Miller COMPUTER INTERFACE NSPR 8933 AND 9184 Owner's manual

Miller
Brand
Miller
Model
COMPUTER INTERFACE NSPR 8933 AND 9184
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Millerfi
March
1992
FORM:
OM-135
583C
MODEL:
Computer
Interface
(Per
NSPR
8933
And
9184)
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
Tel.
414-734-9821
PRINTED
IN
U.S.A
111111
~ax
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial
number
preface
of
XC
or
newer)
This
limited
werrenty
supersedes
all
previous
MILLER
werrenties
end
is
esciusive
with
no
other
guerentees
or
werranties
espressed
o
implied.
LIMITED
WARRANTY
Subject
to
the
terms
end
conditions
below.
MILLER
Electric
Mtg.
Co.,
Aopleton,
Wisconsin.
warrants
to
its
original
reteil
putcheser
that
new
MILLER
esuipment
sold
after
the
effective
date
of
this
limited
warranty
is
free
of
de
fects
in
materiel
and
workmanship
at
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES.
EXPRESS
OR
IMPLIED.
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
warranty
periods
listed
below.
MtLLER
will
repair
or
replace
any
war
ranted
parts
or
components
that
fail
due
to
such
defects
in
materiel
or
workmanship
MILLER
must
be
notified
in
writing
within
thirty
(30)
days
of
such
delect
or
failure.
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
such
a
failure
within
the
warranty
time
periods.
All
warranty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
and
are
as
follows:
1.
5
Years
Parts
3
Yests
Labor
Original
main
power
rectifiers
2.
3
Years
Parts
and
Lebor
Transformer/Rectifier
Power
Sources
*
Plasma
Arc
Cuffing
Power
Sources
*
Semi-Automatic
and
Automatic
Wire
Feeders
Robots
3.
2
Years
Parts
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufecturer.)
4.
1
YearParts
and
Labor
Motor
Driven
Guns
*
Process
Controllers
*
Water
Coolant
Systems
*
HF
Units
Grids
Spot
Welders
Load
Banks
SDX
Transformers
Running
Gear/Trsilers
Field
Options
(NOTE
Field
options
are
covered
under
True
Blue~M
for
the
remaining
warranty
period
of
the
product
they
ere
installed
in.
or
for
a
minimum
of
one
year
whichever
is
greeter)
5.
6
Months
Batteries
6.
90
Days
Parts
and
Labor
MIG
GunsiTIG
Torches
Plasma
Cutting
Torches
Remote
Controls
Accessory
Kits
*
Replacement
Parts
MILLERS
True
BiuerM
Limited
Warranty
shall
not
apply
to:
1
Items
furnished
by
MILLER,
but
manufactured
by
others,
ouch
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
it
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactors
end
relays.
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip
ment
that
has
been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
has
been used
for
operation
-
outside
of
the
specifications
for
the
equipment.
.
-
-
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
CIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EOUIPMENT
In
the
event
ot
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be.
at
MILLERS
option
(1)
repair;
or
(2)
replacement;
or.
where
authorized
in
writing
by
MILLER
in
appropriate
cases.
(3)
the
reasonable
coat
of
repair
or
replace-
mast
Stan
authorized
MILLER
service
station;
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
risk
and
espense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
atAppfeton,
Wisconsin.
or
F.O.B.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costs
of
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMtTTED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUStVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
LIABLE
FOR
DIRECt
INDIRECt
SPECIAL.
INCIDENTAL
OR
CONSEQUENTtAL
DAMAGES
)INCLUDtNG
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CON
TRACt
TORT
OR
ANY
OTHER
LEGAL
THEORY
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY.
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE.
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION.
MIGHT
ARISE
BY
tMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implIed
warranty
lasts,
or
the
esciusion
ol
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spa
cilic
legal
rights.
and
other
rights
may
be
available,
but
may
vary
from
state
to
stale.
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
other
than
as
stated
herein,
and
to
the
extant
that
they
may
not
be
waived,
the
limitations
and
exclusions
set
out
above
may
not
apply.
This
Limited
Wsrranly
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
r
ci
,
Th~(~
I
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
or
damage
with
the
delivering
carrier.
Assistance
for
filing
or
settling
Claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date
of
Purchase
miller
5/92
ERRATA
SHEET
December
2,
1992
FORM:
OM-135
583C
Use
above
FORM
number
when
ordering
extra
manuals.
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
CHANGES
TO
SECTION
3
INSTALLATION
Change
Section
3-GB.
ROBOT
INTERFACE
WELDING
POWER
SOURCE
CONNECTIONS:
REMOTE
17
Connections
3.
For
units
used
with
Pulstar
450
welding
power
source,
it
is
necessary
to
change
internal
connections
in
the
robot
interlace.
Proceed
as
follows:
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shutdown
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures.
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.
a.
Open
front
panel
access
door.
b.
Locate
lead
72
at
pin
F
of
REMOTE
17
receptacle
RC16.
c.
Cut
lead
72
as
close
to
receptacle
as
possible.
d.
Splice
lead
72
to
lead
77
at
REMOTE
14
receptacle
RC13
pin
D.
e.
