Miller KA000000 Owner's manual

KA000000
Miller
Brand
Miller
Model
KA000000
Type
Owner's manual

This manual is also suitable for

Millerfi
December
1990
FORM:
OM-138
426-A
MODEL:
Robot
Interface
(Per
NSPR
8945)
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
both
this
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
Installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
useonly
by
persons
trained
and
experienced
In
the
safe
operation
of
weiding
equip
ment.
Do
not
allow
untrained
persons
to
Install,
operate,
or
maintain
this
unit.
Contact
your
distributor
If
you
do
not
fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
Muir
Grc,~
Ltd.,
Con~ny
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
PRINT~D
IN
U.S.A.
liE
LIMITED
WARRANTY
EFFECTIVE:
AUGUST
8,
1990
This
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
hereof,
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin
war
rants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
MILLER
is
free
from
defect
in
workmanship
and
material
as
of
the
time
and
place
of
delivery
by
MILLER.
No
warranty
is
made
by
MILLER
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
accessories
and
other
items
are
sold
subject
to
thewarranties
of
their
respective
manufacturers,
if
any.
All
engines
are
warrantied
by
their
manufacturer
for
two
years
from
date
of
original
purchase,
except
Deutz
engines
which
have
a
one
year,
2000
hour
warranty.
Except
as
specified
below,
MILLERs
warranty
does
not
apply
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
come
in
contact
with
the
welding
wire
including
nozzles
and
nozzle
insulators
where
failure
doas
not
result
from
defect
in
workmanship
or
material.
MILLER
shall
be
required
to
honor
warranty
claims
on
war
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Loadbanks
lyear
3.
Original
main
power
rectifiers
3
years
(labor
1
year
only)
4.
All
welding
guns,
feeder/guns
and
torches
90
days
5.
All
other
MILLERMATIC
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive
of
labor
60
days
7.
Batteries
6
months
provided
that
MILLER
is
notified
in
writing
within
thirty
(30)
days
of
the
date
of
such
failure.
As
a
matter
of
general
policy
only,
MILLER
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
MILLERs
breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be,
at
MILLERs
option
(1)
repair
or
(2)
replace-
mentor,
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
MILLER
service
station
or
(4)
payment
of
or
credit
for
the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
service
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
MILLER
shall
instruct
the
claimant
on
the
warranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WARRANTY~
GUARANTY
OR
REPRE
SENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
L
:I~l
oI~.I3a42eA-
1V9O
RECEIVING-HANDLING
Before
unpacking
equipment,
checkcartonforanydam-
Use
the
following
spaces
to
record
the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
hon
and
Serial
or
Style
Number
of
your
unit.
The
intor
claims
for
loss
or
damage
with
the
delivering
carTler.
mation
is
located
on
the
data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor
and/or
the
equipment
manufactur-
Model______________________________
ers
Transportation
Department.
Serial
or
Style
No.___________________
When
requesting
information
about
this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date
of
Purchase
____________________
Number.
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
General
Information
And
Safety
I
1-2.
Safety
Alert
Symbol
And
Signal
Words
1
SECTION
2-
SPECIFICATIONS
2-1.
Description
1
SECTiON
3-INSTALLATION
3-1.
Site
Selection
2
3-2.
Equipment
Installation
2
3-3.
Gas/Current
Sensing
Control
Interconnections
3
3-4.
Voltage
Sensing
Connections
3
3-5.
Robot
Interface
Welding
Power
Source
Connections
4
3-6.
Robot
Interface
Robot
Control
Unit
Connections
4
3-7.
Arc
Failure
Light
Terminal
Strip
Connections
5
3-8.
Welding
Wire
Installation
5
SECTION
4-OPERATOR
CONTROLS
4-1.
Power
Switch
6
4-2.
Jog
Push
Buttons
6
4-3.
Purge
Push
Button
6
4-4.
Voltmeter
6
4-5.
Wire
Speed
Meter
7
4-6.
Peak
Amps/Inductance
Meter
7
4-7.
Indicator
Ughts
7
4-8.
Bumback
Control
7
SECTION
5SEQUENCE
OF
OPERATION
5-1.
Input
Signals
From
Robot
Control
Unit
7
5-2.
Output
Signals
From
Robot
Interface
7
Section
No.
Page
No.
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
Routine
Maintenance
7
6-2.
Overload
Protection
8
6-3.
