Miller KB049104 Owner's manual

Miller
Brand
Miller
Model
KB049104
Category
Welding System
Type
Owner's manual

This manual is also suitable for

t
Millerfi
April
1991
FORM:
OM-141
182
Effective
With
Serial
No.
KB049104
MODEL:
Robot
PAC
Interface
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
oniy
by
persons
trained
and
experienced
in
the
sate
operation
of
weiding
equip
ment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructIons.
MILLER
ELECTRIC
Mtg.
Co.
A
Miller
Group
Ltd..
Company
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
SC-145
177
PRINTED
IN
U.S.A
uj
LIMITED
WARRANTY
EFFECTIVE:
AUGUST
6,
1990
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
hereof,
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin
war
rants
to
its
Distributor/Dealer
that
all
new
and
unused
Equipment
furnished
by
MILLER
is
free
from
defect
in
workmanship
and
material
as
of
the
time
and
place
of
delivery
by
MILLER.
No
warranty
is
made
by
MILLER
with
respect
to
engines,
trade
accessories
or
other
items
manufactured
by
others.
Such
engines,
trade
accessories
and
other
items
are
sold
subject
to
the
warranties
of
their
respective
manufacturers,
if
any.
All
engines
are
warrantied
by
their
manufacturer
for
two
years
from
date
of
original
purchase.
except
Deutz
engines
which
have
a
one
year,
2000
hour
warranty.
Except
as
specified
below,
MILLERs
warranty
does
not
apply
to
components
having
normal
useful
life
of
less
than
one
(1)
year,
such
as
spot
welder
tips,
relay
and
contactor
points,
MILLERMATIC
parts
that
come
in
contact
with
the
welding
wire
including
nozzles
and
nozzle
insulators
where
failure
does
not
result
from
defect
in
workmanship
or
material.
MILLER
shall
be
required
to
honor
warranty
claims
on
war
ranted
Equipment
in
the
event
of
failure
resulting
from
a
defect
within
the
following
periods
from
the
date
of
delivery
of
Equipment
to
the
original
user:
1.
Arc
welders,
power
sources,
robots,
and
1
year
components
2.
Load
banks
1
year
3.
Original
main
power
rectifiers
3
years
(labor
1
year
only)
4.
All
welding
guns,
feeder/guns
and
torches
.
.
90
days
5.
All
other
MILLERMATIC
Feeders
1
year
6.
Replacement
or
repair
parts,
exclusive
of
labor
60
days
7.
Batteries
6
months
provided
that
MILLER
is
notified
in
writing
within
thirty
(30)
days
of
the
date
of
such
failure.
As
a
matter
of
general
policy
only,
MILLER
may
honor
claims
submitted
by
the
original
user
within
the
foregoing
periods.
In
the
case
of
MILLERs
breach
of
warranty
or
any
other
duty
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
therefore
shall
be.
at
MILLERs
option
(1)
repair
or
(2)
replace
ment
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
authorized
MILLER
service
station
or
(4)
payment
of
or
credit
for
the
purchase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
Customers
risk
and
expense.
MILLERs
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton.
Wisconsin.
or
FOB.
at
a
MILLER
authorized
service
facility,
therefore,
no
compensation
for
transportation
costs
of
any
kind
will
be
allowed.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
MILLER
shall
instruct
the
claimant
on
the
warranty
claim
procedures
to
be
followed.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRE
SENTATION
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHAN
TABILITY
OR
OF
F!TNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
EXCEPT
AS
EXPRESSLY
PROVIDED
BY
MILLER
IN
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
ULTIMATE
PURCHASE
BY
COMMERCIAUINDUSTRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLERS
WARRANTIES
DO
NOT
EXTEND
TO,
AND
NO
RESELLER
IS
AUTHORIZED
TO
EXTEND
MILLERS
WARRANTIES
TO,
ANY
CONSUMER.
1.
I
OM-141
1824/91
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam-
Use
the
following
spaces
to
record
the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number
of
your
unit.
The
infor
claims
for
loss
or
damage
with the
delivering
carrier.
mation
is
located
on
the
data
card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
the
distributor
anWor
the
equipment
manufactur-
Model
_____________________________
ers
Transportation
Department.