Cover
splice
with
electrical
tape
or
other
insulation.
f.
Close
and
secure
front
panel
access
door.
a
CAUTION:
WELDING
POWER
SOURCE
may
not
respond
with
output
corresponding
to
set
value.
Be
sure
welding
power
source
main
control
board
has
been
modified
to
use
a
0
to
+10
volt
command.
See
welding
power
source
Owners
Manual
for
modification
procedure.
CHANGES
TO
SECTION
8
PARTS
LIST
Change
Parts
List
as
follows:
18-.
PCi
148320.
19-
1065380007751
19-
094481
152371
0937270007459
141
162
134731
079
739
152370
079534
079 739
154098
+141
700
**First
digit
represents
page
no
digits
following
dash
represent
item
no.
+Included
w/Hub
&
Spindle
Assembly.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Dia.
--
Mkgs.
Part
No.
Replaced
With
Description
Quantity
19-
19-
....116964..
094482...
20-
072
292
20-
Added
20-
CIRCUIT
CARD,
voltage
control
1
BRACKET,
mtg
potentiometer
1
HOUSING
PLUG
&
PINS,
(consisting
of)
1
CONNECTOR,
circ
pin
push-in
18-l4ga
14
CONNECTOR,
circ
clamp
str
rlf
1
Clamps
are
now
md.
w/Connectors
HOUSING
PLUG
&
SOCKETS,
(consisting
of)
....
1
CONNECTOR,
circ
skt
push-in
24-l8ga
14
CONNECTOR,
circ
clamp
str
rif
1
SHAF1~
support
spool
1
RING,
retaining
ext
.625
shaft
x
.O5Othk
1
WASHER,
flat
stl
.640
ID
x
1.000
OD
x
I
4ga
thk
..
I
Added
+605
941
OM.135
583C
3/92
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
rating
label
or
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
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.
Motor
Connection
3
3-5.
Voltage
Sensing
Connections
3
3-6.
Robot
Interface
Welding
Power
Source
Connections
4
3-7.
Robot
Interface
Robot
Control
Unit
Connections
4
3-8.
Arc
Failure
Light
Terminal
Strip
Connections
5
3-9.
Preset
Controls
6
3-10.
Peak
Amps/Inductance
Control
6
3-11.
Preflow,
Postflow,
And
Burnback
Time
Presets
6
3-12.
Welding
Wire
Installation
7
3-13.
Setting
DIP
Switches
On
DVC
Board
PCI
7
SECTION
4OPERATOR
CONTROLS
4-1.
Power
Switch
8
4-2.
Jog
Push
Buttons
8
4-3.
Purge
Push
Button
8
4-4.
Voltmeter
8
4-5.
Wire
Speed
Meter
8
4-6.
Peak
Amps/Inductance
Meter
8
4-7.
Indicator
Lights
8
SECTiON
1
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
1-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
A.
General
The
following
safety
alert
symbol
and
signal
words
are
Information
presented
in
this
manual
and
on
various
a-
used
throughout
this
manual
to
call
attention
to
and
den
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
tify
different
levels
of
hazard
and
special
instructions.
design,
installation,
operation,
maintenance,
and
It
This
safety
alert
symbol
is
used
with
the
signal
troubleshooting
which
should
be
read,
understood,
and
4~
words
WARNING
and
CAUTION
to
call
atten
followed
for
the
safe
and
effective
use
of
this
equipment.
tion
to
the
safety
statements.
B.
Safety
WARNING
statements
identify
procedures
or
The
installation,
operation,
maintenance,
and
trouble-
practices
which
must
be
followed
to
avoid
seri
shooting
of
arc
welding
equipment
requires
practices
ous
personal
injury
or
loss
of
life.
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in-
CAUTION
statements
identify
procedures
or
stalled,
operated,
and
maintained
only
by
qualified
per-
practices
which
must
be
followed
to
avoid
minor
sons
in
accordance
with
this
manual
and
all
applicable
personal
injury
or
damage
to
this
equipment.
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
Safety
Rules
For
Operation
Of
Arc
Weld-
IMPORTANT
statements
identify
special
instructions
ing
Power
Source
in
the
welding
power
source
Owners
necessary
for
the
most
efficient
operation
of
this
equip
Manual.
ment.
SECTION
2
SPECIFICATIONS
Table
2-1.
Specifications
Component
Dimensions
Weight
Height
Width
Depth
Net
Ship
Robot
Interface
22-1/2in.
(572
mm)
16-1/2in.
(419
mm)
6~1/4in.*
(159
mm)
38lbs.
(17
kg)
Total
61
lbs.
(27.7
kg)
Gas/Current
Sensing
Control
4-1/2
in.
(108
mm)
5-1/2
in.
(140
mm)
10-1/2
in.
(267
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
gas/current
sensing
control
contains
the
gas
valve,
The
robot
interface
control
is
designed
to
interface
with
a
shunt,
and
current
sensing
reed
relay.
GMF
robot
and
an
Arc
Pak
350,
Deltaweld,
Maxtron,
or
These
components
function
with
the
robot
system
when
Pulstar
450
welding
power
source.
This
unit
provides
using
the
Gas
Metal
Arc
Welding
(GMAW)
process.
digital
display
of
weld
volts,
wire
feed
speed,
and
peak
amperage
or
inductance.
