Miller RCSP-XL Owner's manual

Miller
Brand
Miller
Model
RCSP-XL
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Millerfi
May1991
FORM:
OM-138
992A
MODEL:
RCSP-XL
Synergic
Pulse
Robot
Control
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
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
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
Miller
Group
Ltd..
Company
P.O.
Box
1079
Appleton,
WI
54912
USA
Te.
414-734-9821
SC.139
884
PRINTED
IN
U.S.A.
I
J
LIMITED
WARRANTY
EFFECTIVE:
AUGUST
6,
1990
1.~
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
detect
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
the
warranties
of
their
respective
manufacturers.
it
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
does
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.
Load
banks
1
year
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
ment
or,
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
F.O.B..
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
F!TNESS
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.
I
OM-138
9g2A-
5I~i
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use
the
following
spaces
to
record
the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number
of
your
unit.
The
infor
claims
for
loss
or
damage
with
the
delivering
carrier.
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
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
2
3-2.
Voltage
Sensing
Cable
Connection
To
Wire
Drive
Assembly
3
3-3.
Synergic
Pulse
Panel
Computer
Interface
Connections
3
3-4.
Internal
DIP
Switch
Positions
3
3-5.
Connection
For
Nonpulse
Welding
3
3-6.
Connections
For
Remote
Pulse/Nonpulse
Control
4
3-7.
Field
Installation
Instructions
For
Synergic
Pulse
Panel
RCSP-XL
Onto
Computer
Interface
4
SECTION
4-
ROBOT
PROGRAM
MODIFICATIONS
4-1.
Amendment
To
Robot
Owners
Manual
Section
4
System
Set
Up
.
6
4-2.
Amendment
To
Robot
Owners
Manual
Section
5
Teaching
6
SECTION
5-
OPERATOR
CONTROLS
5-1.
Wire
Size
Select
Switch
And
Standard
Mode
Indicator
Light
8
5-2.
Wire
Type
Select
Switch
9
5-3.
Recommended
Shielding
Gas
Indicator
Lights
9
5-4.
No
Program
Indicator
Light
9
SECTION
6
SEQUENCE
OF
OPERATION
6-1.
Gas
Metal
Arc
Welding
(GMAW)
11
6-2.
Shutting
Down
11
SECTION
7-
MAINTENANCE
&
TROUBLESHOOTING
7-1.
Inspection
And
Upkeep
12
7-2.
Overload
Protection
12
7-3.
Circuit
Board
Handling
Precautions
12
7-4.
Troubleshooting
13
Section
No.
Page
No.
SECTION
8-
ELECTRICAL
DIAGRAMS
Diagram
8-1.
Circuit
Diagram
14
Diagram
8-2.
Circuit
Diagram
For
Offset
Supply
Circuit
Board
PC5
14
Diagram
8.3.
Circuit
Diagram
For
Interface
Circuit
Board
PCi
15
Diagram
8-4.
Wiring
Diagram
17
Diagram
8-5.
Circuit
Diagram
For
Selector
Board
PC6
18
SECTION
9
PARTS
LIST
Figure
9-1.
Main
Assembly
20
Figure
9-2.
Circuit
Card,
Offset
Supply
PC5
23
Figure
9-3.
Circuit
Card,
Interface
PCi
25
LIST
OF
CHARTS
AND
TABLES
Table
7-1.
Troubleshooting
13
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
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
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.
a
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
a
a
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid seri
ous
personal
injury
or
loss
of
life.
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
2INTRODUCTION
2-1.
DESCRIPTION
The
robot
Synergic
Pulse
panel
is
a
synergic
control
de
signed
to
be
used
with
the
ARC
PAK
350
or
MAXTRON
300
welding
power
sources,
MILLER
Computer
Inter
face,
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
are
pro
grammed
so
that
they
can
be
adjusted
using
a
single
control
as
opposed
to
adjusting
individual
controls.
If
pulse
welding,
arc
power
parameters
are
wire
feed
speed,
background
amperage,
peak
amperage,
pulse
frequency,
and
pulse
width;
if
non-pulse
welding,
arc
power
parameters
are
wire
feed
speed,
arc
voltage,
and
inductance.
