March
1~di
FORM:
OM-878B
MODEL
MR-5
COMPUTER
INTERFACE
GAS/CURRENT
SENSING
CONTROL
OWN
ERS
MANUAL
fullER
MILLER
ELECTRIC
MFG.
CO.
718
S.
BOUNDS
ST,
P.O.
Box
1079
APPLETON.
WI
54912
USA
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
equipment.
Do
not
allow
untrained
persons
to
Install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
Effective
With
Serial
No.
JH149410
NWSA
CODE
NO.
4579
PAINTED
IN
U.S.A.
LIMITED
WARRANTY
EFFECTIVE:
OCTOBER
1,
1988
~
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
condi-
In
the
case
of
Millers
breach
of
warranty
or
any
other
duty
tions
hereof,
Miller Electric
Mfg.
Co..
Appleton,
Wisconsin
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
warrants
to
its
Distributor/Dealer
that
all
new
and unused
therefore
shall
be,
at
Millers
option
(1)
repair
or
(2)
replacement
~i
~\
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
or,
where
authonzed
in
writing
by
Miller
in
appropriate
cases,
(3)
7
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
Miller
service
station
or
14)
payment
of
or
credit
for
the
purchase
-
accessories
or
other
items
manufactured
by
others.
Such
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
~
~
engines,
trade
accessories
and
other
items
are
sold
subject
to
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
7~
the
warranties
of
their
respective
manufacturers,
if
any
.
All
option
of
repair
or
replacement
will
be
F.O.B.,
Factory,
at
engines
are
warranted
by
their
manufacturer
for
one
year
from
Appleton,
Wisconsin,
or
F.O.B.,
at
a
MILLER
authorized
service
date
of
original
purchase,
except
Tecumseh
engines
which
facility,
therefore,
no
compensation
for
transportation
costs
of
have
a
two
year
warranty,
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
Miller
shall
instruct
the
claimant
on
the
warranty
Except
as
specified
below,
Millers
warranty
does
not
apply
claim
procedures
to
be
followed.
*
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
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
~
,~)
wire
including
nozzles
and
nozzle
insulators
where
failure
does
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTA-
k~.
not
result
from
defect
in
workmanship
or
material.
TION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
.~
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
~
Miller
shall
be
required
to
honor
warranty
claims
on
war-
MIGHT
ARISE
BY
IMPLICATiON,
OPERATION
OF
LAW,
,~
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
~
within
the
following
periods
from
the
date
of
delivery
of
Equip-
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
OF
/1
ment
to
the
original
user:
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
~.
.1
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EX
1.
Arc
welders,
power
sources,
robots,
and
components
.
1
year
CLUDED
AND
DISCLAIMED
BY
MILLER.
~\
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor
-
1
year
onlyl
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
4.
Allweldingguns.
feeder/gunsand
plasma
torches...
90
days
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
5.
All
other
Millermatic
Feeders
1
year
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUSTRIAL
6.
Replacement
or
repair
parts,
exclusive
of
labor
..
60
days
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
~
7.
Batteries
6
months
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
provided
that
Miller
is
notified
in
writing
within
thirty
(30)
days
CONSUMER
USE.
MILLERS
WARRANTIES
DO NOT
EXTEND
~
of
the
date
of
such
failure.
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
As
a
matter
of
general
policy
only,
Miller
may
honor
claims
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
submitted
by
the
original
user
within
the
foregoing
periods.
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
AMENDMENT
TO
SECTION
5
-
MAINTENANCE
&
TROUBLESHOOTING
Amend
Figure
5
-
3.
Circuit
Diagram
For
Computer
Interface
(see
page
2
on
this
Errata
Sheet)
Effective
With
Serial
No.
JH293950
Dia.
Part
Replaced
**
Mkgs.
No.
With
Description
Quantity
2-1
113
327
117
607
CONTROL
PANEL
1
3-56
PC4
109
571
117
833
CIRCUIT
CARD,
display
1
6-
R74
009
173
009
173
POTENTIOMETER
(qtychg)
1
6-
R84,94
039 329
035
823
RESISTOR,
carbon
film
0.25
watt
100
ohm
2
6-
R95
035 823
082
178
POTENTIOMETER,
cermet25
turn
0.5
watt
10K
ohm
11-
Ri
-5
044
635
030
028
RESISTOR,
carbon
0.5
watt
1
.5K
ohm
12-
109
936
117
617
CONTROLBOX,gas/currentsensor
12-6
010
610
115
104
CONNECTOR,
clamp-cable
1/2
inch
1
CR3
110
386
RELAY,
enclosed
24
volts
ac
DPDT
1
**First
digit
represents
page
no
-
digits
following
dash
represent
item
no.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Oct.