OM-135
583
Page
1
SECTION
3
INSTALLATION
3-1.
SITE
SELECTION
Select
an
installation
site
which
provides
the
following:
1.
Correct
input
power
supply
(see
unit
rating
label)
2.
Shielding
gas
supply
(if
applicable)
3.
Water
supply
(if
applicable)
4.
Adequate
ventilation
and
fresh
air
supply
5.
No
flammables
6.
A
clean
and
dry
area
7.
Proper
temperature
that
avoids
extremes
of
heat
or
cold
8.
Proper
airflow
around
unit
9.
Adequate
space
to
open
and
remove
cover
and
wrapper
for
installation,
maintenance,
and
repair
functions.
Mounting
holes
provide
the
capability
to
install
and
se
cure
the
system
components
in
a
permanent
location.
Table
2-1
gives
overall
dimensions.
3-2.
EQUIPMENT
INSTALLATION
A.
Supplied
Equipment
The
following
equipment
is
supplied
as
standard
and
re
quires
installation
or
assembly:
1.
Weld
Control
with
Gas/Current
Sensing
Control
Cord
and
Motor
Cord
2.
Gas/Current
Sensing
Control
3.
Hub
and
Spindle
Assembly
4.
Spindle
Support
5.
10
ft.
(3
m)
Weld
Control
Welding
Power
Source
Interconnecting
Cords
6.
10
ft.
(3m)
Gas
Hose
7.
Voltage
Sensing
Cord
B.
Equipment
Location
When
deciding
on
equipment
location,
consider
the
fol
lowing:
1.
The
equipment
must
be
mounted
to
a
structure
capable
of
supporting
the
weight
of
the
equip
ment.
2.
The
lead
lengths
of
the
cords
supplied
with
the
equipment
will
limit
the
area
in
which
the
equip
ment
can
be
located.
Some
cords
can
be
ex
tended
by
using
optional
extension
cords
(check
with
welding
equipment
distributor).
OM-135
583
Page
2
3.
The
interconnecting
cords
must
be
routed
so
that
they
are
not
caught,
pinched,
or
strained
during
welding
operations.
4.
One
weld
output
cable
must
be
routed
through
the
Gas/Current
Sensing
control.
5.
Welding
wire
must
be
routed
so
that
it
does
not
contact
the
weld
control
or
any
other
grounded
equipment.
C.
Equipment
Installation
Obtain
appropriate
mounting
brackets
or
adapter
plates
as
necessary
and
mounting
hardware.
Prepare
struc
ture
for
equipment
installation.
Secure
weld
control,
Gas/Current
Sensing
control,
and
all
other
equipment
onto
structures
in
the
welding
area.
D.
Hub
Installation
(Figure
3-1)
The
hub
assembly
is
supplied
with
the
robot
interface.
Remove
the
hub
assembly
from
the
shipping
carton,
and
install
it
as
follows:
1.
Remove
hex
nut
from
end
of
hub
support
shaft.
2.
Align
keyway
and
insert
hub
support
shaft
through
selected
hole
in
hub
support.
Hole
selec
tion
in
hub
support
depends
on
wire
spool
size.
Be
sure
the
brake
washers
are
properly
seated
in
the
hub.
3.
Reinstall
hex
nut
Onto
support
shaft.
Tighten
hex
nut
until
a
slight
drag
is
felt
while
turning
hub.
4.
Install
welding
wire
according
to
Section
3-12.
SA-126
870
Hub
Support
Shaft
Hub
Assembly
Washer
Hex
Nut
Hub
Support
Fiber
Figure
3-1.
Hub
Assembly
Installation
3-3.
GAS/CURRENT
SENSING
CONTROL
INTER
CONNECTIONS
(Figure
3-2)
a
WARNING:
ELECTRIC
SHOCK
can
kilt.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
interconnections.
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.
Figure
3-2.
Right
Side
View
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
sens
ing
control,
and
rotate
threaded
collar
fully
clock
wise.
B.
Weld
Cable
Connections
For
Electrode
Positive/Reverse
Polarity,
route
cable
from
welding
power
source
POSITIVE
weld
output
ter
minal
to
the
gas/current
sensing
control,
through
the
cur
rent
sensing
reed
relay,
to
the
wire
drive
assembly,
and
connect
cable
to
weld
cable
terminal
(see
Motor/Drive
Assembly
Owners
Manual
for
location).
C.
Gas
Connections
Connect
hose
from
gas
regulator/flowmeter
(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/flowmeter
at
the
source.
3-4.
MOTOR
CONNECTION
Align
keyways,
insert
14-pin
plug
from
motor
cord
into
matching
receptacle
RC7
on
weld
control,
and
tighten
threaded
collar.
Align
keyways,
insert
14-socket
plug
from
motor
cord
into
matching
free-hanging
receptacle
from
motor,
and
tighten
threaded
collar.
3-5.
VOLTAGE
SENSING
CONNECTIONS
(Figure
3-3)
1.
Align
keyway,
insert
4-socket
plug
into
matching
receptacle
RC12
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Connect
lead
with
ring
terminal
to
wire
drive
as
sembly,
along
with
the
weld
cable
from
the
weld
ing
power
source,
as
shown
in
Figure
3-3.
