Miller KC304685 Owner's manual

Miller

October

1992

FORM:

OM-154

145

Effective

With

Serial

No.

KC304685

MODEL:

Robotic

Interface

Control

Gas/Current

Sensing

Control

Spool

Support

Assembly

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

MILLER

ELECTRIC

Mfg.

Co.

A

Miller

Group

Ltd..

Company

the

safety

material

throughout

both

manuals,

before

installing,

operating,

or

maintaining

this

equipment.

This

unit

and

these

instructions

are

for

use

only

P.O.

Box

1079

Appleton,

WI

54912

USA

by

persons

trained

and

experienced

In

the

safe

operation

of

welding

equip-

Tel.

414-734-9821

ment.

Do

not

allow

untrained

persons

to

install,

operate,

or

maintain

this

unit.

Contact

your

distributor

if

you

do

not

fully

understand

these

instructions.

Ref.

ST-157

095

PRINTED

IN

U

S.A

I

I

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1992

(Equipment

wlth.a

serial

number

preface

of

XC

or

newer)

This

limited

warranty

supersedes

all

warranties

and

is

exclusive

with

rro

other

guarantees

or

warranties

expressed

or

implied

i,t

LIMITED

WARRANTY



Sublect

to

the

terms

and

conditions

below.

MILLER

Electric

MIg

Co

.

dooleton

Wisconsin.

warrants

to

its

original

retail

purchaser

that

new

MILLER

equoment

sold

after

the

effective

date

of

this

limited

warranty

is

freest

de

fects

in

material

and

workmanship

at

the

time

it

is

shipped

by

MILLER

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES.

EXPRESS

OR

IMPLIED.

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS

Within

the

warranty

periods

listed

below.

MILLER

wilt

repair

or

replace

any

war

ranted

pans

or

components

that

tail

due

to

such

defects

in

material

or

workmanship

MILLER

must

be

notilied

in

writing

within

thirty

(30)

days

of

such

detect

or

failure,

at

which

lime

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.

AtI

warranty

time

periods

start

on

the

date

that

the

equipment

was

delivered

to

the

original

retail

purchaser.

and

are

as

follows

5

Years

Psrts

-

3

Years

Labor

Original

main

power

rectifiers

2

3

Years



Parts

and

Labor



TrsnslormerlRectiher

Power

Sources



Plasma

Arc

Cutting

Power

Sources



Semi-Automatic

and

Automatic

Wire

Feeders



Robots

3.

2

Years



Parts

and

Labor



Engine

Driven

Welding

Generators

INOTE.

Engines

are

warranted

separately

by

the

engine

manufacturer

I

d.

t

Year



Parts

and

Labor



Motor

Driven

Guns



Process

Controllers



Water

Coolant

Systems



HF

Units



Grids



Spot

Welders



Load

Banks



SDX

Transformers



Running

Gesr/Trsilers



Field

Options

(NOTE.

Field

options

are

covered

under

True

Blue

tor

the

remaining

warranty

period

of

the

product

they

are

installed

in,

or

for

a

minimum

of

one

year



whichever

is

grealer.I

5.

6

Months



Batteries

6.

90

Days



Parts

and

Labor

*

MIG

GunsiTIG

Torches



Plasma

Cutting

Torches



Remote

Controls



Accessory

Kits



Reolscement

Psr.o

MILLERS

True

BluarM

Limited

Warranty

shall

not

aoolb

to,

Items

lurnished

by

MILLER.

but

manufactured

by

others.

such

as

engines

or

trade

accessories

These

items

are

covered

by

the

manufacturers

warranty,

if

any

2

Consumable

componm3ls:

such

as

contact

tips,

cutting

nozzles,

confactors

and

relays

3,

Eguipmenl

th5t

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

eguioment

which

has

not

had

reasonable

and

necessary

maintenance,

or

equipment

which

hss

been

used

for

operation

outside

of

the

specifications

for

the

eouiomenl

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIAUJINDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EGUIPMENT

In

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

exclusive

remedies

shall

be.

at

MILLERS

option

tI

repsir,

or

(21

replacement,

or,

where

authorized

in

writing

by

MILLER

in

appropnsfe

cases.