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.
IMPORTANT:
When
using
MAXTRON
300
welding
power
source,
it
is
recommended
that
it
be
equipped
with
field
kit
MILLER
Part
No.
146722.
OM-138
992
Page
1
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
Owners
Manual
for
location).
3.
Connect
remaining
lead
with
ring
terminal
to
the
workpiece.
3-3.
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
RCI4
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.
3-4.
INTERNAL
DIP
SWITCH
POSITIONS
(Figure
3-2)
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
welding
power
source,
and
be
sure
equipment
cannot
be
accidently
energized
before
inspecting
or
installing.
CAUTION:
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
properly
grounded
wrist
strap
BEFORE
changing
DIP
switch
positions
or
handling
circuit
boards.
IMPORTANT:
Both
DIP
switch
positions
must
be
changed
to
the
OFF
position
before
using
this
unit
with
the
MAXTRON
300
welding
power
source.
This
unit
has
an
internal
DIP
switch
SW1
on
Interface
Circuit
Board
PCI
which
consists
of
two
switches.
Both
switches
are
factory
set
in
the
ON
position
for
use
with
the
ARC
PAK
350
welding
power
source.
Both
switches
must
be
placed
in
the
OFF
position
when
using
this
unit
with
the
MAXTRON
300
welding
power
source.
To
check
or
change
the
positions
of
the
DIP
switch,
proceed
as
follows:
1.
Remove
side
panel.
2.
Locate
Interface
Circuit
Board
PCi,
the
third
cir
cuit
board
behind
the
operator
control
panel.
3.
Locate
DIP
switch
SW1
on
the
right
side
of
PCi
(see
Figure
3-2).
4.
Place
switches
in
the
desired
positions.
The
posi
tions
are
factory
set
in
the
ON
position
and
only
need
to
be
changed
for
use
with
the
MAXTRON
300.
5.
Reinstall
and
secure
the
side
panel.
IMPORTANT:
When
using
this
unit
with
the
MAXTRON
300,
the
welding
power
source
Mode
Switch
on
the
front
panel
must
be
set
in
the
CC
position
for
pulsed
welding
or
CV
for
nonpulsed
welding.
If
the
MAXTRON
300
is
equipped
with
field
kit
MILLER
Part
No.
146722,
the
Mode
Switch
can
remain
in
the
CC
position
for
all
welding
applications
and
pulse/non
pulse
switching
is
done
through
the
17-position
connection.
If
the
Mode
switch
is
in
the
CV
position,
only
CVapplica
tions
are
available.
Inductance
is
controlled
from
the
welding
power
source
front
panel
control.
a
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_______
________
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0
C
C.
C
Figure
3-2.
DIP
Switch
Location
On
PCi
interface
circuit
~
Board
~ci
Dip
Switch
C
S6.138
265
OM-138
992
Page
3
3-5.
CONNECTION
FOR
NONPULSE
WELDING
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
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
2Tterminals
B
and
C
to
2T
terminals
A
and
B.
4.
Reinstall
unit
top
cover
and
side
panel.
3-6.
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
the
factory
ready
for
pulsed
welding.
if
selection
of
pulse/nonpulse
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.
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
B
and
C
on
2T.
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
Owners
Manual
Section
4
System
Set-Up:
Input/Output
Terminal
Block
Connections.
9.
To
program
pulse/nonpulse
selection,
see
robot
Owners
Manual
Section
5
Teaching:
Logic
Data
For
Programs.
3-7.
FIELD
INSTALLATION
INSTRUCTIONS
FOR
SYNERGIC
PULSE
PANEL
RCSP-XL
ONTO
COMPUTER
INTERFACE
(Figures
3-1
And
3-3)
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.
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.
1.
Remove
Computer
Interface
top
cover
and
side
panels.
2.
Disconnect
Synergic
Pulse
panel
wiring
harness
from
panel
Interface
circuit
board
PCI.
3.
Remove
side
panel
from
Synergic
Pulse
panel.