Serial
or
Style
No.___________________
When
requesting
information
about
this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date
of
Purchase
____________________
Number.
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
General
Information
And
Safety
1
1-2.
Safety
Alert
Symbol
And
Signal
Words
1
SECTION
2-
INTRODUCTION
2-1.
Description
1
SECTION
3-
INSTALLATION
3-1.
Field
Installation
Instructions
For
PAC
Interface
Panel
To
Computer
Interface
2
3-2.
Shock
Sensor
Unit
Assembly
And
Installation
To
Robot
3
3-3.
Torch
And
Torch
Cable
Installation
To
Robot
3
3-4.
Ground
Cable
Connections
5
3-5.
Ground
Cable,
Torch
Cable,
And
PAC
Interface
Panel
Cord
Internal
Connections
To
Power
Source
5
3-6.
PAC
Interface
Panel
Computer
Interface
Connection
6
3-7.
PAC
Interface
Panel
Power
Source
Connection
7
3-8.
Computer
interface
Input
Power
Connections
7
SECTION
4-
ROBOT
PROGRAM
MODIFICATIONS
4-1.
Setting
Up
Plasma
(Non-Standard)
Torch
For
MRH
Robot
7
4-2.
Amendment
To
Robot
Owners
Manual
Section
4
System
Set
Up
.
8
SECTION
5-
ELECTRICAL
DIAGRAMS
Diagram
5-1.
Circuit
Diagram
For
Robot
PAC
System
11
Diagram
5-2.
Circuit
Diagram
For
Robot
PAC
Interface
Panel
12
Diagram
5-3.
Circuit
Diagram
For
Filter
Board
PCi
0
12
Diagram
5-4.
Wiring
Diagram
For
Robot
PAC
Interface
Panel
13
SECTION
6
PARTS
LIST
14
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
plasma
arc
cutting
equipment
requires
prac
tices
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
applica
ble
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
Safety
Rules
and
Safety
Rules
For
Plasma
Arc
Cutting
(PAC)
in
the
power
source
Owners
Manual.
1-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
The
following
safety
alert
symbol
and
signal
words
are
used
throughout
this
manual
to
call
attention
to
and
iden
tify
different
levels
of
hazard
and
special
instructions.
a
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
a
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
persona
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equip
ment.
SECTION
2INTRODUCTION
2-1.
DESCRIPTION
with
a
shielded
torch
(MILLER
Part
No.
141751),
The
robot
PAC
interfac
e
panel
is
a
control
designed
to
be
MILLER
Computer
Interf
ace,
and
MRH
r
obot
system
for
used
with
a
Spectrum
1500
plasma
arc
cutter
equipped
the
Plasma
Arc
Cutting
(PAC)
process.
SECTION
3
INSTALLATION
Plug
PLG21
Connects
To
Computer
lnterfac
Receptacle
RC8
(see
Section
Robot
computer
~nterf
ace
Robot
Computer
Interface
Input
Power
Receptacle
RC11
Location
(se
Section
34
and
Computer
interface
Owners
Manual)
SC.145
Ill
PAC
Interface
Panel
Receptacle
RC2O
(see
Section
3-1)
Figure
3-1.
PAC
interface
Panel
OM-141
182
Page
1
Ground
Stud
Location
Left
Side
View
Of
Computer
Interface
Figure
3-2.
Computer
Interface
Internal
Connections
Ret
SB-139
887
3-1.
FIELD
INSTALLATION
INSTRUCTIONS
FOR
PAC
INTERFACE
PANEL
TO
COMPUTER
IN
TERFACE
(Figures
3-1
And
3-2)
J~
WARNING:
ELECTRIC
SHOCK
can
kill.
______
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
power
source,
and
disconnect
input
power
employing
lock
ouVtagging
procedures
before
beginning
this
installation.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shuthng
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
CAUTION:
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
properly
grounded
wrist
strap
BEFORE
handling
circuit
boards.
Perform
work
only
at
a
static-safe
work
area.
INCORRECT
INSTALLATION
or
misaligned
plugs
can
damage
circuit
board.
Be
sure
that
plugs
are
properly
installed
and
aligned.