Reinstallation
Of
Hub
Assembly
8
6-4.
Display
Board
PC4
Meter
Check
8
6-5.
Circuit
Board
Handling
Precautions
9
SECTION
7-
ELECTRICAL
DIAGRAMS
Diagram
7-1.
Circuit
Diagram
For
Robot
Interface
10
Diagram
7-2.
Circuit
Diagram
For
Voltage
Control
Board
PCi
11
Diagram
7-3.
Circuit
Diagram
For
Motor
Control
Board
PC2
12
Diagram
7-4.
Circuit
Diagram
For
Interface
Board
PC3
14
Diagram
7-5.
Circuit
Diagram
For
Meter
Display
Board
PC4
14
Diagram
7-6.
Circuit
Diagram
For
Interface
Board
PC5
15
Diagram
7-7.
Circuit
Diagram
For
Wire
Touch
Board
PC6
15
Diagram
7-8.
Circuit
Diagram
For
Gas/Current
Control
16
SECTION
8
PARTS
LIST
Figure
8-1.
Circuit
Card,
Voltage
Control
PCi
22
Figure
8-2.
Circuit
Card,
Motor
Speed
Digital
PC2
24
Figure
8-3.
Circuit
Card,
Meter
PC4
26
Figure
8-4.
Circuit
Card,
Isolation/Amplifier
PC5
27
Figure
8-5.
Circuit
Card,
Wire
Touch
PC6
28
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
troubleshooting
which
should
be
read,
understood,
and
followed
forthe
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
~fl
accordance
with
this
manual
and
all
applicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
Safety
Rules
For
Operation
Of
Arc
Weld
ing
Power
Source
in
the
welding
power
source
Owners
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.
4A
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.
4~
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
necessary
for
the
most
efficient
operation
of
this
equip
ment.
SECTION
2-
SPECIFICATIONS
Table
2-1.
SpecIficatIons
Component
Dimensions
Weight
Height
Width
Depth
Net
Ship
Robot
Interface
22-1/2
ifl.
(572
mm)
16-1/2
in.,
(419
mm)
6-1/4
in.~
(159
mm)
38
lbs.
(17
kg)
Total
61
lbs.
(27.7
kg)
Gas/Current
Sensing
Control
4-1/2
in.
(108
mm)
8-3/4
in.
(222
mm)
14
in.
(355
mm)
5
lbs.
(2.3
kg)
Spool
Support
Assembly+
13-3/4
in.
(349
mm)
8-3/4
in.
(222
mm)
8-1/2
in.
(216
mm)
6
lbs.
(2.7
kg)
Add
2-1/4
in.
(57
mm)
for
brake
resistor.
+Spool
Support
without
optional
wire
reel.
Add
7/8
in.
(22
mm)
for
front
panel
knob.
2-1.
DESCRIPTION
The
robot
interface
control
is
designed
to
interface
with
a
Automatix
robot
and
an
Arc
Pak
350,
Deltaweld,
Max
tron,
or
Pulstar
450
welding
power
source.
This
unit
pro
vides
digital
display
of
weld
volts,wire
feed
speed,
and
peak
amperage
or
inductance.
The
gas/current
sensing
control
contains
the
gas
valve,
contactor,
and
current
sensing
reed
relay.
These
components
function
with
the
robot
system
when
using
the
Gas
Metal
Arc
Welding
(GMAW)
process.
OM-138
426
Page
1
A.
Robot
Interface
Gas/Current
Sensing
Control
Connections
1.
Align
keyways,
insert
14-pin
Amp
plug
into
matching
receptacle
RC9
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyways,
insert
16-pin
Amp
plug
into
matching
receptacle
RC16
on
gas/current
sensing
control,
and
rotate
threaded
collar
fully
clockwise.
B.
Weld
Cable
Connections
For
Electrode
Positive/Reverse
Polarity,
route
one
cable
from
welding
power
source
POSITIVE
weld
output
ter
minal
to
the
gas/current
sensing
control,
and
connect
to
the
contactor.
Connect
second
weld
cable
to
remaining
terminal
on
contactor,
route
through
the
current
sensing
reed
relay,
to
the
wire
drive
assembly,
and
connect
cable
to
weld
cable
terminal
(see
Motor/Drive
Assembly
Own
ers
Manual
for
location).
C.