13)

the

reasonable

cost

of

iepair

or

replace

ment

stan

authorized

MtLLER

service

station,

or

~(

payment

of

or

credit

for

the

pur

chase

price

Itess

reasonable

deprecialion

based

upon

actual

usel

upon

return

of

the

goods

at

customers

risk

and

expense.

MILLERS

oplion

of

repair

or

repfacemenf

will

be

F

0.8

Factory

at

Appleton.

Wisconsin.

or

F

0.8.

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

EX7ENT

PERMITTED

BY

LAW,

THE

REMEDIES

PROVtDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MILLER

BE

LIABLE

FOR

DIRECt

INDIRECT.

SPECIAL,

INCIDENTAL

OR

CONSEOUENTfAL

DAMAGES

IINCLUDf

NO

LOSS OF

PROFIT),

WHETHER

BASED

ON

CON

TRACt

TORT OR

ANY

OTHER

LEGAL

THEORY

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANT?,

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

IMPLICATION.

OPERATION

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALINO.

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

slates

in

the

U.S.A.

do

not

allow

limitations

of

how

long

an

implIed

warranty

lasts,

or

the

exclusion

of

incidental,

indirect,

special

or

consequential

damages,

so

the

above

limitation

or

esclusion

may

nol

apply

to

you.

This

warranty

provides

spe

cihc

legal

rights,

and

other

rights

may

be

availasle,

but

may

vary

from

state

to

state.

In

Canada.

legislation

in

some

provinces

provides

to,

certain

additional

warranties

or

remedies

other

Ihan

as

stated

herein,

and

to

the

extent

that

they

may

not

be

waived,

the

limitations

and

exclusions

set

out

above

may

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

and

other

righls

may

be

available.

buf

may

vary

from

province

to

province.

1.

~~1

5*

RECEIVING-HANDLING

Before

unpacking

equipment,

Check

carton

for

any

damage

that

may

haVB

occurrBd

during

shipment.

File

any

claims

for

loss

or

damage

with

the

delivering

carrier.

Assistance

for

filing

or

settling

claims

may

be

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

or

Style

Number.

Use

the

following

spaces

to

record

Model

Designation

and

Serial

or

Style

Number

of

your

unit.

The

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

miller

5192

ERRATA

SHEET

Deember

2,

1992

FORM:

OM-154

145

After

this

manual

was

printed,

refinements

in

equipment

design

occurred.

This

sheet

lists

exceptions

to

data

appearing

later

In

this

manual.

AMENDMENT

TO

SECTION

3INSTALLATION

Amend

Figure

3-2.

DVC

DIP

Switch

Setting

Label

S2

Si

1

2

1

2

3

4

5

DELTAWELD

300

ON

DELTAWELD

451

0

ON

DELTAWELD

651

0

ON ON

MAXTRON

300,

400

ON ON

MAXTRON

450

ON

XMT

200/300

ON

ARC

PAK35O

ON ON

ON

SHOPMASTER

300

ON

DIMENSION

400

ON

A

ON

PULSTAR

450

ON

Figure

3-2.

DVC

DIP

Switch

Setting

Label

AMENDMENT

TO

SECTION

8

ELECTRICAL

DIAGRAMS

Amend

Diagram

8-1.

Circuit

Diagram

For

Robotic

Interface

Control

(see

Pages

2

and

3

on

this

Errata

Sheet)

Amend

Diagram

8-3.

Circuit

Diagram

For

Interface

Board

PCi

(see

Pages

4

and

5

on

this

Errata

Sheet)

Amend

Diagram

8-4.

Circuit

Diagram

For

DVC

Board

PC8

(see

Pages

6

and

7

on

this

Errata

Sheet)

Add

Diagram

8-16.

Wiring

Diagram

For

Robotic

Interface

Control

(see

Pages

8

and

9

on

this

Errata

Sheet)

Add

Diagram

8-17.

