONTROL
MILLER
ELECTRIC
Mt
g
.
Co.
START
DIAGNOSIS
920731
08:30
WELCOME
TO
DIAGNOSIS
MILLER
COOPERATIVE
CONTROL
STEP
OFINITIAL
DIAGNOSIS
1,
2,
3, 4,
5,
920731
08:30
TEACH
SERVO
OFF
TEACH
EDIT
FILE
ALLOT
LOCK
>
OM-164
438
Page
9
6.
Press
the
SERVO
ON
button
on
the
Operation
Module
or
Teach
Pendant
and
operation
can
begin
in
the
Teach
mode.
7.
Press
the
MECHANISM
ME~-
key
to
select
mechanism
2
(simultaneous)
or
mechanism
4
(cooperative),
and
check
the
appropriate
mechanism
LED
for
illumination
on
the
Teach
Pendant.
8.
Press
the
TEACH
ENABLE
key,
and
use
the
Axis
keys
on
the
Teach
Pendant
to
move
external
axis
for
aligning
origin
marks
(see
Figure
3-5).
Figure
3-5.
Location
Of
Origin
Marks
9.
Press
the
FUNCTION
APPLICATION
key
for
additional
functions
to
appear
on
the
display.
AXIS
ML4
TEACH
SERVO
ON
TEACH
EDIT
FILE
ALLOT
LOCK
AXIS
ML4
TEACH
SERVO
ON
PARMTER
CHECK
MANAGE
SYS.SET
MEMORY
OM-164
438
Page
10
10.
Press
the
______
key
to
select
system
setup.
AXIS
ML4
TEACH
SERVO
ON
ABSO
RESTART
MSTRING
CONTROL
MANUAL
11.
Press
the
Fl
key
to
select
absolute
offset
adjustment.
AXIS
ML4
ABSO
OFFSET
SETTING
TEACH
SELECT
MECHANISM
SERVO
ON
MECH
.
1
MEG
H.
2
MECH
.3
MECH
.4
MECH
.5
12.
Press
the
FUNCTION
APPLICATION
key~
>
for
additional
functions
to
appear
on
the
display.
AXIS
ML4
ABSO
OFFSET
SETTING
TEACH
SELECT
MECHANISM
SERVO
ON
ABS
RST
OM-164
438
Page
11
13.
Press
the
J
Fl
J
key
to
select
absolute
reset.
AXIS
ML4
ENCODERS
OF
ALL
AXES
WILL
BE
TEACH
RESET.
SERVO
POWER
WILL
TURN
OFF
SERVO
ON
EXECUTE
14.
Press
the
EXECUTE
function,
Fl
key,
to
start
the
absolute
reset
operation.
ABSO
OFFSET
ADJUSTMENT
OF
ALL
TEACH
MECHANISMS
SHOULD
BE
DONE,
AFTER
CONTROL
POWER
RETURNING
ON.
SERVO
OFF
15.
A
beeping
sound
will
begin
after
the
absolute
reset
operation
is
completed
by
the
Robot
Control.
Turn
off
Robot
Control
input
power
by
placing
the
power
switch
handle
on
the
Robot
Control cabinet
door
in
the
OFF
position,
wait
5
seconds,
and
turn
on
input
power.
WELCOME
TO
DIAGNOSIS
MILLER
COOPERATIVE
CONTROL
MILLER
ELECTRIC
Mfg
.
Co.
START
DIAGNOSIS
920731
08:30
OM-164
438
Page
12
WELCOME
TO
DIAGNOSIS
MILLER
COOPERATIVE
CONTROL
STEP
OFINITIAL
DIAGNOSIS
1,
2,
3,
4,
5,
920731
08:30
TEACH
SERVO
OFF
TEACH
EDIT
FILE
ALLOT
LOCK
16.
Do
the
absolute
offset
adjustment
procedure
beginning
at
Step
2
of
Section
B.
B.
Absolute
Offset
Adjustment
To
perform
the
absolute
offset
adjustment,
proceed
as
follows:
N
OTE
~
Servo
motor
assemblies
for
external
axes
contain
electromagnetic
preventing
the
axes
from
moving
when
servo
power
is
off.
The
position
axes can
only
be
changed
using
the
Axis
keys
when
servo
power
is
on.
brakes
of
these
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:
WELCOME
TO
DIAGNOSIS
MILLER
COOPERATIVE
CONTROL
MILLER
ELECTRIC
Mfg
.
Co.
START
DIAGNOSIS
920731
08:30
OM-164
438
Page
13
WELCOME
TO
DIAGNOSIS
MILLER
COOPERATIVE
CONTROL
STEP
OFINITIAL
DIAGNOSIS
1,
2,
3,
4,
5,
920731
08:30
TEACH
SERVO
OFF
TEACH
EDIT
FILE
ALLOT
LOCK
2.
Press
the
SERVO
ON
button
on
the
Operation
Module
or
Teach
Pendant
and
operation
can
begin
in
the
Teach
mode.
AXIS
ML4
TEACH
SERVO
ON
TEACH
EDIT
FILE
ALLOT
LOCK
>
3.
Press
the
MECHANISM
key
to
select
mechanism
2
(simultaneous)
or
mechanism
4
(cooperative),
and
check
the
appropriate
mechanism
LED
for
illumination
on
the
Teach
Pendant.
4.
Press
the
TEACH
ENABLE
key,
and
use
the
Axis
keys
on
the
Teach
Pendant
to
move
external
axis
for
aligning
origin
marks
(see
Figure
3-5).
OM-164
438
Page
14
/