27,
1987
FORM:
OM-878B
IVtLTI
~
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PCI
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RCII1
~
IPC9
~
POHEP
1+1
1
Pt_GO
7
RCI6
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RCI61
Pt_Ga
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_________
_____________________
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0
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22
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0
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31
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OE
90
F
260
0
5/0
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500
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400
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450
1
0
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F
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1.73
JJ
J
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Pa
GA
PS
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Y
Z
H
J
Ek
MN
k
172
Circuit
Diagram
No.
C-ill
610
Figure
5
-
3.
Circuit
Diagram
For
Computer
Interface
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
-
INTRODUCTION
1
-
1.
General
Information
And
Safety
2
1
-
2.
Receiving-Handling
2
1
-
3.
Description
2
SECTION
2
-
INSTALLATION
2-1.
Location
2
2
-
2.
Gas/Current
Sensing
Control
Connections
2
2
-
3.
Computer
Interface
-
Welding
Power
Source
Connections
3
SECTION
3
-
FUNCTION
OF
CONTROLS
3
-
1.
Power
Switch
4
3
-
2.
Overload
Protection
4
3
-
3.
Voltmeter
4
3-4.
WireSpeedMeter
4
3
-
5.
Indicator
Lights
4
SECTION
4
-
SEQUENCE
OF
OPERATION
4
-
1.
Input
Signal
From
Welding
Power
Source
5
4
-
2.
Output
Signals
From
Computer
Interface
5
4
-
3.
Wire
Stick
Check
5
SECTION
5
-
MAINTENANCE
&
TROUBLESHOOTING
5
-
1.
Inspection
And
Upkeep
6
5
-
2.
Overload
Protection
6
5
-
3.
Display
Board Meter
Check
7
5
-
4.
Board
Replacement
Procedures
7
5
-
5.
Troubleshooting
Chart
8
5
-
6.
Use
Of
Indicator
Lights
For
Troubleshooting
10
SECTION
1
-
INTRODUCTION
Model
Weight
MR-5DW
31
lbs.
(14
kg)
Gas/Current
Sensing
Control
5
lbs.
(2.3
kg)
+
16.5
in.
(419
mm)
case
only
5/16
in.
(7.9
mm)
4-1/2
in.
(108
mm)
1II~IiIii
~
Diameter
2
Holes
/
9-7/8
in.
10-1/2
in.
(251
mm)
(267
mm)
Figure
1
-
1.
Specifications
In.
mm)
TB-i09
847
TB-i
10
320
OM-878
Page
1
1
-
1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
labels,
tags,
and
plates
on
the
unit
pertains
to
equip
ment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equip
ment.
B.
Safety
The
installation,
operation,
maintenance,
and
troubleshooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
installed,
operated,
and
maintained
only
by
qualified
persons
in
accordance
with
this
manual
and
all
ap
plicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
-
Safety
Rules
For
Operation
Of
Arc
Welding
Power
Source
in
the
welding
power
source
Owners
Manual.
CAUTION
statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
A
third
signal
word,
______________,
highlights
instruc
tions
which
need
special
emphasis
to
obtain
the
most
efficient
operation
of
this
equipment.
1
-
2.
RECEIVING-HANDLING
-
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
will
be
furnished
by
the
manufacturer
on
re
quest
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equip
ment,
it
is
essential
that
Model
Description
and
Serial
Number
of
the
equipment
be
supplied.
1
-
3.
DESCRIPTION
Safety
instructions
specifically
pertaining
to
this
unit
ap
pear
throughout
this
manual
highlighted
by
the
signal
words
____________
___________
which
identify
different
levels
of
hazard.
The
computer
interface
control
contains
wire
feed
speed
and
weld
voltage
control
circuitry,
digital
voltmeter
and
wire
feed
speed
meter,
and
circuitry
to
in
terface
with
the
robot
control
unit.
statements
include
installation,
operation,
and
maintenance
procedures
or
practices
which
if
not
carefully
followed
could
result
in
serious
personal
injury
or
loss
of
life.