Gas
Connections
Connect
hose
from
gas
regulator/fiowmeter
(customer
supplied)
at
gas
source
to
IN
fitting
on
gas/current
sens
ing
control.
Connect
gas
hose
from
wire
drive
assembly
to
fitting
on
gas/current
sensing
control.
The
gas
flow
must
be
accurately
controlled
by
a
regulator/fiowmeter
at
the
source.
D.
Motor
Connection
Align
keyways,
insert
14-pin
plug
from
motor
cord
into
matching
receptacle
RC7
on
gas/current
sensing
con
trol,
and
rotate
threaded
collar
fully
clockwise.
S-0401
FIgure
3-3.
Voltage
Sensing
Connections
At
Wire
Drive
Assembly
3-4.
VOLTAGE
SENSING
CONNECTIONS
(Figure
3-3)
1.
Align
keyway,
insert
4-socket
plug
into
matching
re
ceptacle
RCI2
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
T~-119
~
2.
Connect
lead
with
ring
terminal
to
wire
drive
assem
bly,
along
with
the
weld
cable
from
the
welding
pow
er
source,
as
shown
in
Figure
3-3.
3.
Connect
lead
with
clamp
to
the
workpiece.
3-3.
GAS/CURRENT
SENSING
CONTROL
INTER
CONNECTIONS
(Figure
3-2)
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
locko
uttagging
procedures
before
making
inter
connections.
Lockoutltaggirtg
procedures
consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
oft
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
Gas/Current
sensing
Control
Receptacle
RC9
14-Pin
Receptacle
RC13
10-Socket
Receptacle
RC19
Location
Nut
10-PIn
Receptacle
RC15
Location
Flat
Washer
Weld
Cable
Lug
Location
Arc
Sensing
Receptacle
RC12
24-Socket
Receptacle
RC17
Figure
3-2.
Right
Side
View
OM-138
426
Page
3
3-5.
ROBOT
INTERFACE
-
WELDING
POWER
SOURCE
CONNECTIONS
(FIgures
3-2
And
3-3)
4~
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
locko
ut/tagging
procedures
before
making
inter
connections.
Lockout/tagging
procedures
consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
There
are
three
cords
supplied
for
interconnection
be
tween
the
robot
interface
and
welding
power
source.
Ex
amine
cords
and
select
proper
cord
for
the
connection.
A.
REMOTE
14
ConnectIons
1.
Align
keyway,
insert
14-socket
plug
into
matching
receptacle
RC13
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyway,
insert
14-pin
plug
into
matching
re
ceptacle
on
welding
power
source,
and
rotate
threaded
collar
fully
clockwise.
B.
REMOTE
17
ConnectIons
1.
Align
keyway,
insert
17-socket
plug
into
matching
receptacle
RC16
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyway,
insert
17-pin
plug
into
matching
re
ceptacle
on
welding
power
source,
and
rotate
thread
collar
fully
clockwise.
C.
REMOTE
10
Connections
1.
Align
keyway,
insert
10-socket
plug
into
matching
receptacle
RC1
5
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyway,
insert
plug
into
matching
receptacle
on
the
welding
power
source,
and
rotate
threaded
collar
fully
clockwise.
If
the
welding
power
source
is
equipped
with
a
REMOTE
14/17
selector
switch,
place
the
switch
in
the
REMOTE
14
position.
Make
connections
to
both
REMOTE
14
and
REMOTE
17
receptacles.
3-6.
ROBOT
INTERFACE
-
ROBOT
CONTROL
UNIT
CONNECTIONS
(Figure
3-2)
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
locko
ut/tagging
procedures
before
making
inter
connections.
Lockout/tagging
procedures
Consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
luses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
1.
Obtain
proper
cords,10-pin,
and
24-pin
Amphenol
plugs
(not
supplied).
2.
Connect
conductors
at
one
end
of
cord
to
appropri
ate
sockets
in
plug.
3.
Align
keyway,
insert
plug
into
matching
receptacle
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
4.
Route
and
connect
conductors
at
remaining
end
of
cords
to
the
robot
control
unit.
The
input
and
output
signals
at
the
sockets
of
receptacle
RC1
7
and
RC1
9
by
means
of
the
robot
interface
control
circuitry
are
as
follows:
Receptacle
RC17
Socket
A:
Socket
B:
Socket
C:
Peak
Amps/Inductance
signal
positive.
Peak
Amps/Inductance
signal
common.