4.
Install
frame
onto
left
side
of
Computer
Interface
with
sheet
metal
screws
(see
Figure
3-1).
5.
Connect
leads
25
and
27
to
terminals
I
and
U
on
the
Voltage
Control
Board
in
the
Computer
Inter
face
(polarity
is
not
important).
a
OM-1
38992
Page
4
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
3-3).
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.
Left
Side
View
Of
Computer
Interface
Strip
3T
f.
Connect
lead
45
to
2TC.
g.
Connect
lead
60
to
3TB.
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.
9.
Install
side
panel
onto
Synergic
Pulse
panel.
10.
Reinstall
Computer
Interface
right
side
panel.
11.
Install
supplied
top
cover
onto
the
Computer
In
terface
Synergic
Pulse
panel.
Right
Side
View
Of
Computer
Interface
SB.139
887
Figure
3-3.
Electrical
Installation
Voltage
Control
Board
Corn
I
Terminal
Strip
IT
Motor
Terminal
Strip
2T
Control
Board
OM-138
992
Page
5
SECTION
4-
ROBOT
PROGRAM
MODIFICATIONS
IMPORTANT:
The
robot
program
must
be
changed
to
accommodate
synergic
welding.
The
following
informa
(ion
pertains
to
the
robot
Owners
Manual.
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.
4-1.
AMENDMENT
TO
ROBOT
OWNERS
MANU
AL
SECTION
4
SYSTEM
SET
UP
Before
the
Synergic
Pulse
panel
will
work,
the
robot
sys
tem
data
must
be
updated.
Update
System
Data
4
(weld
ing
power
source
selection)
to
SYNERGIC
according
to
instructions
in
Section
4.22.1.
If
the
Synergic
Pulse
panel
WIRE
SIZE
SELECT
Switch
is
in
the
STANDARD
position,
robot
system
data
must
be
updated.
Update
System
Data
4
to
GMAW
according
to
instructions
in
Section
4.22.1.
4-2.
AMENDMENT
TO
ROBOT
OWNERS
MANU
AL
SECTION
5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
IMPORTANT:
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
SELECTkeys
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:
POOl
SOOl
M6
P
6
0.
IMPORTANT:
The
display
examples
used
with
state
ments
such
as
will
appear
as
shownmay
not
match
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.
If
the
arc
start
function
data
will
be
the
next
data
recorded
after
previous
taught
data,
the
display
will
appear
as
shown:
POOl
S005
M4
0
P
60
f
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:
POOl
S003
M4
25P
1L
039i
0.5S
+
+
Arc
Length
WeldIn~Speed
In
1PM
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).
Manual
Operating
Sp
ad
+
Current
Recorded
Data
(May
Also
Se
0
Data)
Arc
Power
In
Percent
+
Preflow
Time
In
Seconds
OM-138
992
Page
6
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,
i,
S)
after
the
value
to
be
changed
flashes.
POOl
S003
M4
25P
1L
0391
0
.
5S
Table
5-2.
Ranges
And
Increments
Of
Arc
Start
Welding
Parameter
Values
W
elding
Parameter
Setting
Range
Increment
Arc
Power
Oto
lOOP
1
P
Arc
Length
5
to
+5
L
1
L
Welding
Speed
4
to
234
ipm
1
ipm
Preflow
Time
0
to
9.9
sec.
0.1
sec.
3)
Enter
a
number
value
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
1L
039
i
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.
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
39
i
I
I
Previous
Current
Recorded
Recorded
Data
Data
IMPORTANT:
The
display
examples
used
with
state
ments
such
as
willappearas
shownmay
not
match
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
function,
and
a
typical
display
will
appear
as
shown:
POOl
S005
M4
l8P
lL
0.2S
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,
L,
S,
S)
after
the
value
to
be
changed
flashes.
POOl
S005
M4
18P
1
L
0.2
S
0
.5
S
Table
5-3.
Ranges
And
Increments
Of
Arc
End
Welding
Parameter
Values
Welding
Parameter
Setting
Range
Increment
Arc
Power
0
to
100
P
1
P
Arc
Length
5
to
+5
L
1
L
Crater
Fill
Time
0
to
9.9
sec.