WARNING
The
gas/current
sensing
control
contains
the
gas
valve
and
current
sensing
reed
relay.
These
components
function
with
the
robot
system
when
using
the
Gas
Metal
Arc
Welding
(GMAW)
pro
cess.
SECTION
2
-
INSTALLATIONI
2
-
1.
LOCATION
(Figure
1
-
1)
-
The
location
should
allow
room
to
open
and
remove
covers
and
wrappers
for
installation,
maintenance
and
repair.
Lead
lengths
must
be
considered
when
locating
components.
Mounting
holes
are
provided
in
each
component
for
mounting
purposes.
Figure
1-1
gives
unit
dimensions.
Normally
the
computer
interface
is
mounted
on
top
of
the
robot
control
unit.
The
gas/current
sensing
control
should
be
mounted
in
line
between
the
welding
power
source
and
wire/drive
assembly.
See
installation
sec
tion
of
robot
manual
for
specific
information.
The
service
life
and
efficiency
of
the
system
are
reduced
when
it
is
subjected
to
high
levels
of
dust,
dirt,
moisture,
corrosive
vapors,
and
extreme
heat.
2
-
2.
GAS/CURRENT
SENSING
CONTROL
CON
NECTIONS
(Figures
2-1
And
2-2)
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
1.
Insert
16-pin
Amp
plug
from
interconnecting
cord
into
corresponding
receptacle
on
the
gas/current
sensing
control,
and
rotate
collar
clockwise.
2.
Route
weld
cable
from
welding
power
source
positive
weld
output
terminal,
through
the
gas/current
sensing
control,
the
the
wire
drive
assembly.
3.
Connect
hose
from
gas/current
sensing
control
to
gas
supply
regulator/flowmeter.
The
gas
flow
must
be
accurately
controlled
by
a
regulator/flowmeter
at
the
source.
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
we/ding
power
source,
and
robot
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
in
terconnections.
WARNING
WARNING
and
CAUTION
OM-878
Page
2
Voltage
Control
Receptacle
RC13
Welding
Power
Source
interface
Receptacle
RC17
if
Applicable
tWhen
Filter
Interface
Is
Not
Used:
White
Lead
~Terminal
35
Green
Lead
-
Terminal
36
Blue
Lead
-
Terminal
50
Red
Lead
-
Terminal
52
18-109
848-A
2
-
3.
COMPUTER
INTERFACE
-
WELDING
POWER
SOURCE
CONNECTIONS
(Figures
2-1
And
2-2)
WARNING:
____
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
we/ding
power
source,
and
robot
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
in
terconnections.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
There
are
three
separate
cords
used
for
interconnec
tions
between
the
computer
interface
and
welding
power
source.
Examine
and
select
the
proper
cord
for
the
following
connections.
A.
Voltage
Sensing
Connections
1.
Connect
lead
with
ring
terminal
to
wire
drive
assembly
where
weld
cable
from
welding
power
source
is
connected.
2.
Connect
lead
with
clamp
to
work
table.
B.
Voltage
Control
Connections
1.
Insert
5-pin
Amphenol
plug
on
remaining
end
of
cord
into
corresponding
receptacle
on
welding
power
source,
and
rotate
collar
clockwise.
Filter
lnterface
RC1
1
Figure
2
-
1.
Rear
Panel
View
Gas/Current
Sensing
Control
Receptacle
RC9
115
VAC/Contactor
Control
Cord
Deltaweld
Welding
Power
Source
Arc
Failure
Connection
In
Robot
Control
Unit
Touch
Sensor
Motor
Control
Cord
Figure
2
-
2.
Interconnection
Diagram
18-109
851
OM-878
Page
3
2.
Place
welding
power
source
REMOTE
VOLTAGE
control
switch
in
the
ON
position.
C.
115VAC/Contactor
Control
Connections
1.
Insert
two-pole
twistlock
plug
from
cord
into
contactor
control
receptacle
on
welding
power
source,
and
rotate
plug
clockwise.
2.
Place
welding
power
source
REMOTE
CONTAC
TOR
control
switch
in
the
ON
position.
3.
Insert
three-pole
twistlock
plug
from
cord
into
11
5VAC
receptacle
on
the
welding
power
source,
and
rotate
clockwise.