Wiring

Diagram

For

Gas/Current

Sensing

Control

(see

Page

10

on

this

Errata

Sheet)

Add

Diagram

8-18.

Wiring

Diagram

For

Optional

RCSP-R

Panel

(see

Page

ii

on

this

Errata

Sheet)

AMENDMENT

TO

SECTION

9

PARTS

LIST

Amend

Parts

List

as

follows:

Dia.

Part

Mkgs.

No.

47-

Added

49-7

083147

49-

115092

49-

115093

49-25

..

PC8

..

148320

~First

digit

represents

page

no



digits

following

dash

represent

item

no.

BE

SURE

TO

PROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

DVC

SWITCH

SETTINGS

O



On

For

Optional

Soft

Start.

Turn

Off

Si

-3.

A



On

For

Optional

Hot

Start.

S.150

864~B

Replaced

With

Description

070

371

.

BLANK,

snap-in

nyl

1.093/1.125

mtg

hole

black

1

Deleted

115

092

.

HOUSING

PLUG

&

SOCKETS,

(qty

chg

added

PLG24)

3

115

093

.

HOUSING

PLUG

&

SOCKETS,

(qty

chg

added

PLG28)

2

152

371

.

CIRCUIT

CARD,

voltage

control

(Eff

w/KC330884)

1

Quantity

Diagram

8-1.

Circuit

Diagram

For

Robotic

Interface

Control

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ARC

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SAFETY

PRECAUTIONS

a

WARNING

ARC

WELDING

can

be

hazardous.

PROTECT

YOURSELF

AND

OTHERS

FROM

POSSIBLE

SERIOUS

INJURY

OR

DEATH.

KEEP

CHILDREN

AWAY.

PACEMAKER

WEARERS

KEEP

AWAY

UNTIL

CONSULTING

YOUR

DOCTOR.

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as

in

most

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to

certain

hazards

occurs.

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sate

when

precautions

are

taken.

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given

below

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only

a

summary

of

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more

complete

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that

will

be

found

in

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Safety

Standards

listed

on

the

Read

and

follow

all

Safety

Standards.

HAVE

ALL

INSTALLATION,

OPERATION,

MAINTENANCE,

AND

REPAIR

WORK

PERFORMED

ONLY

BY

QUALIFIED

PEOPLE.

ELECTRIC

SHOCK

can

kill.

Touching

live

electrical

parts

can

cause

fatal

shocks

or

severe

burns.

The

electrode

and

work

circuit

is

electrically

live

whenever

the

output

is

on.

The

input

power

circuit

and

machine

internal

circuits

are

also

live

when

power

is

on.

in

semiautomatic

or

automatic

wire

welding,

the

wire,

wire

reel,

drive

roll

housing,

and

all

metal

parts

touching

the

welding

wire

are

electrically

live.

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installed

or

improperly

grounded

equipment

is

a

hazard.

1.

Do

not

touch

live

electrical

parts.

2.

Wear

dry,

hole-free

insulating

gloves

and

body

protection.

3.

Insulate

yourself

from

work

and

ground

using

dry

insulating

mats

or

covers.

ARC

RAYS

can

burn

eyes

and

skin;

ARC

RAYS

NOISE

can

damage

hearing.

Arc

rays

from

the

welding

process

produce

intense

heat

and

strong

ultraviolet

rays

that

can

burn

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

NOISE

2.

3.

4.

5.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

ANSI

Z49.

I

listed

in

Safety

Standards)

to

protect

your

face

and

eyes

when

welding

or

watching.

Wear

approved

safety

glasses.

Side

shields

recommended.

Use

protectIve

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

Wear

protective

clothing

made

from

durable,

flame-resistant

1.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

material

(wool

and

leather)

and

foot

protection.



I,

.

-.-

to

your

health.

FUMES

AND

GASES

can

be

hazardous

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health.

5.

6.

wearing

an

air-supplied

respirator.

Shielding

gases

used

for

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

welding

can

displace

air

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.

Do

not

weld

in

locatIons

near

degreasing,

cleaning,

or

spraying

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

operations.