Peak
Amps/inductance
signal
wiper.
Sig
nal
vanes
0-4.8
volts
for
Pulstar
or
0-10
volts
for
Arc
Pak
Circuit
Common.
Jog
signal
with
respect
to
socket
F.
Circuit
Common.
Weld
Start
with
respect
to
socket
N.
Circuit
Common.
Wire
Feed
Speed
signal
positive.
Wire
Feed
Speed
signal
common.
Wire
Feed
Speed
signal
wiper.
Signal
va
ries
0-8
volts.
Arc
Voltage
signal
positive.
Arc
Voltage
signal
common.
Arc
Vo~age
signal
wiper.
Signal
varies
0-10
volts.
Socket
V:
Arc
Failure
contact.
Socket
W:
Arc
Failure
contact.
Socket
X:
Current
detect
contact.
Socket
Y:
Current
detect
contact.
IMPORTANT:
The
remaining
sockets
in
the
receptacle
are
not
used.
Receptacle
RC19
Socket
A:
Torch
Position
signal
with
respect
to
socket
Socket
D:
Torch
Position
signal
with
respect
to
socket
Socket
F:
Socket
G:
Socket
L:
Socket
M:
Socket
N:
Socket
P:
Socket
0:
Socket
R:
Socket
S:
Socket
1:
Socket
U:
0.
A.
OM-138
426
Page
4
Socket
F:
Circuit
common.
d.
Connect
+24
vdc
to
remaining
side
of
normally-
Socket
G:
Torch
Position
initiate
signal
with
respect
open
robot
control
relay
contact.
to
socket
F.
e.
Connect
a
lead
from
one
side
of
robot
control
Socket
I:
Circuit
common.
coil
to
weld
alarm
terminal.
Socket
J:
Gas
control
with
respect
to
socket
~.
f.
Connect
proper
voltage
source
(115
vac,
24
vac,
or
24
vdc)
between
common
terminal
and
IMPORTANT:
The
remaining
sockets
in
the
receptacle
remaining
side
of
robot
control
relay
coil.
are
not
used.
Robot
Control
Unit
Robot
Interface
3~7.
ARC
FAILURE
LIGHT
TERMINAL
STRIP
CON-
Weld
Alarm
Terminal
Common
Terminal
NECTIONS
(FIgure
34)
it
So
Equipped
if
SO
Equipped
iT
for
control
connections.
Loosen
screws
on
strain
relief
There
are
two
terminal
strips
inside
the
robot
interface
~
on
unit
right
side
panel
if
applicable,
open
front
panel
ac
cess
door,
and
locate
appropriate
terminal
strip
for
con
nections.
Tighten
screws
on
strain
relief
if
necessary,
_________________________
and
close
and
secure
front
panel
access
doorwhen
pro-
Arc
Failure
1TM
Indicator
Light
cedure
is
finished.
The
ARC
FAILURE
light
on
the
robot
interface
front
pan-
Robot
Control
Unit
el
is
turned
on
and
off
by
a
signal
from
the
robot
control
Common
Terminal
Weld
Alarm
Terminal
unit.
Obtain
proper
length
of
18
gaugel2-conductor
cord
If
So
Equip
if
So
Equipped
for
this
connection,
and
proceed
as
follows:
~
WARNING:
ELECTRIC
SHOCK
can
kIll.
To
Volta
e
Source
I
Do
not
touch
live
electrical
parts.
(115VAC,
2~&AC,
24V0C)
I
Shut
down
unit,
welding
power
source,
and
Isolation
Relay
CR1
robot,
and
disconnect
input
power
employing
(
~
locko
ut/tagging
procedures
before
making
inter
connections.
Robot
Control
Robot
interface
Lockout/tagging
procedures
consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re-
CR1
11
moving
fuses
from
fuse
box,
or
shutting
off
and
424~~C
~O~1
h0~~
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
1.
For
robot
control
units
when
24
vdc
is
used
(Figure
_________________________
3-4):
Arc
Failure
1TM
Indicator
Light
a.
Route
cord
through
strain
relief
on
right
side
so~
panel
of
robot
interface,
and
make
proper
con-
Figure
3-4.
Arc
Failure
Light
Connections
nections
to
1TL
and
1TM.
b.
Route
and
connect
remaining
end
of
cord
to
3-8.