SECTION
3
-
FUNCTION
OF
CONTROLS
Speed
Meter
T8109
847
3.
-
1.
POWER
SWITCH
(Figure
3-1)
-
Placing
the
POWER
switch
in
the
ON
position
applies
input
power
to
the
interface.
The
interface
must
be
on
for
the
robot
to
weld.
Placing
the
POWER
switch
in
the
OFF
position
shuts
the
interface
down.
3
-
2.
OVERLOAD
PROTECTION
(Figure
3-1)
A.
Fuse
Protection
The
interface
is
protected
from
damage
due
to
an
inter
nal
short
or
excessive
overload
by
fuse
Fl.
If
fuse
Fl
should
open,
the
interface
would
shut
down.
See
Sec
tion
5-2
for
replacement
procedures.
B.
Wire
Drive
Motor
Circuit
Breaker
The
drive
motor
is
protected
from
damage
due
to
overload
by
circuit
breaker
CB1.
If
circuit
breaker
CB1
should
open,
the
interface
would
shut
down.
The
reset
button
would
have
to
be
manually
depressed
to
reset
the
circuit
breaker.
3
-
3.
VOLTMETER
(Figure
3-1)
-
The
voltmeter
displays
weld
voltage
to
the
nearest
tenth
of
a
volt
while
welding
and
preset
voltage
while
idling.
3
-
4.
WIRE
SPEED
METER
(Figure
3-1)
-
The
wire
speed
meter
displays
preset
wire
feed
speed
to
the
nearest
inch
per
minute
while
welding
and
idling.
Actual
and
preset
wire
feed
speed
are
the
same
due
to
the
wire
feed
speed
feedback
circuit.
3
-
5.
INDICATOR
LIGHTS
(Figure
3-1)
-
There
are
five
indicator
lights
on
the
interface.
These
are
a
visual
indication
of
various
process
functions.
The
GAS
light
turns
on
to
indicate
that
the
gas
valve
is
energized
and
shielding
gas
should
flow.
The
CONTACTOR
light
turns
on
when
the
welding
power
source
contactor
is
energized
to
indicate
that
weld
output
is
available.
The
WIRE
FEED
light
turns
on
when
the
wire
feed
motor
energizes
to
indicate
that
wire
feed
is
started.
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
when
there
is
an
arc
outage
while
welding.
Circuit
Breaker
Fuse
Voltmeter
Gas
Indicator
Light
Wire Feed
Arc
Failure
Indicator
Light
Current
Indicator
Light
Figure
3
-
1.
Front
Panel
View
OM-878
Page
4
SECTION
4
-
SEQUENCE
OF
OPERATION
4
-
1.
INPUT
SIGNAL
FROM
WELDING
POWER
SOURCE
(Figure
4-1)
-
The
welding
power
source
and
wire
drive
motor
send
signals
to
the
computer
inter
face.
These
signals
are
used
to
determine
weld
parameters.
During
welding
these
signals
are
compared
to
preset
welding
values
and
compensations
are
made
to
keep
weld
parameters
at
preset
levels.
4
-
2.
OUTPUT
SIGNALS
FROM
COMPUTER
IN
TERFACE
(Figure
4-2)
-
The
interface
interprets
the
input
signals
from
the
welding
power
source,
wire
drive
motor,
robot,
and
wire
stick
check
circuit.
The
output
of
the
computer
interface
regulates
the
welding
power
source
and
wire
feed
functions
while
welding.
weld
Start
Relay
Open
Wire
Feed
Speed.
_______________
Command
I1
I
.1:
0
to
by
-
I
I
I
Voltage
S
I
command
_f
o
to
by
Close
Wire
Inching
I
S
Output
To Motor
______Si-
Gas
Valve
I
I
Pref
low
Time
.s.~
.s-__
Poatflow
~
I-.
Wire
Stick
Check
(at
Arc
End)
Time
p_fl______
4
-
3.
WIRE
STICK
CHECK
(Figure
4-1)
-
After
the
weld
is
completed,
the
wire
stick
check
is
performed
to
determine
if
the
welding
wire
has
burned
back
out
of
the
weld
puddle.
Feedback
is
used
to
determine
if
the wire
is
free
of
the
weld.
If
the
feedback
indicates
the
wire
is
free
of
the
weld,
the
robot
can
cycle
to
its
next
sequence.
Figure
4
-
3.