0.1
sec.
Postflow
Time
0
to
9.9
sec
0.1
sec.
I
Arc
Power
In
Percent
I
I
I
Arc
Length
Crater
Fill
Time
Postf
low
Time
In
Seconds
In
Seconds
OM-138
992
Page
7
3)
Enter
a
number
value
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).
P00
1
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.
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
S006
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
for
the
specific
type
and
size
of
wire
chosen.
Together,
the
switches
determine
the
relationship
of
the
various
arc
power
parameters.
IMPORTANT:
When
using
this
unit
with
the
MAXTRON
300,
the
welding
power
source
Mode
Switch
on
the
front
panel
must
be
set
in
the
CC
position
for
pulsed
welding
or
CV
for
nonpulsed
welding.
If
the
MA.XTRON
300
is
equipped
with
field
kit
MILLER
Part
No.
146722,
the
Mode
Switch
can
remain
in
the
CC
position
for
all
welding
applications
and
pulse/nonpulse
switching
is
done
through
the
17-position
connection.
If
the
Mode
switch
is
in
the
CV
position,
only
CV
applica
tions
are
available.
Inductance
is
controlled
from
the
welding
power
source
front
pane!
control.
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.
Standard
Mode
Indicator
Light
Wire
Type
Selector
Switch
Wire
Size
Selector
Switch
No
Program
Recommended
Shielding
indicator
Light
Gas
Indicator
Lights
Figure
5-1.
Operator
Controls
SB.139
885
OM-138
992
Page
8
If
the
unit
is
operated
in
a
nonpulse
condition,
arc
power
parameters
are
wire
feed
speed,
arc
voltage,
and
induc
tance.
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
SELECTSw1tch
in
the
.045
position
when
welding
with
.047
in.
diameter
welding
wire.
5-2.
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
typeand
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.
lithe
unit
is
operated
in
a
nonpulse
condition,
arc
power
parameters
are
wire
feed
speed,
arc
voltage,
and
induc
tance.
IMPORTANT:
When
using
this
unit
with
the
MAXTRON
300,
the
welding
power
source
Mode
Switch
on
the
front
panel
must
be
set
in
the
CC
position
for
pulsed
welding
or
CV
for
nonpulsed
welding.
If
the
MAXTRON
300
is
equipped
with
field
kit
MILLER
Part
No.
146722,
the
Mode
Switch
can
remain
in
the
CC
position
for
all
welding
applications
and
pulse/nonpulse
switching
is
done
through
the
17-position
connection.
If
the
Mode
switch
is
in
the
CV
position,
only
CV
applica
tions
are
available.
Inductance
is
controlled
from
the
welding
power
source
front
panel
control.
5-3.
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.
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
Section
5-4).
5-4.
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
Wire
Type
STL1
STL2
NI
SS1
SS2
ALl
AL2
SI
BR
CUST.
.030
*
*
*
* *
*
*
*
*
.035
98ArI2
02
75Ar/25
HE
98Ar/2
02
*
Ar
Ar
Ar
.045
*
98Ar/2
02
75ArI25
HE
98Ar/2
02
Ar
Ar
Ar
98Ar/2
02
.062
*
*
*
Ar
Ar
*
OM-138
992
Page
9
TbIe
5-1.
Synergic
Pulse
Panel
Welding
Schedules
(Continued)
NONPULSE
WELDING
Wire
Type
STL1
STL2
NI
SS1
SS2
ALl
AL2
SI
BR
CUST.
.030
CO2
75Ar/25
CO2
SPCL
98Ar/2
02
*
* *
.035
CO2
75Ar/25
CO2
SPCL
98Ar/2
02
Ar
Ar
Ar
.045
CO2
75Ar/25
CO2
SPCL
98Ar/2
02
Ar
Ar
*
CO2
.062
*
*
*
*
Ar
Ar
* *
*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
mini
mum
to
maximum
wire
feed
speed.