The

heat

and

rays

of

the

arc

can

react

with

vapors

to

form

highly

toxic

and

irritating

gases.

.

remove

welding

fumes

and

gases.

7.

Do

not

weld

on

coated

metals,

such

as

galvanized,

lead.

or

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

cadmium

plated

steel,

unless

the

coating

is

removed

from

the

4.

Read

the

Material

Safety

Data

Sheets

(MSDS5)

and

the

manufacturers

instruction

for

metals,

consumables,

coatings,

weld

area,

the

area

is

well

ventilated,

and

if

necessary,

while

wearing

an

air-supplied

respirator.

The

coatings

and

any

metals

and

cleaners.

containing

these

elements

can

give

off

toxic

fumes

if

welded.

WELDING

can

cause

fire

or

explosion.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

Sparks

and

spatter

fly

off

from

the

welding

arc.

The

flying

sparks

and

hot

metal,

weld

spatter,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

burns.

Accidental

contact

of

electrode

or

welding

wire

to

metal

obiects

can

cause

sparks,

overheating,

or

fire,

6.

7.

8.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

Do

not

weld

on

closed

containers

such

as

tanks

or

drums.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long.

possibly

unknown

paths

and

causing

electric

shock

and

fire

1.

Protect

yourself

and

others

from

flying

sparks

and

hot metal.

hazards.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

9.

Do

not

use

welder

to

thaw

frozen

pipes.

3.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

10.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

If

this

is

not

possible,

tightly

cover

them

with

approved

covers,

contact

tip

when

not

in

use.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

11.

Wear

oil-free

protective

garments

Such

as

leather

gloves.

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

heavy

shirt,

cuffiess

trousers,

high

shoes,

and

a

cap.

4

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury,

I

Chipping

and

grinding

cause

flying

metal.

As

welds

~

cool,

they

can

throw

off

slag.

I.

2.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

recommended.

Wear

proper

body

protection

to

protect

skin.

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

When

making

input

connections,

attach

proper

grounding

conductor

first.

7.

Turn

off

all

equipment

when

not

in

use.

8.

Do

not

use

worn,

damaged.

undersized,

or

poorly

spliced

cables.

9.

Do

not

wrap

cables

around

your

body.,

10.

Ground

the

workpiece

to

a

good

electrical

(earth)

ground.

11.

Do

not

touch

electrode

if

in

contact

with

the

work

or

ground.

12.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

13.

Wear

a

safety

harness

f

working

above

floor

level.

14.

Keep

all

panels

and

covers

securely

in

place.

4.

Disconnect

input

power

or

stop

engine

before

installing

or

servicing

this

equipment.

,.I

992

CYLINDERS

can

explode

if

damaged.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

If

damaged.

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

and

arcs

2.

Install

and

secure

cylinders

ri

an

upright

position

by

chaining

them

to

a

stationary

support

or

epuipment

cylinder

rack

to

prevent

falling

or

tipoing

A

WARNING

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

4.

Never

allow

a

welding

electrode

to

touch

any

cylinder.

5.

Use

only

correct

shielding

gas

cylinders,

regulators.

hoses,

and

fittings

designed

for

the

specific

application~

maintain

them

and

associated

parts

in

good

condition.

6.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve

7.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

ri

use

or

connected

for

use.

8.

Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.

1,

from

American

Welding

Society.

550

N.W.

LeJeune

Rd.

Miami

FL

33126

Safety

and

Health

Standards,

OSHA

29

CFR

1910.

from

Superinten.

dent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Recommended

Sate

Practices

for

the

Preparation

for

Welding

and

Cutting

of

Containers

That

Have

Held

Hazardous

Substances.

Amen.

can

Welding

Society

Standard

AWS

F4

1,

from

American

Welding

So

ciety.

550

N.W.

LeJeune

Rd.

Miami,

FL

33126

National

Electrical

Code,

NFPA

Standard

70.

from

National

Fire

Pro

tection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

Safe

Handling

of

Compressed

Gases

in

Cylinders,

CGA

Pamphlet

P-I,

from

Compressed

Gas

Association.