3.
Connect
lead
with
clamp
to
the
workpiece.
Flat
Washer
Weld
Cable
Lug
Location
S.0401
Motor
Control
Receptacle
RC7
Location
Gas/Current
Sensing
Control
Receptacle
RC9
14-Pin
Receptacle
RC13
Strain
Relief
10-Pin
Receptacle
RC15
Location
17-
PIn
Receptacle
RC16
Robot
Control-
Robot
Interface
Receptacle
RC17
Nut
Figure
3-3.
Voltage
Sensing
Connections
At
Wire
Drive
Assembly
OM-135
583
Page
3
3-6.
ROBOT
INTERFACE
WELDING
POWER
Lockout/tagging
procedures
Consist
of
padlock-
SOURCE
CONNECTIONS
(Figure
3-2)
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
oft
and
~
WARNING:
ELECTRIC
SHOCK
can
kill.
red-tagging
circuit
breaker
or
other
disconnect-
Do
not
touch
live
electrical
parts.
ing
device.
a
CAUTION:
IMPROPER
USE
OF
SOCKET
r
Shut
down
unit,
welding
power
source,
and
can
cause
equipment
damage.
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
Use
socket
r
only
when
using
a
Karel
Coat
rol
interconnections.
ler.
Lockout/tagging
procedures
consist
of
padlock-
Activating
+24
volts
dc
at
socket
r
can
damage
ing
line
disconnect
switch
in
open
position,
re-
other
brand
equipment
connected
to
recep
moving
fuses
from
fuse
box,
or
shutting
off
and
tacle
RC1
7.
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
1.
Obtain
a
proper
cord
and
37-pin
Amphenol
plug
(not
supplied).
There
are
four
cords
supplied
for
interconnection
be-
2.
Connect
conductors
at
one
end
of
cord
to
appropri
tween
the
robot
interface
and
welding
power
source.
Ex-
ate
sockets
in
plug.
amine
cords
and
select
proper
cord
for
the
connection.
3.
Align
keyway,
insert
37-pin
plug
into
matching
re
A.
REMOTE
14
Connections
ceptacleon
robot
interface,
and
rotate
threaded
col
lar
fully
clockwise.
1.
Align
keyway,
insert
14-socket
plug
into
matching
4.
Route
and
connect
conductors
at
remaining
end
of
receptacle
RC13
on
robot
interface,
and
rotate
cord
to
the
robot
control
unit.
threaded
collar
fully
clockwise.
The
input
and
output
signals
at
the
sockets
of
receptacle
2.
Align
keyway,
insert
14-pin
plug
into
matching
re-
RC17
by
means
of
the
robot
interface
control
circuitry
ceptacle
on
welding
power
source,
and
rotate
are
as
follows:
threaded
collar
fully
clockwise.
Socket
A:
+
Arc
Volts;
0-10
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
A
(ana
B.
REMOTE
17
Connections
log
common)
equals
0-50
volts
dc
output.
1.
Align
keyway,
insert
17-socket
plug
into
matching
Socket
B:
Arc
Volts;
analog
common
for
Socket
B
(+
receptacle
RC16
on
robot
interface,
and
rotate
Arc
Volts).
threaded
collar
fully
clockwise.
Socket
C:
+
Peak~Amps;
0-10
volts
dc
input
from
ro
2.
Align
keyway,
insert
17-pin
plug
into
matching
re-
bot
control
unit
with
respect
to
Socket
0
ceptacle
on
welding
power
source,
and
rotate
(analog
common)
equals
0-500
amperes
thread
collar
fully
clockwise.
dc
output.
Socket
D:
Peak
Amps;
analog
common
for
Socket
C
C.
REMOTE
10
Connections
(+
Peak
Amps).
1.
Align
keyway,
insert
10-socket
plug
into
matching
Socket
E:
+
Wire
Feed
Speed;
0-10
volts
dc
input
receptacle
Rd
5
on
robot
interface,
and
rotate
from
robot
control
unit
with
respect
to
threaded
collar
fully
clockwise.
Socket
F
(analog
common)
equals
0-1000
1PM.
2.
Align
keyway,
insert
plug
into
matching
recep
Socket
F:
Wire
Feed
Speed;
analog
common
for
tacle
on
the
welding
power
source,
and
rotate
threaded
collar
fully
clockwise.
Socket
E
(+
Wire
Feed
Speed).
Socket
J:
Voltage
Feedback;
tOOV
(arc
voltage)
=
If
the
welding
power
source
is
equipped
with
a
REMOTE
1
OV
(feedback
signal)
with
respect
to
14/17
selector
switch,
place
the
switch
in
the
REMOTE
Socket
K.
14
position.
Make
connections
to
both
REMOTE
14
and
Socket
K:
Voltage
Feedback;
analog
common
for
REMOTE
17
receptacles.
Socket
J.
Socket
L:
Current
Feedback;
500A
(weld
current)
=
3-7.
ROBOT
INTERFACE
ROBOT
CONTROL
1OV
(feedback
signal)
with
respect
to
UNIT
CONNECTIONS
(Figure
3-2)
Socket
M.