Wire
Stick
Check
If
the
feedback
indicates
the
wire
is
stuck,
the
welding
power
source
is
sent
a
1
.25
VDC
command
signal
to
provide
minimum
welding
power
source
output.
The
contactor
is
pulsed
on.
If
the
wire
was
stuck,
the
pulsed
voltage
should
be
enough
to
free
the
wire.
Feedback
is
~sed
to
determine
if
the
wire
is
now
free
of
the
weld.
If
the
feedback
indicates
the
wire
is
free,
the
robot
can
cy
cle
to
its
next
sequence.
If
the
wire
remains
stuck,
the
robot
will
shut
down,
a
Weld
Abnormal
error
will
be
displayed
on
the
robot
pro
gram
module,
and
the
wire
must
be
physically
removed
from
the
weld.
Arc
Initiation
Input
From
Motor
WeldAbnormal
Detect
r
Open
when
abnormality
occurs.
1OVDC
5VDC
Voltage
Command
I.25V0C
2.5VDC
Start
Time
Figure
4
-
1.
Input
Signal
Timing
Chart
Contactor
200
millIseconds
ii
P~~fl
FL
Arc
Iniation
-.
close
Open
p
Crater
Fill
If
the
feedback
indicates
the
wire
is
still
stuck,
a
higher
voltage
command
is
given,
and
the
contactor
pulsed
to
free
the
welding
wire.
The
check
is
performed
and
two
________
more
voltage
increases
are
used
to
try
and
free
the
welding
wire
(see
Figure
4-3).
O.2to0.3sec_.~.~
;_u.
Start
Time
Figure
4
-
2.
Output
Signal
Timing
Chart
OM-878
Page
5
SECTION
5
-
MAINTENANCE
b
TROUBLESHOOTING
IMPORTANT
_____________
Every
six
months
inspect
the
labels
on
this
unit
for
legibility.
All
precautionary
labels
must
be
maintained
in
a
clearly
readable.
state
and
replaced
when
necessary.
See
the
Parts
List
for
part
number
of
precautionary
labels.
5
-
1.
INSPECTION
AND
UPKEEP
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
internally
inspecting
or
servicing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
Usage
and
shop
conditions
will
determine
the
frequency
and
type
of
maintenance.
Inspect
equipment
as
follows:
1.
Repair
or
replace,
as
required,
all
hoses,
cords,
and
cables;
give
particular
attention
to
frayed
and
cracked
insulation
and
areas
where
it
enters
equipment.
2.
Remove
grease
and
grime
from
components;
moisture
from
electrical
parts
and
cables.
5
-
2.
OVERLOAD
PROTECTION
(Figure
3-1)
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
internally
inspecting
or
servicing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
IMPROPER
FUSES
can
damage
this
CAUTION
unit.
If
replacement
becomes
necessary,
use
only
fuses
of
the
proper
size,
type,
and
rating
(see
Parts
To
replace
the
fuse,
proceed
as
follows:
1.
Depress
and
rotate
fuse
holder
cover
counterclockwise.
2.
Pull
out
fuse
with
cover
when
fuse
holder
cover
is
free.
3.
Insert
new
fuse
into
fuse
holder
cover.
4.
Install
fuse
with
fuse
holder
cover
back
into
unit.
V1~2
Power
Supply
For
~
V2~>
Voltmeter
0
-
5Vdc
S~
V2
+
Input
Command
For
0
-
.5
Vdc
Input
Command
For
Wire
Speed
1PM
Meter
0
-
.8
Vdc
Figure
5
-
1.
Display
Board
Meter
Checks
Corrosponds
to
0
-
50
volt
welding
power
source
Output.
Corresponds
to
0
-
800
ipm
output
of
the
wire
drive
motor.
List).
5.
Depress
and
rotate
fuse
holder
cover
clockwise
until
cover
is
secure.
Rear
View
Of
Display
Board
PC4
Vini
Power
Supply
For
V1
+
Wire
Speed
PM
Meter0-5Vdc
OM-878
Page
6
5
-
3.
DISPLAY
BOARD
METER
CHECK
(Figure
3.
Gently
pull
board
straight
away
from
front
panel.
5-1)
-
Check
points
are
provided
on
the
display
board
Do
not
pull
up
or
down;
otherwise,
the
meters
for
checking
power
supply
and
input
command
for
the
and
LEDs
may
be
damaged.