In
NONPULSE
mode,
STL2
is
used
with
75
Ar125
CO2
shielding
gas
for
short
circuit
welding
from
minimum
to
maximum
wire
feed
speed.)
NI
=
High
Nickel
Alloy
SS1
=
Stainless
Steel
(In
PULSE
mode,
SSI
is
used
with
98
Ar/2
02
shielding
gas
for
spray
transfer
welding
from
minimum
to
maximum
wire
feed
speed.
In
NONPULSE
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
maxi
mum
wire
feed
speed.)
ALl
=
4043
Aluminum
AL2
=
5356
Aluminum
SI
BR
=
Silicon-Bronze
*CUST.
=
Position
usually
reserved
for
programming
a
welding
schedule
not
included
in
the
standard
programming
of
the
unit.
At
this
time,
the
welding
schedule
programmed
for
this
position
is
as
follows:
*PULSE
Welding
=
.045
409
flux-cored
stainless
steel
welding
wire
*NONPULSE
Welding
=
.045
AWS
class
E71T-l
flux-cored
welding
wire
Shielding
Gas:
CO2
=
Carbon
Dioxide
75
Ar/25
CO2
=
75%
Argon
25%
Carbon
Dioxide
SPCL
=
Tn-Mix:
90%
Helium
7.5%
Argon
2.5%
Carbon
Dioxide
AR
=
Argon
98
Ar/2
02
=
98%
Argon
2%
Oxygen
~75
Ar/25
HE
=
75%
Argon
25%
Helium
~This
shielding
gas
is
not
included
on
nameplate
of
the
Synergic
Pulse
panel.
OM-138
992
Page
10
SECTION
6
SEQUENCE
OF
OPERATION
WARNING:
ELECTRiC
SHOCK
can
kill;
MOVING
PARTS
can
cause
serious
Injury;
IMPROPER
AIRFLOW
AND
EXPOSURE
TO
ENVIRONMENT
can
damage
Internal
parts.
Do
not
touch
live
electrical
parts.
Keep
all
covers
and
panels
in
place
while
operating.
Do
not
touch
welding
wire
or
any
metal
part
in
contact
with
it
while
welding.
The
welding
wire
and
all
metal
parts
in
contact
with
it
carry
weld
output
when
the
welding
power
source
contactor
is
energized.
Warranty
is
void
if
any
of
the
equipment
is
oper
ated
with
any
portion
of
the
outer
enclosure
removed.
ARC
RAYS,
SPARKS,
AND
HOT
SURFACES
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
correct
eye,
ear,
and
body
protection.
FUMES
AND
GASES
can
seriously
harm
your
health.
Keep
your
head
out
of
the
fumes.
Ventilate
to
keep
from
breathing
fumes
and
gases.
If
ventilation
is
inadequate,
use
approved
breathing
device.
WELDING
WIRE
can
cause
puncture
wounds.
Do
not
point
gun
toward
any
part
of
the
body,
any
conductive
surface,
or
other
personnel.
HOT
METAL,
SPATTER,
AND
SLAG
can
cause
fire
and
burns.
Watch
for
fire.
Keep
a
fire
extinguisher
nearby,
and
know
how
to
use
it.
Do
not
use
near
flammable
material.
Allow
work
and
equipment
to
cool
before
handling.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
weld
ing
operations.
See
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
in
the
welding
power
source
Owners
Manual
for
basic
welding
safety
information.
6-1.
GAS
METAL
ARC
WELDING
(GMAW).
1.
Install
and
connect
robot
system
according
to
its
Owners
Manuals.
IMPORTANT:
When
using
this
unit
with
the
MAXTRON
300,
the
welding
power
source
Mode
Switch
on
the
front
panel
must
be
set
in
the
CC
position
for
pulsed
welding
or
CV
for
nonpulsed
welding.
If
the
MA.XTRON
300
is
equipped
with
field
kit
MILLER
Part
No.
146722,
the
Mode
Switch
can
remain
in
the
CC
position
for
all
welding
applications
and
pulse/nonpulse
switching
is
done
through
the
17-position
connection.