~
WARNING:
ELECTRIC
SHOCK
can
kill.
Socket
M:
Current
Feedback:
analog
common
for
Do
not
touch
live
electrical
parts.
Socket
L.
Socket
N:
Wire
Stuck
Signal;
return
for
Socket
P.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
Socket
P:
Wire
Stuck
Signal
output
to
robot
control
lockout/tagging
procedures
before
making
unit
with
respect
to
Socket
N;
indicates
interconnections.
wire
is
stuck
to
work.
OM-135
583
Page
4
Socket
A:
Contactor
Control;
contact
closure
from
ro-
unit.
Obtain
proper
length
of
18
gauge/2-conductor
cord
bot
control
unit
with
respect
to
Socket
a,b
for
this
connection,
and
proceed
as
follows:
(Circuit
Common).
WARNING:
ELECTRIC
SHOCK
can
kill.
Socket
S:
Gas
Control;
contact
closure
from
robot
Do
not
touch
live
electrical
parts.
control
unit
with
respect
to
Socket
a,b
(Cir-
Shut
down
unit,
welding
power
source,
and
cuit
Common).
robot,
and
disconnect
input
power
employing
Socket
U:
Jog
Forward;
contact
closure
from
robot
lockouVtagging
procedures
before
making
in
terconnections.
control
unit
with
respect
to
Socket
a,b
(Cir
cuit
Common).
Lockout/tagging
procedures
consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
Socket
V:
Jog
Reverse;
contact
closure
from
robot
moving
fuses
from
fuse
box,
or
shutting
off
and
control
unit
with
respect
to
Socket
a,b
(Cir-
red-tagging
circuit
breaker
or
other
disconnect
cuit
Common).
ing
device.
Sockets
a,b:
Circuit
Common
for
Sockets
R,
S,
U,
and
1.
For
robot
control
units
when
24
vdc
is
used
(Fig
V;
all
circuit
voltages
referenced
to
this
ure
3-4):
point,
a.
Route
cord
through
strain
relief
on
right
side
panel
of
robot
interface,
and
make
proper
con-
Socket
d:
Current
Detect
output
to
robot
control
unit
nections
to
2TE
and
2TF.
with
respect
to
Socket
m.
b.
Route
and
connect
remaining
end
of
cord
to
Socket
h:
Weld
Standby
output
to
robot
control
unit
weld
alarm
terminal
and
ground
connection
at
with
respect
to
Socket
m
(Digital
Com-
the robot
control
unit.
mon);
indicates
robot
interface
is
In
stand
by.
This
is
a
normally-open
contact.
c.
Connect
+24
vdc
to
common
relay
contact
ter
minal.
Socket
m:
Digital
Common
for
Sockets
d
and
h.
2.
For
robot
control
units
when
115
or
24
vac,
or
24
Socket
r:
+24
volts
dc.
(Option
For
Karel
Controller)
vdc
is
used
(Figure
3-4):
Socket
s:
Chassis
ground.
a.
Route
cord
through
strain
relief
on
right
side
panel
of
robot
interlace,
and
make
proper
con-
IMPORTANT:
The
remaining
sockets
in
the
receptacle
nections
to
2TE
and
2TF.
are
not
used.
b.
Obtain
a
115
or
24
vac,
or
24
vdc
isolation
relay
CR1,
and
install
into
robot
control.
3-8.
ARC
FAILURE
LIGHT
TERMINAL
STRIP
CONNECTIONS
(Figure
3-4)
c.
Route
and
connect
remaining
end
of
cord
to
one
side
of
the
normally-open
robot
control
relay
There
are
two
terminal
strips
inside
the
robot
interface
contact
and
ground.
for
control
connections.
Loosen
screws
on
strain
relief
on
unit
right
side
panel
if
applicable,
open
front
panel
ac-
d.
Connect
+24
vdc
to
remaining
side
of
normally
cess
door,
and
locate
appropriate
terminal
strip
for
con-
open
robot
control
relay
contact.
nections.
Tighten
screws
on
strain
relief
if
necessary,
e.
Connect
a
lead
from
one
side
of
robot
control
and
close
and
secure
front
panel
access
door
when
pro-
coil
to
weld
alarm
terminal.
cedure
is
finished.
f.
Connect
proper
voltage
source
(115
vac,
24
The
ARC
FAILURE
light
on
the
robot
interface
front
pan-
vac,
or
24
vdc)
between
common
terminal
and
el
is
turned
on
and
off
by
a
signal
from
the
robot
control
remaining
side
of
robot
control
relay
coil.
OM-135
583
Page
5
Robot
Control
Unit
Robot
Interface
Weld
Alarm
Terminal
If
So
Equipped
1.
Open
interface
control
door.
Arc
Failure
2TF
Indicator
Light
Arc
Failure
2TF
Indicator
Light
2.
Locate
Preset
circuit
board
PC7
on
inside
of
door
(see
Figure
3-5).
3.
Locate
WFS
Preset
R3
and
Voltage
Preset
R4
on
PC7.
4.
While
watching
VOLTS
and
WIRE
FEED
meters,
adjust
potentiometers
to
desired
preset
conditions.
5.
