Miller KE555371 Owner's manual

Millerﬁ

August

1994

Form:

OM-1

64

438A

Effective

With

Serial

No.

KE555371

OWNERS

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

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1992

(Equipment

with

a

serial

number

preface

of

ICC

or

newer)

This

limited

warranty

supersedes

all

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

manufacturers

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.

5veeraParta3YearaLabor

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

MILLERS

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

customers

risk

and

expense.

MILLERS

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

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment.

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

Serial

or

Style

No.

______________________________________________

Date

of

Purchase

________________________________________________

miller

9/93

SAFETY

GUIDELINES

A.

ROBOTIC

SAFETY

Read,

understand,

and

comply

with

all

safety

rules

at

the

beginning

of

robot

Owners

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

4OPERATION

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

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

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

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

Owners

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

C

a.

C)

0

m

C,

0

In

0

0

0

-I.

cn

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

Owners

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

Owners

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

Owners

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

Owners

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

920731

08:30

WELCOME

TO

DIAGNOSIS

MILLER

COOPERATIVE

CONTROL

STEP

OFINITIAL

DIAGNOSIS

1,

2,

3, 4,

5,

920731

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

920731

08:30

OM-164

438

Page

12

WELCOME

TO

DIAGNOSIS

MILLER

COOPERATIVE

CONTROL

STEP

OFINITIAL

DIAGNOSIS

1,

2,

3,

4,

5,

920731

08:30

TEACH

SERVO

OFF

TEACH

EDIT

FILE

ALLOT

LOCK

16.

Do

the

absolute

offset

adjustment

procedure

beginning

at

Step

2

of

Section

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

920731

08:30

OM-164

438

Page

13

WELCOME

TO

DIAGNOSIS

MILLER

COOPERATIVE

CONTROL

STEP

OFINITIAL

DIAGNOSIS

1,

2,

3,

4,

5,

920731

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

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Miller KE555371 Owner's manual

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Miller KE555371 Owner's manual

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