EXCESSIVE
PRESSURE
can
break
circuit
board.
Use
only
minimal
pressure
and
gentle
move
ment
when
disconnecting
or
connecting
board
plugs
and
removing
or
installing
board.
IMPORTANT:
All
directions,
such
as
left
or
right,
are
with
respect
to
the
operator
facing
the
Computer
Inter
face
front
panel.
Retain
all
hardware
removed
during
this
procedure
for
reinstallation
unless
specifically
told
otherwise.
1.
Remove
Computer
Interface
top
cover
and
left
side
panel.
2.
Remove
side
panel
from
PAC
Interface
panel.
3.
Install
PAC
Interface
frame
onto
left
side
panel
of
Computer
Interface
with
sheet
metal
screws
re
moved
in
Step
1
(see
Figure
3-1).
4.
Make
the
following
internal
connections
to
the
Computer
Interface
(see
Figure
3-2).
a.
Remove
jumper
link
between
terminals
B
and
C
on
terminal
strip
2T.
b.
Connect
lead
26from
the
PAC
Interface
panel
to
terminal
B
on
terminal
strip
2T.
c.
Connect
lead
60
from
the
PAC
Interface
panel
to
top
mounting
screw
on
filter
FL1.
d.
Connect
green
lead
from
the
PAC
Interface
panel
to
the
ground
stud
located
directly
above
terminal
strip
2T.
IMPORTANT:
Remove
the
outside
star
washer
from
the
ground
stud
to
make
room
for
the
green
lead
terminal.
e.
Remove
plug
PLG3
from
receptacle
RC1
on
In
terface
Board
PC4.
Motor
Control
Terminal
Board
PC2
Strip
21
a
OM-141
182
Page
2
f.
Connect
plug
PLG1O
from
the
PAC
Interface
panel
to
Interface
Board
PC4
receptacle
RC1
where
plug
PLG3
was
removed
in
Step
4e
(plug
PLG3
is
not
connected
for
this
application).
5.
Reinstall
side
panel
onto
PAC
Interface
panel.
6.
Install
supplied
top
cover
onto
the
Computer
In
terface
PAC
Interface
panel.
3-2.
SHOCK
SENSOR
UNIT
ASSEMBLY
AND
IN
STALLATION
TO
ROBOT
(FIgure
3-3)
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
power
source,
and
dis
connect
input
power
employing
lockoutitag
ging
procedures
before
inspecting
or
install
ing.
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.
MOVING
PARTS
can
cause
serious
Injury.
Keep
away
from
moving
parts.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
seivicing.
To
assemble and
install
the
shock
sensor
unit,
refer
to
Figure
3-3
and
proceed
as
follows:
1.
If
applicable,
remove
existing
gun/torch
and
insu
lator
plate
from
robot
arm.
2.
Install
supplied
insulator
plate
to
robot
arm
with
screws
removed
in
Step
1.
3.
Assemble
shock
sensor,
mounting
bracket,
and
torch
clamp
as
shown
in
Figure
3-3.
4.
Install
shock
sensor
unit
to
the
insulator
plate
in
stalled
in
Step
2
with
supplied
screws.
3-3.
TORCH
AND
TORCH
CABLE
INSTALLATION
TO
ROBOT
(Figures
3-3
Through
3-5)
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
power
source,
and
dis
connect
input
power
employing
lockoutitagging
procedures
before
inspecting
or
installing.
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.
MOVING
PARTS
can
cause
serious
injury.
Keep
away
from
moving
parts.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
seivicing.
Strain
Relief
Rod
Fitting
(see
Section
3.3)
Insulator
Plate
Sensor
Leads
Section
3-3)
Shock
Sensor
Mounting
Bracket
Torch
Clamp
Figure
3-3.
Shock
Sensor
Unit
Assembly
And
installation
SB.145
210
OM-141
182
Page
3
1.
If
applicable,
remove
the
existing
wire
feed
motor!
reed
relay
mounting
bracket
and
stabilizer
brace
from
the
robot
(refer
to
robot
Owners
Manual
for
bracket
and
brace
locations).
Reinstall
the
two
lift
ing
brackets
only
(see
robot
Owners
Manual
and
Figure
3-4).