OM-135
583
Page
6
Close
and
secure
interface
control
door.
3-11.
PREFLOW,
POSTFLOW,
AND
BURNBACK
TIME
PRESETS
On
the
left
side
of
the
interface
control
there
are
three
snap-in
blanks.
Beneath
these
snap-in
blanks
are
screwdriver
adjustable
potentiometers.
The
top
poten
tiometer
sets
preflow
time
from
0
to
6 seconds.
The
middle
potentiometer
sets
postf
low
time
from
0
to
6
sec
onds.
The
bottom
potentiometer
sets
burnback
time
from
approximately
5
to
250
milliseconds.
Common
Terminal
If
So
Equipped
/
CR/
2T~
+24VDC
Robot
Control
Unit
Common
Terminal
Weld
Alarm
Terminal
If
So
Equipp~~~_1/
If
So
Equipped
To
Voltage
Source
(115VAC,
24VAC,
24VDC)
Isolation
Relay
CR1
Robot
Control
Robot
Interlace
CR1
2TE
+24V0C
f--j
~0~-
Ref
SA-139
296
Figure
3-5.
Preset
Board
PC7
3-10.
PEAK
AMPS/INDUCTANCE
CONTROL
This
unit
is
shipped
for
use
with
a
two
analog
channel
robot.
This
means
that
peak
amperage
or
inductance
can
be
set
at
the
interface
using
potentiometer
R4.
R4
is
located
beneath
the
snap-in
blank
on
the
lower
left
cor
ner
of
the
interface
front
door.
This
unit
can
be
used
with
a
three
channel
robot
where
the
robot
control
sets
peak
amperage.
A
jumper
link
must
be
moved
on
terminal
strip
1
T
to
accomodate
the
three
channel
robot.
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
changing
internal
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.
1.
Open
interface
control
door.
Locate
terminal
strip
1
T.
2.
Move
the
jumper
from
between
1
TE
and
1
TF
to
be
tween
lTD
and
1TE.
3.
Close
and
secure
interlace
control
door.
S-0292
Figure
3-4.
Arc
Failure
Light
Connections
3-9.
PRESET
CONTROLS
(Figure
3-5)
The
unit
is
shipped
from
the
factory
with
preset
values
of
wire
feed
speed
and
voltage
(300
ipm
at
20
volts).
If
a
value
is
not
preset
for
the
voltage
and
wire
feed
speed,
the
robot
system
will
not
start.
To
change
preset
values,
proceed
as
follows:
j~
WARNING:
ELECTRIC
SHOCK
can
kill.
_____
Do
not
touch
live
electrical
parts.
Power
is
applied
to
the
weld
control
during
the
following
procedure.
3-12.
WELDING
WIRE
INSTALLATION
(Figure
3-6)
C.
Adjustment
Of
Hub
Tension
(Figure
3-1)
Figure
3-6.
Optional
Wire
Reel
And
Reel-Type
Wire
Installation
A.
Installation
Of
Spool-Type
Wire
1.
Remove
retaining
ring.
2.
Slide
spool
of
wire
onto
hub
so
that
wire
feeds
off
bottom
of
spool.
3.
Rotate
spool
until
hole
in
spool
aligns
with
pin
in
hub.
Slide
spool
onto
hub
until
it
seats
against
back
flange
of
the
hub.
4.
Reinstall
retaining
ring
onto
hub.
B.
Installation
Of
Optional
Wire
Reel
And
Reel-
Type
Wire
1.
Remove
retaining
ring
and,
if
applicable,
wire
reel
assembly
from
hub.
2.
Lay
wire
reel
assembly
flat
on
a
table
or
floor.
3.
Remove
spanner
nut
from
wire
reel
assembly.
4.
Remove
wire
retainer,
and
install
wire
onto
wire
reel.
Be
sure
that
wire
feeds
off
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.
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.
3-13.
SETTING
DIP
SWITCHES
ON
DVC
BOARD
PCi
(Figure
3-7)
DIP
switches
Si
and
S2
on
DVC
board
PC
1
allow
setting
the
proper
command
signal
voltage
level
for
controlling
voltage
output
at
a
welding
power
source.
To
change
factory
set
position
of
DIP
switches
from
a
Deltaweldfi
451
to
another
welding
power
source,
proceed
as
fol
lows:
Shut
down
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
setting
DIP
switches.
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.
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
properly
grounded
wrist
strap
BE
FORE
handling
circuit
boards.
Perform
work
only
at
a
static-safe
work
area.
1.
Open
Computer
Interface
front
panel
access
door.
2.
Locate
DVC
board
PCi
on
rear
panel
inside
the
interface.
3.
Set
position
of
DIP
switches
Si
and
S2
according
to
label
inside
interface
and
Figure
3-7
for
appro
priate
welding
power
source.
4.
Close
and
secure
door.
a
CAUTION:
INCORRECT
DVC
BOARD
DIP
SWITCH
POSITION
can
cause
equipment
malfunction.
DVC
DIP
switch
is
facto,j
set
for
operation
with
Deltaweldfi
451
welding
power
source.
See
Figure
3-7
for
DVC
DIP
switch
setting
when
using
another
welding
power
source.