VOLT
meter
and
WIRE
SPEED
1PM
meter.
4.
To
replace
meter(s)
proceed
as
follows:
WARNING:
____
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Be
sure
that
personnel
performing
testing
pro
cedures
are
familiar
with
and
follow
standard
safe
ty
practices.
Shut
down
unit
before
making
or
changing
meter
or
test
equipment
lead
connections.
ELECTROSTATIC
DISCHARGE
(ESD)
can
damge
electronic
components.
Do
not
touch
any
electronic
components
unless
a
properly
grounded
wrist
strap
is
worn
while
stan
ding
on
a
grounded,
static-dissipating
mat.
Transport
all
static-sensitive
components
in
pro
per
static-shielding
carriers
and
packages.
Perform
work
only
at
a
static-safe
work
area.
a)
Remove
nuts
and
lock
washers
from
meter
support.
b.
Gently
pull
meter
straight
Out
of
socket.
Re
tain
spacers.
c.
Slide
spacers
onto
new
meters
supports.
d.
Push
meter
into
socket
with
meter
supports
protruding
through
to
rear
of
board.
e.
Reinstall
lock
washers
and
nuts
to
secure
meter
to
board.
Do
not
overtighten
nuts
or
meter
may
be
damaged.
1.
Remove
computer
interface
top
cover.
5.
To
install
a
replacement
display
board,
carefully
line
board
up
with
front
panel
openings
for
2.
Locate
display
board
PC4.
meters
and
LEDs.
3.
Check
voltage
according
to
Figure
5-1.
6.
Reinstall
securing
screws.
4.
If
a
meter
power
supply
and
command
voltage
is
7.
Reinstall
top
cover
on
unit.
correct
and
the
meter
is
not
working,
replace
the
meter
(see
Section
5-4).
B.
Voltage
Board
(PCi).
Motor
Board
(PC2).
In
terface
Board
(PC3),
and
RF
Filter
Board
5.
If
the
power
supply
or
command
voltage
is
incor-
(PC6)
Replacement
rect,
replace
display
board
PC4
(see
Section
1.
Remove
top
cover
from
unit.
5-4).
2.
For
Voltage
Board
PCi:
5
-
4.
BOARD
REPLACEMENT
PROCEDURES
a.
Disconnect
lead
4
from
terminal
U
and
lead
38
from
terminal
T.
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
or
servicing.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
electronic
components.
Do
not
touch
any
electronic
components
unless
a
properly
grounded
wrist
strap
is
worn
while
stan
ding
on
a
grounded,
static-dissipating
mat.
Transport
all
static-sensitive
components
in
pro
per
static-shielding
carriers
or
packages.
Perform
work
only
at
a
static-safe
work
area.
b.
Disconnect
plug
PLG14
from
receptacle
RC14
on
board.
c.
Remove
board.
d.
Install
replacement
board.
e.
Connect
PLG14
to
RC14.
f.
Connect
lead
4
to
terminal
U
and
lead
38
to
terminal
T.
3.
For
Motor
Board
PC2:
a.
Remove
securing
screw
and
unlatch
stand
off.
A.
Display
Board
(PC4)
And
Meter
Replace-
b.
Gently
pull
board
from
receptacle
RC5.
ment
c.
Install
new
board.
1.
Remove
top
cover
from
unit.
d.
Reinstall
securing
screw
and
latch
standoff.
2.
Remove
screws
securing
board
to
stand-offs.
Do
not
remove
stand-offs.
OM-878
Page
7
4.
For
Interface
Board
PC3:
Shut
down
unit,
we/ding
power
source,
and
robot
and
disconnect
input
power
employing
a.
Disconnect
plugs
PLG18
and
PLG19
from
lockout/tagging
procedures
before
internally
receptacles
RC1
8
and
RC1
9.
inspecting
or
servicing.
Lockout/tagging
procedures
consist
of
padlocking
line
b.
Remove
board.
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
c.
Install
replacement
board.
breaker
or
other
disconnecting
device.
d.
Connect
PLG18
to
RC18
and
PLG19
to
MOVING
PARTS
can
cause
serious
injury.
R
C
19.
I
Keep
c/ear
of
moving
parts.
HOT
SURFACES
can
cause
severe
burns.
5.
For
RF
Filter
Board
PC6:
Allow
cooling
period
before
servicing.