2.
If
applicable,
remove
the
wire
feed
hub
support
from
the
robot
(refer
to
robot
Owners
Manual
for
hub
support
location).
Install
supplied
torch
cable
support
bracket
in
location
where
hub
support
was
secured
(see
Figure
3-4).
3.
The
torch
cable
is
shielded
and
enclosed
in
a
black
protective
case.
Secure
torch
in
torch
clamp
using supplied
shim.
Position
torch
in
the
torch
clamp
so
that
torch
clamp
is
located
approximate
ly
in
the
center
of
the
torch
handle.
IMPORTANT:
Before
operating,
see
Section
4
and
ro
bot
Owners
Manual
for
instructions
for
absolute
offset
adjustment.
When
doing
this
procedure,
remove
the
shield
cup,
tip,
and
electrode
from
torch
and
install
the
supplied
brass
tip
gauge
and
holder
(see
Figure
3-5
and
torch
Owners
Manual).
4.
If
applicable,
remove
the
existing
clamps
sus
pended
from
the
outlet
cable
support
arm
and
re
place
them
with
the
two
supplied
larger
clamps.
Route
torch
cable
through
the
new
clamps
(see
Figure
3-4).
5.
Two
sections
of
tubular
strain
relief
rod
are
supplied
to
add
tension
to
the
torch
cable
to
pre
vent
pinching
and
to
keep
the
torch
cable
clear
of
the
robot.
Both
sections
attach
to
the
coupling
on
the
torch
cable
support
bracket
and
are
routed
along
the
torch
cable.
The
shorter,
thinner
rod
goes
between
the
torch
cable
support
bracket
and
the
shock
sensor.
The
longer,
thicker
rod
goes
between
the
torch
cable
support
bracket
and
the
power
source.
Install
the
strain
relief
rods
as
follows:
a.
Starting
near
the
shock
sensor,
route
one
end
of
strain
relief
rod
along
the
torch
cable
(on
the
Out
side
of
the
protective
casing)
by
running
it
under
the
existing
securing
straps
and
through
the
two
outlet
cable
support
arm
clamps
installed
in
Step
4.
b.
Insert
one
end
of
rod
into
the
fitting
on
top
of
the
shock
sensor
and
secure
with
supplied
set
screws
(see
Figure
3-3).
c.
Insert
other
end
of
rod
into
the
smaller
coupling
on
the
torch
cable
support
bracket
installed
in
Step
2,
and
secure
with
supplied
setscrews.
d.
Route
the
other
strain
relief
rod
under
the
torch
cable
securing
straps
along
the
remaining
sec
tion
of
torch
cable.
Insert
one
end
into
the
re
maining
torch
cable
support
bracket
coupling
and
secure
with
supplied
setscrews.
Strain
Relief
Rods
Outlet
Cable
Support
Arm
Shock
Sensor
Cable
Clamps
MRH
Robot
Strain
Relief
Rod
Shock
Sensor
Cable
Torch
Braided
Ground
Cable
Ground
Rod
PAC
interface/Power
115VAC
input
Source
Cord
Power
Cord
Figure
3-4.
Robot
PAC
System
OM-141
182
Page
4
,-~
Electrode
Wrench
Electrode
Shield
~
~
Torch
Cup
Body
Brass
Tip
Gauge
)
SA-145
254
Figure
3-5.
Torch
Brass
Tip
Gauge
And
Holder
For
Absolute
Offset
Adjustment
6.
Route
remaining
end
of
torch
cable
to
the
power
source
for
internal
connections
(see
Section
3-5B).
7.
The
supplied
10
ft
(3
m)
shielded
shock
sensor
cable
connects
the
shock
sensor
to
the
robot
base
(see
Figure
3-4).
To
install
shock
sensor
cable,
proceed
as
follows:
a.
Route
shock
sensor
cable
under
the
torch
cable
securing
straps
(on
the
outside
of
the
protective
casing)
and
through
the
two
outlet
cable
support
arm
clamps
so
that
the
two
leads
with
friction
connectors
are
located
near
the
shock
sensor.
The
other
end
of
the
cable
has
a
connector
and
an
uninsulated
ground
lead
with
a
ring
terminal,
and
should
be
located
near
the
rear
of
the
robot
axis
1
housing.
b.