Retaining
Ring
Wire
Retainer
Wire
Reel
Spanner
Nut
Hub
Hub
Support
SC~127
308
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
OM-135
583
Page
7
DVC
SWITCH
SETTINGS
S2
Si
i
2
i
2
3
4
5
DELTAWELD
300
ON ON
ON
DELTAWELD
451
0
ON
ON
DELTAWELD
651
0
ON ON
MAXTRON
300,
400
ON
ON
MAXTRON
450
ON
ON
ON
XMT
200/300
ON ON
ON
ARC
PAK35O
ON
ON
ON
SHOPMASTER
300
ON
ON ON
DIMENSION
400
ON
A
A
ON
Figure
3-7.
DVC
DIP
Switch
Setting
Label
SECTION
4-OPERATOR
CONTROLS
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
FWD
and
JOG
REV
push
buttons
are
momen
tary-contact
switches.
Pushing
either
JOG
button
ener
gizes
the
wire
feed
motor
without
energizing
the
welding
power
source
contactor.
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.
4-5.
WIRE
SPEED
METER
(Figure
4-1)
The
wire
speed
meter
displays
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
whde
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
five
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.
O
On
For
Optional
Soft
Start.
Turn
Off
Si
-3.
A
On
For
Optional
Hot
Start.
S-150864.A
OM-135
583
PageS
Contactor
indicator
Light
Gas
Indicator
Light
Wire
Feed
Indicator
Light
Current
Indicator
Light
Figure
4-1.
Front
Panel
Controls
Circuit
Breaker
(See
Section
6-2)
Power
Switch
Purge
Push
Button
Switch
Jog
REV.
Push
Button
Switch
Jog
FWD.
Push
Button
Switch
Ret.
SB-hg
645-A
Wire
Feed
Speed
010V
=
0-1000
1pm
Output
Volts
0-1OV
=
O-50V
Peak
Amps
0-500
Amps
Output
Jog
Advance
Shielding
Ge.
Figure
5-1.
Input
And
Output
Signal
Timing
Chart
Indicator
Light
SECTION
5
SEQUENCE
OF
OPERATION
Jog
Retract
Robot
To
Weld
Control
Ge.
On
Arc
On
IPower
On,
Standby
Weld
Control
J
Corrent
Detect
To
Robot
1
1Wlra
Stock
Olltpot
Voltage
Wire
Fend
Normal
Abnormal
Ret.
TA-ass
0b4
OM-1
35
583
Page
9
2.
Slide
the
following
items
onto
the
hub
support
shaft
in
order
given.
a.
Spring
b.
Keyed
Washer
c.
Fiber
Washer
d.
Brake
Washer
e.
Hub
f.
Brake
Washer
g.
Fiber
Washer
3.
Align
keyway,
and
insert
hub
support
shaft
through
selected
hole
in
hub
support.
4.
Install
hex
nut
onto
hub
support
shaft.
Tighten
hex
nut
until
a
slight
drag
is
felt
while
turning
hub.
5.
Install
welding
wire
according
to
Section
3-12.
6-4.
DISPLAY
BOARD
PC4
METER
CHECK
(Fig
ure
6-2)
Check
points
are
provided
on
the
display
board
PC4
for
checking
power
supply
and
input
command
for
the
meters.
f~
WARNING:
ELECTRIC
SHOCK
can
kill.
_____
Do
not
touch
live
electrical
parts.
Be
sure
that
personnel
performing
testing
procedures
are
familiar
with
and
follow
stan
dard
safety
practices.
Shut
down
unit
before
making
or
changing
meter
or
test
equipment
lead
connections.
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
a
properly
grounded
wrist
strap
BEFORE
handling
circuit
boards.
Transport
all
static-sensitive
components
in
proper
static-shielding
carriers
and
pack
ages.
Perform
work
only
at
a
static-safe
work
area.
1.
Open
robot
interface
access
door.
2.
Locate
display
board
PC4.
3.
Check
voltage
according
to
Figure
6-2.
4.
If
a
meter
power
supply
and
command
voltage
is
correct
and
the
meter
is
not
working,
replace
the
meter
(see
Section
6-5
and
contact
nearest
Fac
tory
Authorized
Service
Station).
5.
If
the
power
supply
or
command
voltage
is
incor
rect,
replace
display
board
PC4
(see
Section
6-5
and
contact
nearest
Factory
Authorized
Service
Station).
Ring
Spanner
Nut
Wire
Reel
Keyed
Washer
Brake
Washer
Hub
Support
Shaft
OPTIONAL
Hub
Fiber
Washer
Fiber
Washer
Brake
Washer
Figure
6-1.
Hub
And
Reel
Assemblies
Hub
Support
Ref.
SC.127
328
OM-135
583
Page
11
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
inspect
ing,
maintaining,
or
servicing.
Lockoutltagging
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.
6-6.
TROUBLESHOOTING
a
Ref.
SD-117
838-B
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
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.
CAUTION:
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
properly
grounded
wrist
strap
BE
FORE
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.
Allow
cooling
period
before
servicing.
Troubleshooting
to
be
performed
only
by
qualified
persons.