1235

Jefferson

Davis

High

way,

Suite

501,

Arlington,

VA

22202.

Code

for

Safety

in

Welding

and

Cutting,

CSA

Standard

Wi

17.2.

from

Canadian

Standards

Association.

Standards

Sales.

178

Rexdale

Bou

levard,

Rexdale,

Ontario.

Canada

M9W

I

R3.

Safe

Practices

For

Occupation

And

Educational

Eye

And

Face

Prof

ec

tion,

ANSI

Standard

Z87.1,

from

American

National

Standards

Institute,

1430

Broadway,

New

York,

NY

10018.

Cutting

And

Welding

Processes.

NFPA

Standard

518.

from

National

Fire

Protection

Association,

Batterymanch

Park.

Quincy,

MA

02269

ENGINES

can

be

hazardous.

..

.~

ENGINE

EXHAUST

GASES

can

kill.

1.

2.

Use

equipment

outside

in

open,

well-ventilated

areas

It

used

in

a

closed

area,

vent

engine

exhaust

outside

and

Engines

pr

oduce

harmful

exhaust

gases.

away

from

any

building

air

intakes.

ENGINE

FUEL

can

cause

fire

or

1.

Stop

engine

before

checking

or

adding

fuel.

explosion.

2.

Do

not

add

fuel

while

smoking

or

it

unit

is

near

any

sparks

or

open

ftames.

Engine

fuel

is

highly

flammable.

3.

4.

5.

Allow

engine

to

cool

before

fueling.

If

possible,

check

and

add

fuel

to

cold

engine

before

beginning

lob.

Do

not

overfill

tank



allow

room

for

fuel

to

expand.

Do

not

spill

fuel.

If

fuel

is

spilled,

clean

up

before

starting

engine.

MOVING

PARTS

can

cause

injury.

Moving

parts,

such

as

fans,

rotors,

and

belts

can

cut

fingers

and

hands

and

catch

loose

clothing,

3.

4.

Have

only

qualified

people

remove

guards

or

covers

for

maintenance

and

troubleshooting

as

necessary.

To

prevent

accidental

starting

during

servicing,

disconnect

negative

()

battery

cable

from

battery.

1.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

2.

Stop

eng

ne

before

installing

or

connecting

unit.

SPARKS

can

cause

BATTERY

GASES

TO

EXPLODE;

BATTERY

ACID

can

burn

eyes

and

skin,

5.

6.

Keep

hands,

hair,

loose

clothing,

and

tools

away

from

moving

parts.

Reinstall

panels

or

guards

and

close

doors

when

servicing

is

finished

and

before

starting

en9ine.

1.

2.

Always

wear

a

face

shield

when

working

on

a

battery.

Stop

engine

before

disconnecting

or

connecting

battery

cables.

3.

Do

not

allow

tools

to

cause

sparks

when

working

on

a

battery.

Batteries

contain

acid

and

generate

explosive

gases.

4.

5.

Do

not

use

welder

to

charge

batteries

or

jump

start

vehicles.

Observe

correct

polarity

(+

and

)

on

batteries.