WELDING
WIRE
INSTALLATION
(Figure
3-5)
weld
alarm
terminal
and
ground
connection
at
A.
Installation
Of
Spool-Type
Wire
the
robot
control
unit.
1.
Remove
retaining
ring.
c.
Connect
+24
vdc
to
common
relay
contact
ter
minal.
2.
Slide
spool
of
wire
onto
hub
so
that
wire
feeds
off
bottom
of
spool.
2.
For
robot
control
units
when
115
or24
vac,
or24
vdc
is
used
(Figure
3-4):
3.
Rotate
spool
until
hole
in
spool
aligns
with
pin
in
hub.
Slide
spool
onto
hub
until
it
seats
against
back
a.
Route
cord
through
strain
relief
on
right
side
flange
of
the
hub.
panel
of
robot
interface,
and
make
proper
con-
4.
Reinstall
retaining
ring
onto
hub.
nections
to
1TL
and
ITM.
b.
Obtain
a
115
or
24
vac,
or
24
vdc
isolation
relay
B.
InstallatIon
Of
Optional
Wire
Reel
And
Reel-
CR1,
and
install
into
robot
control.
Type
Wire
1.
Remove
retaining
ring
and,
if
applicable,
wire
reel
c.
Route
and
connect
remaining
end
of
cord
to
one
assembly
from
hub.
side
of
the
normally-open
robot
control
relay
contact
and
ground.
2.
Lay
wire
reel
assembly
flat
on
a
table
or
floor.
OM-138
426
Page
5
Retaining
Ring
Wir.
Retainer
3.
Remove
spanner
nut
from
wire
reel
assembly.
4.
Remove
wire
retainer,
and
install
wire
onto
wire
reel.
Be
sure
that
wire
feeds
ott
bottom
of
reel.
5.
Reinstall
wire
retainer
and
spanner
nut
onto
wire
reel.
6.
Slide
wire
reel
assembly
onto
hub,
and
rotate
as
sembly
until
hub
guide
pin
is
seated
in
reel.
7.
Reinstall
retaining
ring
onto
hub.
C.
Adjustment
Of
Hub
Tension
(FIgure
3-1)
Check
the
hub
tension
by
slowly
rotating
the
wire
spool
or
reel.
The
wire
should
unwind
freely,
but
hub
tension
should
be
sufficient
to
keep
wire
taut
and
prevent
back
lash
when
the
wire
feed
stops.
If
adjustment
is
required,
loosen
or
tighten
the
hex
nut
on
the
end
of
the
hub
sup
port
shaft
accordingly.
SECTION
4-
OPERATOR
CONTROLS
Figure
4-1.
Front
Panel
Controls
Psi.
TB-Its
645
4-1.
POWER
SWITCH
(FIgure
4-1)
Placing
the
POWER
switch
in
the
ON
position
energizes
the
robot
interface.
The
interface
must
be
on
for
the
ro
bot
to
weld.
Placing
the
POWER
switch
in
the
OFF
posi
tion
shuts
down
the
interface.
4-2.
JOG
PUSH
BUTTONS
(Figure
4-1)
The
JOG
and
JOG
REV
push
buttons
are
momentary-
contact
switches.
The
JOG
buttons
energize
the wire
feed
motorwithout
energizing
the
welding
power
source
contactor.
Holding
both
JOG
buttons
allows
the
wire
to
reverse
into
the
gun.
4-3.
PURGE
PUSH
BUTTON
(Figure
4-1)
The
PURGE
push
button
is
a
momentary-contact
switch.
This
switch
energizes
the
gas
solenoid
and
purges
the
shielding
gas
line
of
the
gun.
The
PURGE
push
button
allows
the
flow
meter
to
be
adjusted
without
energizing
the
welding
circuit.
4-4.
VOLTMETER
(Figure
4-1)
The
voltmeter
displays
weld
voltage
to
the
nearest
tenth
of
a
volt
while
welding
and
preset
voltage
while
idling.
Wire
Reel
Spinner
Nut
Hub
Hub
Support
Figure
3-5.
OptIonal
Wire
Reel
And
Reel-Type
Wire
installation
Voltmeter
Wire
Sped
1PM
Meter
Peak
Amps/
Inductance
Meter
Fuse
Circuit
Breaker
(See
Section
6-2)
Wire
Feed
Indicator
Light
Current
Indicator
Arc
Failure
Wire
Touch
Jog
Push
Jog
Rev
Push
Light
Indicator
Light
Indicator
Light
Button
Switch
Button
Switch
OM-138
426
Page
6
4-5.