Troubleshooting
to
be
performed
only
by
qualified
per-
a.
Disconnect
plugs
PLG21
and
PLG22
from
sons.
receptacles
RC21
and
RC22.
It
is
assumed
that
the
computer
interface
was
properly
b.
Remove
board.
installed
according
to
Section
2
of
this
manual,
the
operator
is
familiar
with
the
function
of
controls,
the
c.
Install
replacement
board.
unit
was
working
properly,
and
that
the
trouble
is
not
related
to
the
welding
process.
The
following
chart
is
d.
Connect
PLG21
to
RC21
and
PLG22
to
designed
to
diagnose
and
provide
remedies
for
some
of
RC22.
the
troubles
that
may
develop
in
this
unit.
6.
Reinstall
top
cover
on
unit.
5
-
5.
TROUBLESHOOTING
CHART
WARNING
I
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Use
this
chart
in
conjunction
with
the
circuit
diagrams
while
performing
troubleshooting
procedures.
If
the
trouble
is
not
remedied
after
performing
these
pro
cedures,
the
nearest
Factory
Authorized
Service
Sta
tion
should
be
contacted.
In
all
cases
of
equipment
malfunction,
the
manufacturers
recommendations
should
be
strictly
followed.
TROUBLE
PROBABLE
CAUSE
REMEDY
Unit
does
not
operate.
Fuse
Fl
open.
Check
Fl,
and
replace
if
necessary
(see
Section
5-2).
Correct
overload
problem
before
continuing
operation.
Circuit
breaker
CB1
tripped.
Check
CB1,
and
reset
if
necessary.
Correct
overload
problem
before
continuing
operation.
No
meter
display.
Meter
not
working.
Use
check
points
on
display
board
PC4
to
deter
mine
if
power
is
available
to
meter
(see
Section
5-3).
If
check
points
are
okay,
replace
meter
(see
Section
5-4).
Display
board
PC4
not
working.
Use
check
points
to
determine
if
power
is
available
(see
Section
5-3).
If
check
points
do
not
test
okay,
replace
PC4
(see
Section
5-4).
No
wire
feed.
Robot
signal.
Check
input
signal
from
robot
to
motor
board
PC2.
Signal
should
be
0-10
Vdc
between
pins
K
and
B
(common)
on
RC5.
Relay
CR1
not
working.
Replace
CR1.
Motor
board
PC2
not
work-
ing.
Replace
PC2
(see
Section
5-4).
Wire
feeds
at
maximum.
Tach
board
PC5
at
wire
drive
motor
not
working.
Replace
PC5.
OM-878
Page
8
TROUBLE
PROBABLE
CAUSE
REMEDY
No
arc
voltage
control.
Voltage
control
connec-
tionS.
Check
and
secure
connections
(see
Section
2-3).
Voltage
sensing
connec-
tions.
Check
and
secure
connections
(see
Section
2-3).
REMOTE
VOLTAGE
con-
trol
switch
position.
REMOTE
VOLTAGE
control
switch
on
welding
power
source
must
be
in
ON
position.
Voltage
board
PCi
not
working.
Replace
PCi
(see
Section
5-4).
Incorrect
robot
command
voltage.
Check
robot
command
voltage
at
voltage
board
PCi.
Command
voltage
should
be 0-10
Vdc
bet
ween
pins
C
and
E
(common)
at
RC14.
Robot
shuts
down
due
to
Touch
Sensor
error.
Touch
Sensor
connections.
Check
continuity
of
leads
between
gun/torch
and
gas/current
sensing
control.
Repair
or
replace.
Secure
all
connections.
Robot
moves
when
welding
wire
is
stuck.
Wire
stick
check
connec-
tion.
Be
sure
that
red
lead
is
connected
to
terminal
52
and
blue
lead
is
connected
to
terminal
50
on
welding
power
source
interface
14
position
ter
minal
strip.
Voltage
sensing
connec-
tions.
Check
and
secure
connections
(see
Section
2-3).
Wire
speed
(1PM)
meter
goes
to
zero.
Incorrect
robot
command
voltage.
Check
robot
command
voltage
at
motor
board
PC2.
Signal
should
be
0-10
Vdc
between
pins
K
and
B
(common)
at
RC5.
Motor
board
PC2
not
work-
ing.
Replace
PC2
(see
Section
5-4).
No
wire
retract.