Connect
friction
connectors
to
nearby
matching
leads
extending
from
top
of
shock
sensor
(see
Figure
3-3).
c.
Connect
connector
on
remaining
end
of
shock
sensor
cable
to
nearby
matching
connector
on
leads
extending
from
robot
base.
d.
Connect
ground
lead
ring
terminal
to
robot
base
as
follows:
(1)
Locate
four
black
screws on
robot
base
(near
torch
cable
support
bracket,
see
Figure
3-4)
and
unscrew
the
closest
one.
(2)
To
ensure
good
electrical
conduction,
scrape
away
the
paint
from
the
area
where
the
screw
head
touched
the
base
so
that
bare
metal
is
exposed.
(3)
Attach
ground
lead
ring
terminal
to
base
with
screw
removed
in
Step
dl.
3-4.
GROUND
CABLE
CONNECTIONS
(Figure
3-4)
Install
two
supplied
flat,
braided
ground
cables
as
fol
lows:
1.
Connect
one
end
of
both
ground
cables
to
the
customer-supplied
ground
rod
(see
robot
Own
ers
Manual).
2.
Connect
remaining
end
of
one
ground
cable
to
ro
bot
base
as
follows:
a.
Locate
unused
threaded
hole
on
robot
base
(see
Figure
3-4).
b.
To
ensure
good
electrical
conduction,
scrape
away
enough
paint
from
around
the
hole
so
that
the
ground
cable
terminal
will
touch
bare
metal.
c.
Attach
ground
cable
terminal
to
base
with
supplied
8
mm
bolt.
3.
Route
remaining
end
of
the
other
ground
cable
to
the
power
source
for
internal
connection
(see
Section
3-5A).
3-5.
GROUND
CABLE,
TORCH
CABLE,
AND
PAC
INTERFACE
PANEL
CORD
INTERNAL
CON
NECTIONS
TO
POWER
SOURCE
(Figures
3-4
And
3-6)
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
power
source,
and
dis
connect
input
power
employing
Ioko
ut/tagging
procedures
before
inspecting
or
installing.
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.
MOVING
PARTS
can
cause
serious
injury.
Keep
away
from
moving
parts.
HOT
SURFACES
can
cause
severe
burns.
Allow
cooling
period
before
servicing.
A.
Ground
Cable
Connection
Route
braided
ground
cable
through
opening
in
lower
front
panel
of
power
source
and
connect
to
ground
stud
(see
Section
3-4
And
Figures
3-4
And
3-6).
B.
Torch
Cable
Connections
To
make
torch
cable
internal
connections,
refer
to
Figure
3-6
and
the
torch
and
power
source
Owners
Manuals
and
proceed
as
follows:
1.
Remove
power
source
left
side
panel
and
route
torch
cable
through
opening
in
lower
front
panel
of
power
source.
2.
Remove
existing
jumper
link
from
terminals
9
and
10
on
terminal
strip
and
reinstall
jumper
link
be
tween
terminals
8
and
9.
3.
Connect
bare
copper
ground
lead
from
the
torch
cable
shielding
to
the
ground
stud.
)
OM-141
182
Page
5
Detector
Lead
Torch
Switch
N.O.
Output
Switch
Command
Ref.
Remote
Jumper
Common
Panel
Signal
Ground
11
4.
Connect
and
secure
the
torch
()/coolant
out
ca
ble
to
the
torch
output
connector.
5.
Connect
and
secure
the
pilot
(+)/coolant
in
cable
to
the
pilot
arc
output
connector.
6.
Connect
and
secure
the
gas/air
in
hose
to
the
gas/
input
connector.
7.
Connect
shield
cup
detector
lead
1
to
terminal
1
on
terminal
strip
iT.
8.
Connect
shield
cup
detector
lead
2
to
terminal
2
on
terminal
strip
iT.
9.
Connect
customer-supplied
work
clamp
cable
to
work
(+)
output
terminal.
C.
PAC
Interface
Panel
Cord
Connections
To
make
PAC
Interface
Panel
cord
internal
connections,
refer
to
Figure
3-6
and
proceed
as
follows:
1.