WIRE
SPEED
METER
(Figure
4-1)
The
wire
speed
meterdisplays
preset
wire
feed
speed
to
the
nearest
inch
per
minute
while
welding
and
idling.
Ac
tual
and
preset
wire
feed
speed
are
the
same
due
to
the
wire
feed
speed
feedback
circuit.
4-6.
PEAK
AMPS/INDUCTANCE
METER
(Figure
4-1)
When
used
with
the
Pulstar
welding
power
source,
the
meter
displays
preset
peak
weld
amperage
to
the
near
est
ampere
while
welding
and
idling.
When
used
with
the
Arc
Pak
welding
power
source,
in
ductance
is
displayed
in
percentage.
4-7.
INDICATOR
LIGHTS
(Figure
4-1)
There
are
seven
indicator
lights
on
the
interface.
These
are
visual
indications
of
various
process
functions.
The
GAS
light
turns
on
when
the
gas
valve
is
energized
to
indicate
shielding
gas
flow.
The
CONTACTOR
light
turns
on
when
the
welding
pow
er
source
contactor
is
energized
to
indicate
that
weld
output
is
available.
The
WIRE
FEED
light
turns
on
when
the
wire
drive
motor
is
energized
to
indicate
that
wire
is
feeding.
The
CURRENT
light
turns
on
when
the
current
detect
relay
is
energized
to
indicate
that
an
arc
is
established.
The
ARC
FAILURE
light
turns
on
only
when
properly
connected
according
to
instructions
in
Section
3-7,
and
there
is
an
arc
outage
while
welding.
The
WI
RE
TOUCH
light
turns
on
when
the
torch
position
initiate
contact
at
socket
G
of
RC19
is
closed
and
the
welding
wire
touches
the
workpiece
during
torch
posi
tioning
and
set
up.
The
WELD
ENABLE
light
turns
on
when
the
system
is
energized
and
remains
on
unless
the
torch
position
initi
ate
contact
at
pin
G
of
RC19
is
closed.
4-8.
BURNBACK
CONTROL
The
burnback
control
is
a
screwdriver
adjustable
control
located
beneath
the
snap-in
blank
in
the
lower
left
corner
of
the
front
panel.
Burnback
time
can
be
adjusted
between
5
and
250
milli
seconds.
Rotate
the
control
clockwise
to
increase
burn-
back
time.
By
adjusting
the
control
properly,
the
welding
wire
will
neither
freeze
in
the
weld
puddle
or
the
contact
tube
of
the
gun.
lithe
welding
wire
freezes
to
the
work,
increase
bumback
time.
If
the
welding
wire
burns
back
into
the
contact
tube,
decrease
burnback
time.
SECTION
5
SEQUENCE
OF
OPERATION
5-1.
INPUT
SIGNALS
FROM
ROBOT
CONTROL
5-2.
OUTPUT
SIGNALS
FROM
ROBOT
INTERFACE
UNIT
The
robot
interf
ace
receives
input
signals
for
contactor
The
robot
interface
sends
output
signals
to
the
robot
control,
gas
control,
jog,
welding
volts,
peak
amperage,
control
unit
for
current
sense,
arc
failure,
and
torch
inductance,
torch
positioning,
and
wire
speed.
positioning.
SECTION
6-
MAINTENANCE
&
TROUBLESHOOTING
6-1.
ROUTINE
MAINTENANCE
IMPORTANT:
Every
six
months
inspect
the
labels
on
this
unit
for
legibility.
All
precautionary
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessary.
See
Parts
List
for
part
number
of
precautionary
labels.
Usage
and
shop
conditions
determine
the
frequency
and
type
of
maintenance.
At
minimum,
inspect
equip
ment
every
three
months
as
follows:
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
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-tag9ing
circuit
breaker
or
other
disconnect
ing
device.
MOVING
PARTS
can
cause
serious
injury.
Keep
away
from
moving
parts.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
servicing.
Maintenance
to
be
performed
only
by
qualified
persons.
1.
Repair
or
replace,
as
required,
all
hose
and
cable;
give
particular
attention
to
frayed
and
cracked
insu
lation
and
areas
where
it
enters
equipment.
2.
Remove
grease
and
grime
from
components;
mois
ture
from
electrical
parts
and
cable.