It
is
assumed
that
the
unit
was
properly
installed
accord
ing
to
Section
3
of
this
manual,
the
operator
is
familiar
with
the
function
of
controls,
the
robot
interface
was
working
properly,
and
that
the
trouble
is
not
related
to
the
welding
process.
The
following
table
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
robot
interface.
Use
this
table
in
conjunction
with
the
circuit
diagram
while
performing
troubleshooting
proce
dures.
If
the
trouble
is
not
remedied
after
performing
theseprocedures,
contact
the
nearest
Factory
Author
ized
Service
Station.
In
all
cases
of
equipment
malfunc
tion,
strictly
follow
the
manufacturers
procedures
and
instructions.
REAR
VIEW
OF
DISPLAY
BOARD
Pc4
Input
Command
For
Vo(ts
Meter
...O.5V
=
50V
Input
Command
For
Ammeter
-O.1V
=
100A
Figure
6-2.
Display
Board
Meter
Checks
Power
Supply
For
Volts
Meter
And
Ammeter
0-
5VDC
a
OM~135
583
Page
12
Table
6.1.
Troubleshooting
TROUBLE
PROBABLE
CAUSE
REMEDY
No
arc
voltage
control.
Output
control
connections.
Check
and
secure
connections
(see
Section
3-4).
Voltage
Board
PCi
not
working.
Replace
PCi
(see
Section
6-5
and
contact
near
est
Factory
Authorized
Service
Station).
Incorrect
robot
command
volt-
age.
Check
robot
command
voltage
at
Isolation
Board
PC5.
Command
voltage
should
be
0-10
vdc
be
tween
pins
X
(common)
and
Y
at
RC17.
Incorrect
robot
peak
command
current.
Check
robot
peak
command
current
at
Isolation
Board
PC5.
Peak
command
current
should
be
0-10
vdc
between
sockets
C
and
D
(common)
at
RC17.
Wire
speed
(1PM)
meter
goes
to
zero.
Incorrect
robot
command
volt-
age.
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
working.
Replace
PC2
(see
Section
6-5
and
contact
near
est
Factory
Authorized
Service
Station).
Unit
does
not
operate.
Fuse
Fl
Open.
Check
Fl
and
replace
if
necessary
(see
Section
6-2).
Correct
overload
problem
before
continu
ing
operation.
Circuit
breaker
CB1
tripped.
Check
CB1,
and
reset
if
necessary
(see
Section
6-2).
Correct
overload
problem
before
continu
ing
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
6-4).
If
check
points
are
okay,
replace
meter
(see
Section
6-5
and
contact
nearest
Factory
Autho
rized
Service
Station).
Display
Board
PC4
not
working.
Use
check
points
to
determine
if
power
is
avail
able
(see
Section
6-4).
If
check
points
do
not
test
okay,
replace
PC4
(see
Section
6-5
and
contact
nearest
Factory
Authorized
Service
Station).
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
working.
Replace
PC2
(see
Section
6-5
and
contact
near
est
Factory
Authorized
Service
Station).
Wire
feeds
at
maximum
only.
Tach
board
at
wire
drive
motor
not
working.
Replace
tach
board
(see
motor/drive
assembly
Owners
Manual).
Robot
moves
when
welding
wire
is
stuck.
Wire
stick
connection.
Be
sure
that
leads
from
robot
are
connected
to
sockets
P
and
N
at
RC17.
OM-135
583
Page
13
6-7.
USE
OF
INDICATOR
LIGHTS
FOR
TROUBLESHOOTING
On
Gas
flows:
System
normal
(on.)
Gas
Indicator
Light
II!
Gas
does
not
flow
Gas
flows:
Check
gas
valve
operation.
Check
gas
valve
operation
and
gas
line
for
leaks.
Check
interface
board
PC3.
I
Wire
feeds:
System
normal
(on).
Contactor
open:
Check
interconnecting
cords.
Check
interface
board
PC3.
Wire
does
not
feed:
Check
circuit
breaker
CB1
Check
relay
CR1.
Check
interface
board
PC3.
Contactor
closed:
Check
display
board
PC4.
Off
Contactor
open:
System
normal
(off).
~Off
Wire
does
not
feed:
System
normal
(off).
No
arc:
Replace
reed
relay.
Arc
started:
Replace
reed
relay.
Off
No
arc:
System
normal
(off).
I!
II 1!
No
arc:
Arc
started:
Check
weld
parameters.
Check
signal
from
robot.
Signal
should
be
24
vdc
between
terminals
2TLand
2TM.
Check
display
board
PC4.
Off
On
Gas
does
not
flow
System
normal
(off).
Contactor
Indicator
Lighr
~1~
Contactor
closed:
System
normal
(on).
On~
Wire
Feed
Indicator
Light
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
motor
board
PC2
On
II
Arc
started:
System
normal
(on).
Current
Indicator
Light
~1~
On
~
Arc
Failure
Indicator
Light
Off
No
arc:
Normal
during
idling.
Arc
started:
Normal
while
welding.
OM-135
583
Page
14
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Miller COMPUTER INTERFACE NSPR 8933 AND 9184 Owner's manual

Miller
Brand
Miller
Model
COMPUTER INTERFACE NSPR 8933 AND 9184
Category
Welding System
Type
Owner's manual
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