Route
end
of
supplied
cord
with
loose
leads
through
opening
in
lower
front
of
the
power
source
and
make
internal
connections
as
follows:
a.
Connect
blue lead
from
cord
to
terminal
3
on
1
T.
b.
Connect
orange
lead
from
cord
to
terminal
4
on
iT.
Shielded
Torch
Cabis
(s~
Section
3-58)
PAC
interface
Panel
Cord
(see
Sections
3.5C
and
3.7)
S8.145
220
c.
Connect
yellow
lead
from
cord
to
terminal
5
on
iT.
d.
Connect
brown
lead
from
cord
to
terminal
6
on
iT.
e.
Connect
green
lead
from
cord
to
terminal
8
on
iT.
f.
Connectredleadfrom
cord
to
terminal
11
on
IT.
g.
Connect
the
remaining
five
leads
from
cord
(purple,
black,
white,
gray,
and
the
uninsulated
ground
lead)
to
the
ground
stud.
2.
Reinstall
power
source
left
side
panel.
3.
Route
remaining
end
of
cord
to
PAC
Interface
panel
for
external
connection
(see
Section
3-7).
3-6.
PAC
INTERFACE
PANEL
COMPUTER
IN
TERFACE
CONNECTION
(Figures
3-1
And
3-4),
Connect
plug
PLG21
attached
to
cord
extending
from
the
PAC
Interface
panel
front
panel
to
weld
current
relay
receptacle
RC8
on
the
Computer
interface
front
panel.
Make
connections
as
follows:
Align
keyway,
insert
plug,
and
rotate
threaded
collar
fully
clockwise.
*Torch
()/Coolant
Out
Connector
Shlsld
Cup
Detector
Leeds
I
And
2
*
See
torch
and
power
Source
Owners
Manuals
for
torch
and
work
cable
connection
information.
Figure
3-6.
Power
Source
Internal
Connections
OM-141
182
Page
6
3-7.
PAC
INTERFACE
PANEL
POWER
SOURCE
CONNECTION
(Figures
3-1
And
3-4)
Connect
plug
on
supplied
cord
from
power
source
(see
Section
3-5C)
to
receptacle
RC2O
on
PAC
Interface
pan
el
front
panel
as
follows:
align
keyway,
insert
plug,
and
rotate
threaded
collar
fully
clockwise.
3-8.
COMPUTER
INTERFACE
INPUT
POWER
CONNECTIONS
(Figures
3-1
And
3-4)
Connect
plug
on
supplied
input
power
cord
to
14-pin
in
put
power
receptacle
RC11
on
the
Computer
Interface
front
panel
as
follows:
align
keyway,
insert
plug,
and
ro
tate
threaded
collar
fully
clockwise.
Connect
input
power
plug
on
other
end
of
cord
to
a
115
volts
ac
external
sup
ply.
SECTION
4-
ROBOT
PROGRAM
MODIFICATIONS
IMPORTANT:
The
robot
program
must
be
changed
to
accommodate
plasma
arc
cutting.
The
program
is
fac
tory
set
to
accommodate
factory
installed
plasma
arc
cutting
equipment.
The
following
information
pertains
to
the
robot
Owners
Manual
and
must
be
followed
when
field
installing
plasma
arc
cutting
equipment.
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
robot
and
power
source,
and
dis
connect
input
power
employing
lockout/tag
ging
procedures
before
inspecting
or
install
ing.
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
discon
necting
device.
4-1.
SETTING
UP
PLASMA
(NON-STANDARD)
TORCH
FOR
MRH
ROBOT
(Figure
4-1)
It
is
necessary
to
use
the
robot
Owners
Manual
in
addi
tion
to
this
manual
to
complete
the
proper
installation
of
the
torch.
IMPORTANT:
Follow
entire
procedure
in
presented
order.
1.
Check
System
Data
settings
against
the
test
sheet
supplied
with
the
unit.
These
should
match
before
beginning
installation.
2.
Mount
plasma
arc
cutting
torch
according
to
Sec.
tion
3-3
of
this
manual.
3.
Set
torch
length
according
to
Section
4.5.6
of
the
robot
Owners
Manual.
4.