OM-138
426
Page
7
6-2.
OVERLOAD
PROTECTION
6-3.
REINSTALLATION
OF
HUB
ASSEMBLY
(Fig
ure
6-1)
~
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
pacts.
If
it
becomes
necessary
to
replace
part
or
all
of
the
hub
assembly,
reinstall
the
new
hub
assembly
as
follows:
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
1.
Remove
hub
assembly
from
hub
support,
and
disas
lockout/tagging
procedures
before
inspecting,
semble
discarding
worn
or
broken
parts.
maintaining,
or
ser.icing.
2.
Slide
the
following
items
onto
the
hub
support
shaft
Lockoutltagging
procedures
consist
of
pad-
in
order
given.
locking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
a.
Spring
red-tagging
circuit
breaker
or
other
disconnect-
b.
Keyed
Washer
ing
device.
c.
Fiber
Washer
INCORRECT
FUSE
can
damage
unit.
d.
Brake
Washer
Use
only
replacement
fuse
of
same
size,
type,
and
rating
(see
PartsList).
e.
Hub
f.
Brake
Washer
A.
Wire
Drive
Motor
CircuIt
Breaker
CBI
(Figure
4-1)
g.
Fiber
Washer
a
WARNiNG:
Read
and
follow
safety
informa-
3.
Align
keyway,
and
insert
hub
support
shaft
through
tion
at
beginning
of
Section
6-2
before
pro-
selected
hole
in
hub
support.
ceeding.
4.
install
hex
nut
onto
hub
support
shaft.
Tighten
hex
Circuit
breaker
CB1
protects
the
wire
drive
motor
from
nut
until
a
slight
drag
is
felt
while
turning
hub.
overload
.
If
CB1
opens,
the wire
feed
motorwould
stop.
5.
Install
welding
wire
according
to
Section
3-8.
Should
a
motor
overload
occur
and
CBI
open,
proceed
as
follows:
6-4.
DISPLAY
BOARD
PC4
METER
CHECK
(Figure
6-2)
1.
Check
for
jammed
wire
or
clogged
gun-
liner,
and
correct
problem.
If
wire
jams
often,
replace
gun
liner.
Check
points
are
provided
on
the
display
board
PC4
for
checking
power
supply
and
input
command
for
the
me-
2.
if
motor
overload
occurs
often,
repair
or
replace
wire
ters.
drive
motor.
3.
Check
for
binding
drive
gear
or
misaligned
drive
~
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
five
electrical
parts.
rolls,
and
correct
problem.
Be
sure
that
personnel
performing
testing
4.
Reset
circuit
breaker
by
depressing
the
button.
A
procedures
are
familiar
withandfollowstandard
cooling
period
may
be
necessary
before
the
circuit
safety
practices.
breaker
can
be
reset.
Shut
down
unit
before
making
or
changing
meter
or
test
equipment
lead
connections.
5.
Resume
operation.
ELECTROSTATIC
DISCHARGE
(ESD)
can
B.
Main
Fuse
Fl
(Figure
4-1)
damage
circuit
boards.
Put
on
a
properly
grounded
wrist
strap
a
WARNING:
Read
and
follow
safety
Informa-
BEFORE
handling
circuit
boards.
tlon
at
beginnIng
of
SectIon
6-2
before
pro
ceeding.
Transport
a!!
static-sensitive
components
in
proper
static-shielding
carriers
and
packages.
Fuse
Fl
protects
the
robot
interface
from
an
internal
Perform
work
only
at
a
static-safe
work
area.
short
or
excessive
overload.
If
fuse
Fl
opens,
the
robot
interfaceshutsdown.
Ifthefuseopens,correcttheprob-
1.
Open
robot
interface
access
door.
tern
and
replace
Fl
as
follows:
2.
Locate
display
board
PC4.
1.
Depress
and
rotate
fuse
holder
cover
counterciock-
3.
Check
voltage
according
to
Figure
6-2.
wise.
4.
If
a
meter
power
supply
and
command
voltage
is
2.
Pull
out
fuse
with
cover
when
fuse
holder
cover
is
correct
and
the
meter
is
not
working,
replace
the
me
free.
ter
(see
Section
6-5
and
contact
nearest
Factory
Au
thorized
Service
Station).
3.
Insert
new
fuse
into
fuse
holder
cover.
5.