If
the
Mode
switch
is
in
the
CV
position,
Only
CV
applica
tions
are
available.
Inductance
is
controlled
from
the
welding
power
source
front
panel
control.
2.
Connect
panel
according
to
Section
3.
3.
Position
WIRE
SIZE
SELECT
Switch
for
size
wire
used
~see
Section
5-1).
4.
Position
WIRE
TYPE
SELECT
Switch
for
type
wire
used
(see
Section
5-2).
5.
Place
welding
power
source
front
panel
adjust
ment
control(s)
to
the
maximum
setting.
6.
Rotate
MAXTRON
300
inductance
control
to
de
sired
setting.
7.
Turn
on
shielding
gas
at
its
source.
8.
Energize
robot
system.
9.
Begin
welding.
SHUTTiNG
DOWN
Stop
welding.
Shut
down
robot
system.
Turn
off
shielding
gas
at
the
source.
a
6-2.
1.
2.
3.
a
WARNING:
HIGH
CONCENTRATION
OF
SHIELDING
GAS
can
harm
health
or
kill.
Shut
off
gas
supply
when
not
in
use.
OM-138
992
Page
11
SECTION
7
MAINTENANCE
&
TROUBLESHOOTING
IMPORTANT:
Even,
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:
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.
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.
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
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
unit-Interface
Circuit
Board
PCi,
Logic
Circuit
Board
PC2,
and
Memory
Circuit
Board
PC3are
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
PC
1
is
at
the
top
of
the
stack.
a
OM-138
992
Page
12
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
qualified
persons.
It
is
assumed
that
proper
installation
has
been
made
ac
cording
to
Section
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
Slation
should
be
contacted.
In
all
cases
of
equipment
malfunc
tion,
the
manufacturers
recommendations
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
Owners
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
Owners
Manual.
Synergic
Pulse
panel
controls
not
functional.
Interface
Circuit
Board
PCi
See
Section
7-3
and
contact
nearest
Factory
Au-
thorized
Service
Station.
Memory
Circuit
Board
PC3.
See
Section
7-3
and
contact
nearest
Factory
Au
thorized
Service
Station.
Logic
Circuit
Board
PC2.
See
Section
7-3
and
contact
nearest
Factory
Au
thorized
Service
Station.
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
13
NOTES
OM-138
992
Page
14
pc3
~
eo*Po
II
0 0
66
69
A_
B
C
2T
0
6026
JJ~E~
cACIORY
INSTALLED
FR~4
21(B)
10
IC)
F~
PE~TE
SELECTION
~
N~IPtJLSZ
S~TRGIC
WELOI~G.
INSTALL
.J1~4PER
FP~4
21(A) TO
(B)
~OP
MAP&)AL
NONPULSE
SYNESGIC
WELDING.
SECTION
8
ELECTRICAL
DIAGRAMS
Diagram
8-1.
Circuit
Diagram
Circuit
Diagram
No.
SB-138
381
Diagram
8-2.
Circuit
Diagram
For
Offset
Supply
Circuit
Board
PC5
I
.l
SU
Circuit
Diagram
No.
SB-i
45
345-A
PCI
/2
/4
PC)
_______
24U
i
UINj~UOUT
~
~
0
1-
U
.--
U
~ND
IILI
-241)
PCI
(
SNO
-
I
SU
PSUER/SPOUND
NETS
FOR
CHIPS
RI
4~ISU
8~+ISU
RI
BYPASS
CAPS
4)SU
ISU
LL
RC2
18
OM-138
992
Page
15
UI
C24
HF-
C33
HF
C34
U4
HF-
C32
-HF-
V
Li~
LE
~.-I~US..Iil~
%~cI4.i~J
Diagram
8-3.
Circuit
Diagram
For
Interface
Circuit
Board
PCi
>~r
C49
H~
Cs.
HF---
U?
C39
__3F__U3
T~
T5
C41
3
F
C3i
C41s.
C4?
OM-138
992
Page
16
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Miller RCSP-XL Owner's manual

Miller
Brand
Miller
Model
RCSP-XL
Category
Welding System
Type
Owner's manual
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