Control
relay
CR2
not
work-
ing.
Replace
CR2.
Interface
board
PC3
not
working.
Replace
PC3
(see
Section
5-4).
Incorrect
robot
command
voltage.
Check
robot
command
voltage
at
motor
board
PC2.
Signal
should
be
0-10
Vdc
between
pins
K
and
B
(common)
at
RC5.
Robot
shuts
down.
Loose
weld
output
connec-
tions.
Clean
and
tighten
connections.
Interconnecting
cords.
Check
all
interconnecting
cords
for
breaks;
repair
or
replace.
Check
and
secure
all
connections.
Interface
board
PC3
not
working.
Replace
PC3
(see
Section
5-4).
OM-878
Page9
5-6.
USE
OF
INDICATOR
LIGHTS
FOR
TROUBLESHOOTING
On
Gas
Indicator
Light
Gas
flows:
System
normal
(on).
Gas
does
not
flow:
Gas
flows:
Check
gas
valve
operation.
Check
gas
valve
operation
and
gas
line
for
leaks.
Check
interface
board
PC3.
Gas
does
not
flow:
System
normal
(off).
On
Contactor
open:
Contactor
closed:
Check
interconnecting
Check
display
board
PC4.
cords.
Check
interface
board
PC3.
Wire
Feed
Indicator
Light
Off
Wire
feeds:
System
normal
(on).
Wire
does
not
feed:
Check
circuit
breaker
CB1.
Check
relay
CR1.
Check
interface
board
PC3.
Wire
feeds:
Check
input
signal
from
robot
to
motor
board
PC2.
Signal
should
be
0-10
Vdc
between
pins
K
and
B
(common)
at
RC5.
Check
wire
feed
board
PC2.
Wire does
not
feed:
System
normal
(off).
Arc
started:
System
normal
(on).
No
arc:
Replace
reed
relay.
Arc
started:
Replace
reed
relay.
No
arc:
System
normal
(off).
Arc
started:
No
arc:
Check
signal
from
robot.
Normal
during
idling.
Signal
should
be
24Vdc
between
terminals
2TE
and
2TF.
Check
display
board
PC4.
On-
Contactor
closed:
System
normal
(on).
Contactor
Indicator
Light
e-Off
Contactor
Open:
System
normal
(off).
On
Current
Indicator
Light
II
.~
On
i
Arc
Failure
Indicator
Light
~-
Off
I
I
No
arc:
Check
weld
parameters.
4,
Arc
started:
Normal
while
welding.
OM-878
Page
10
P~R
~
~4TRO
RCI~
5
~IvE
~b
()PHJT~
0l
4
~IVK
~
2T
ST
4T
0*
OA
~0A
OB
OB
S/OB
hoc
Oc
J40c
h~0O
00
.~00
/50E
OE
290F
6SOF
J400
XOG
~OH
5/OH
420J
~0.J
360K
400K
~0L
4501
120fl
440M
P109
6/0
*
*20
B
/29
C
/26
0
3/0
1
/9
F
ho
C
49
H
6
j
0
-4
A
A5c9
B
13
I
1
~~T13I
Circuit
Diagram
No.
C-113
225-A
-o
DI
ID
Figure
5
-
2.
Circuit
Diagram
For
Computer
Interface
G
F
Circuit
Diagram
No.
B-108
982
Figure
5
-
3.
Circuit
Diagram
For
Voltage
Control
Board
PCi
OM-878
Page
12
057
0
Circuit
Diagram
No.
C-083
388
Figure
5
-
4.
Circuit
Diagram
For
Motor
Control
Board
PC2
CA)
4
B
C
GAS
-I
CR5
WIREFEED
MOTOR
~
~
GAS
>E
>AM
J-
ROBOT
CR2
CURRENT
I
>
DETECT
AN
)
AA
CR4
cONTACTOR
>AC
Circuit
Diagram
No.
B-113
431
0
-4
-u
AH
ON
RC18
AA-AN
ON
RCI9
+15
V.
+24
V.
____
~
07
I
___
1C2
ci
14
08
06
0
F
A
G
WELD
START
AE
.JOG
(FWD)
J
WELD
AL
CURRENT
RELAY
AJ
..JOG
(REV)
N
COMMON
AK
REV.
RELAY
K
Figure
5
-
5.
Circuit
Diagram
For
Interface
Board
PC3
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