If
the
power
supply
or
command
voltage
is
incorrect,
4.
Install
fuse
with
fuse
holder
cover
back
into
unit.
replace
display
board
PC4
(see
Section
6-5
and
5.
Depress
and
rotate
fuse holder
cover
clockwise
until
contact
nearest
Factory
Authorized
Service
Sta
cover
is
secure.
tion).
OM-138
426
Pages
Retaining
Ring
Wire
Retainer
Spanner
Nut
Hex
Nut
Hub
Support
Ref.
SC-I
27 328
Ref.
SO.117
838-B
6-5.
CIRCUIT
BOARD
HANDLING
PRECAUTIONS
a
WARNING:
ELECTRIC
SHOCK
can
kIll.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
inspecting,
maintaining,
or
seriicing.
Lockout/tagging
procedures
consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
Circuit
breaker
or
other
disconnect
ing
device.
4A
CAUTION:
ELECTROSTATIC
DISCHARGE
(ESO)
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
minima/pressure
and
gentle
move
ment
when
disconnecting
or
connecting
board
plugs
and
removing
or
installing
board.
Wire
Reel
Keyed
Washer
Brake
Washer
Hub
Support
Shaft
OPTIONAL
Hub
Fiber
Washer
Brake
Washer
FIgure
6-1.
Hub
And
Reel
Assemblies
Input
Command
For
Volts
Meter
..-O.5V
~
50V
Input
Command
For
Ammeter
O.1V
=
bOA
Figure
6-2.
DIsplay
Board
Meter
Checks
Power
Supply
For
Volts
Meter
And
Ammeter
O-5VDC
OM-138
426
Page
9
I
aol
~0
z0l
20l
1.01
I
U?
I
461
201
20
~
101
01
6~
40%
1.0
Wa
o0
001
.0
~
SECTiON
7-
ELECTRICAL
DIAGRAMS
I
3
Cl)
0
z
(5
.0
0
0
E
(5
2
C.)
OM-138
426
Pace
10
0
:3
0)
-ł
0
0
-Ip,
Diagram
7-2.
Circuit
Diagram
For
Control
Board
PCi
Circuit
Diagram
No.
SC-i
35
518
fillAilllllllllflIH
fi1
HI
'
/~/1.
_HPL
fi
JIIILJfflIIL
M.I.
~A~S
AT
ro
~
~IIW
VTTW
~T
TO
~so4
~NT
~J
W
WITH
~T
TO
P~gT
K
Diagram
7-3.
CircuIt
Diagram
For
Motor
Control
Board
PC2
A
L
OM-138
426
Page
12
N 0
F
C P
Circuit
Diagram
No.
SD-083
388-A
OM-138
426
Page
13
Diagram
7-4.
CircuIt
Diagram
For
Interface
Board
PC3
A
A
A
A
A
,i:i~
X1
U
U
A
A A
A
A
A
A
A A
fl\
U
Circuit
Diagram
No.
SB-114
483-A
DIagram
7-5.
Circuit
Diagram
For Meter
Display
Board
PC4
JUU
fuc
Circuit
Diagram
No.
SB-i
23
201
A-P
~
R~O
U-IF
D4
R~4
aA-eQ
~4
Rc27
I~1
r
OM-138
426
Page
14
BYPfISS
FOR
Pt
Lj~j
Diagram
7-6.
CircuIt
Diagram
For
Interlace
Board
PC5
Circuit
Diagram
No.
SB-i
32
087-A
Circuit
Diagram
No.
SA-114
815
.2W
xmi
+2W
CS
At
S
4
A
B
HE
AA
AB
S
14
P
N
L
DIagram
7-7.
Circuit
Diagram
For
Wire
Touch
Board
PC6
OM-138
426
Page
15
RC7
I>
3>-
9>-
7
>
5
>
a
p
/0
-L
REWT
DI
RC
6
-~.
12
-~I4
-~4
.-~
5
-~.
6
-57
-5
I0
8
88
>
d
.7
MIT
2
:3
I>
Circuit
Diagram
No.
SA-1
38742
Diagram
7-8.
CircuIt
Diagram
For
Gas/Current
Control
OM-138
426
Page
16
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34

Miller KA000000 Owner's manual

KA000000
Miller
Brand
Miller
Model
KA000000
Type
Owner's manual
This manual is also suitable for
Download PDF
report

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI

Related papers

Other documents