-~

~

~~~Itii

STEAM

AND

PRESSURIZED

HOT

COOLANT

can

burn

face,

eyes,

and

skin.

under

pressure.

The

coolant

in

the

radiator

can

be

very

hot

and

1.

2.

3.

Oonotremoveradiatorcapwhenengineishot.Allowengine

to

cool.



Wear

gloves

and

put

a

rag

over

cap

area

when

removing

cap.

Allow

pressure

to

escape

before

completely

removing

cap.

~,i

9/92

OM-154

145

10/92

TABLE

OF

CONTENTS

Section

No.

Page

No.

SECTION

1

-

SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

1.1.

Generai

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

3

3-2.

Equipment

Installation

3

3-3.

Setting

DIP

Switches

On

DVC

Board

PC8

4

3-4.

Burnback

Voltage

And

Wire

Stick

DIP

Switch

On

Interface

Board

4

3-5.

YaskawalMotoman

Robot

Control

Unit



Robot

Interface

Set

Up

5

3-6.

Hitachi

Robot

Control

Unit



Robot

Interface

Set

Up

6

3-7.

Panasonic

Robot

Control

Unit



Robot

Interface

Set

Up

7

3-8.

Automatix

Robot

Control

Unit



Robot

Interface

Set

Up

8

3-9.

GMF

Robot

Control

Unit



Robot

Interface

Set

Up

9

3-10.

ABB

Robot

Control

UnitRobot

Interface

Set

Up

10

3-11.

Kawasaki

Robot

Control

Unit



Robot

Interface

Set

Up

11

3-12.

SMIC

Robot

Control

Unit



Robot

Interface

Set

Up

12

3-13.

Gas/Current

Sensing

Control

Interconnections

13

3-14.

Voltage

Sensing

Connections

14

3-15.

Robot

Interface



Welding

Power

Source

Connections

14

3-16.

Connection

For

Nonpulse

Welding

14

3-17.

Optional

RCSP-R

Set-up

For

Using

Maxtron

300

14

3-18.

Welding

Wire

Installation

15

SECTION

4OPERATOR

CONTROLS

4-1.

Power

Switch

And

Pilot

Light

16

4-2.

Jog

Push

Buttons

16

4-3.

Purge

Push

Button

16

4-4.

Voltmeter

16

4-5.

Wire

Speed

Meter

16

4-6.

Ammeter

17

4-7.

Indicator

Lights

17

4-8.

Preflow

Control

17

4-9.

Postflow

Control

18

4-10.

Burnback

lime

Control

18

4-11.

Burnback

Voltage

Control

18

4-12.

Selector

Switch

18

4-13.

Manual

Controls

18

SECTION

5-

OPTIONAL

RCSP-R

OPERATOR

CONTROLS

5-1.

Wire

Size

Select

Switch

And

Standard

Mode

Indicator

Light

19

5-2.

Wire

Size

Indicator

Lights

19

5-3.

Wire

Type

Select

Switch

19

5-4.

Recommended

Shielding

Gas

Indicator

Lights

20

5-5.

No

Program

Indicator

Light

20

SECTION

6

SEQUENCE

OF

OPERATION

6-1.

Optional

RCSP-R

Gas

Metal

Arc

Welding

(GMAW)

22

6-2.

Shutting

Down

22

Section

No.

Page

No.

SECTION

7-

MAINTENANCE

&

TROUBLESHOOTING

7-1.

Routine

Maintenance

23

7-2.

Overload

Protection

23

7-3.

Reinstallation

Of

Hub

Assembly

23

7-4.

Circuit

Board

Handling

Precautions

24

7-5.

Troubleshooting

25

7-6.

Use

Of

Indicator

Lights

For

Troubleshooting

28

SECTION

8

ELECTRICAL

DIAGRAMS

Diagram

8-1.

Circuit

Diagram

For

Robotic

Interface

Control

30

Diagram

8-2.

Circuit

Diagram

For

Analog

Channel

Board

P04

32

Diagram

8-3.

Circuit

Diagram

For

Interface

Board

PCi

34

Diagram

8-4.

Circuit

Diagram

For

DVC

Board

PC8

36

Diagram

8-5.

Circuit

Diagram

For

Motor

Board

P06

38

Diagram

8-6.

Circuit

Diagram

For

Power

Supply

Board

PC5

39

Diagram

8-7.

Circuit

Diagram

For

Isolation

Board

PC2

40

Diagram

8-8.

Circuit

Diagram

For

Display

Board

PC7

40

Diagram

8-9.

Circuit

Diagram

For

Filter

Board

P09

41

Diagram

8-10.

Circuit

Diagram

For

Gas/Current

Sensing

Control

41

Diagram

8-11.

Circuit

Diagram

For

Optional

RCSP-R

Panel

42

Diagram

8-12.

Circuit

Diagram

For

Feedback

Board

PC1O

42

Diagram

8-13.

Circuit

Diagram

For

Optional

RCSP-R

Offset/Supply

Board

P05

43

Diagram

8-14.

Circuit

Diagram

For

Selector

Board

P06

43

Diagram

8-15.

Circuit

Diagram

For

Optional

RCSP-R

Interface

Board

PCi

44

SECTION

9

PARTS

LIST

Figure

9-1.

Main

Assembly

46

Figure

9-2.

Control

Panel

w/Components

48

Figure

9-3.

Door

Assembly

50

Figure

9-4.

Control

Box,

Gas

Current

52

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

in

accordance

with

this

manual

and

all

safety

pre

cautions

listed

in

the

Arc

Welding

Safety

Precautions.

1.2.

SAFETY

ALERT

SYMBOL

AND

SIGNAL

WORDS

The

following

safety

alert

symbol

and

signal

words

are

used

throughout

this

manual

to

call

attention

to

and

iden

tify

different

levels

of

hazard

and

special

instructions,

4A

This

safety

alert

symbol

is

used

with

the

signal

words

WARNING

and

CAUTION

to

call

atten

tion

to

the

safety

statements.

a

WARNING

statements

identify

procedures

or

practices

which

must

be

followed

to

avoid

seri

ous

personal

injury

or

loss

of

life.

a

CAUTION

statements

identify

procedures

or

practices

which

must

be

followed

to

avoid

minor

personal

injury

or

damage

to

this

equipment.

IMPORTANT

statements

identify

special

instructions

necessary

for

the

most

efficient

operation

of

this

equip

ment.

SECTION

2

SPECIFICATIONS

2-1.

DESCRIPTION

The

robotic

interface

control

is

designed

to

interface

an

Arc

Pak

350,

Deltaweld,

or

Maxtron

300

or

450

welding

power

source

to

a

welding

robot.

This

unit

provides

digi

tal

display

of

weld

volts,wire

feed

speed,

and

amperage.

The

gas/current

sensing

control

contains

the

gas

valve,

current

sensing

reed

relay,

and

shunt.

These

components

function

with

the

robot

system

when

using

the

Gas

Metal

Arc

Welding

(GMAW)

and

Gas

Met

al

Arc

Welding

-

Pulsed

Arc

(GMAW-P)

processes.

The

optional

RCSP-R

panel

is

a

synergic

control

de

signed

to

be

used

with

the

Arc

Pak

350

or

Maxtron

300

or

450

welding

power

sources,

robot

interface,

and

the

ro

bot

system.

The

unit

is

designed

for

Gas

Metal

Arc

Weld

ing

(GMAW)

in

both

nonpulsed

and

pulsed

dc

arc

weld

ing

modes.

The

unit

is

shipped

ready

for

pulsed

welding.

The

panel

is

considered

a

synergic

control

because

welding

parameters

which

determine

arc

power

and

arc

length

are

programmed

for

wire

type

and

size

selections

to

allow

adjustment

at

two

controls

rather

than

individual

controls

for

each

parameter.

If

pulse

welding,

arc

power

parameters

are

wire

feed

speed,

background

amper

age,

peak

amperage,

pulse

frequency,

and

pulse

width;

arc

length

is

a

fine

tuning

of

pulse

frequency.

If

non-pulse

welding,

arc

power

parameters

are

wire

feed

speed,

arc

voltage,

and

inductance;

arc

length

is

a

fine

tuning

of

arc

voltage.

When

used

with

its

associated

equipment,

the

optional

RCSP-R

panel

allows

the

operator

to

set

welding

pa

rameters

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.154

145

Page

1

Overall

Dimensions

And

MoUnting

Hole

Locations

Inches

Millimeters

A

21.7/8

556

B

13.3/4

349

i~i

3

76

D

2.1/2

63.5

E

3.1/2

88.9

F

4-1/2

114

G

10-11/16

275

ST

157

095

/

ST080

486-C

Figure

2-1.

Dimensional

Views

in.

mm)

3/8

in.

(10

mm)

25-3/4

in.

(654

mm)

26-1/2

in.

(673

mm)

Opening

For

Receptacle

Kit

Installation

OM-154

145

Page

2

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