Set
wrist
offset
according
to
Section
4.5.7
of
the
robot
Owners
Manual.
5.
Check
for
position
deviation
according
to
Sec
tions
4.5.3
and
4.5.4
of
the
Robot
Owners
Manu
al.
Correct
only
Axis
5
deviation
using
these
pro
cedures.
6.
Set
wire
extension
to
3.0
mm
according
to
Sec
tion
4.5.5
of
the
robot
Owners
Manual.
7.
The
universal
J-bar
is
included
to
record
exact
torch
position
so
that
it
is
possible
to
recover
posi
tion
in
case
of
a
robot
crash.lnstall
universal
J-bar
as
follows:
a.
Remove
2
screws
and
cover
plate
from
bottom
of
Axis
5
gear
housing.
b.
Install
universal
J-bar
onto
Axis
5
by
aligning
in
dex
pin
with
hole
in
housing,
and
securing
with
supplied
screws.
8.
Scribe
marks
on
the
universal
J-bar
to
indicate
exact
torch
position
as
shown
in
Figure
4-1.
9.
Remove
universal
J-bar.
Scribe
Marks
Where
Torch
Tip
touches
Lower
Bar
indexing
Scribe
Marks
Rod
Scribe
around
rod
below
lower
bar
to
record
height.
Tighten
screw
and
setscrew
when
torch
tip
is
touching
lower
bar.
SA.t46
220
Lower
Bar
Setscrew
Figure
4-1.
Scribe
Marks
on
Universal
J-Bar
OM-141
182
Page
7
4-2.
AMENDMENT
TO
ROBOT
OWNERS
MANU
AL
SECTION
4
SYSTEM
SET
UP
Amend
Sections
4.22.1
And
4.22.2
Of
Section
4.22
SElliNG
WELDING
POWER
SOURCE
SPECIFICA
TIONS
IN
SYSTEM
DATA
4
4.22.1.
Welding
Power
Source
Selection
And
Weld
ing
Characteristic
Data
Three
numerical
selections
are
available
for
the
welding
method
set
display
in
System
Data
4
as
follows:
1
Welding
power
source
selection
for
preset
speci
fications.
3
Welding
characteristic
data
for
selecting
specifi
cations.
6
Registers
the
welding
power
source
specifica
tions
in
the
robot
system
memory
and
returns
op
eration
to
the
display
for
System
Data
Set
number
selection.
To
select
welding
power
source
specification
data,
pro
ceed
as
follows:
1.
Place
the
power
switch
handle
on
the
Robot
Con
trol
cabinet
door
in
the
ON
position.
The
Program
Module
dispiay
appears
as
shown
momentarily,
and
all
the
key
pad
LEDs
illuminate
during
the
display
time.
THANK
YOU
WAKE
ME
UP
WELCOME
TO
MILLER!
2.
The
next
display
will
be
for
automatic
self-diagno
sis
of
the
Robot
Control
functions
and
connec
tions.
The
display
during
self-diagnosis
appears
as
shown:
Main
CPU
Software
Version
Number
SELF
DIAGNOSIS
VOlO
I
Step
Number
SELF
DIAGNOSIS
VOlO
10
IMPORTANT:
Automatic
self-diagnosis
after
first
turn
ing
on
power
to
the
Robot
Control
will
follow
the
se
quence
of
steps
from
ito
10.
Do
the
absolute
offset
ad
justment
if
any
of
the
following
alarm
or
error
code
mes
sages
appear
on
the
Program
Module
display
before
continuing
the
operation
mode
selection:
1)
Error2
100000
2)Alarm2
110000
3)
Error
6280000
4)
Error
6290000
If
the
DIAGNOSIS
button
is
pressed
on
the
Operation
Module,
the
sequence
of
steps
will
be
from
0
to
8
be
cause
no
checking
is
done
for
absolute
offset
adjust
ment.
Checkmg
absolute
offset
adjustment
is
only
per
formed
in
automatic
self-diagnosis
after
turning
power
on
to
the
Robot
Control.
3.
Once
automatic
self-diagnosis
is
completed,
the
display
appears
as
shown:
SERVO
POWER
IS
OFF
010010010010010
4.
PresstheTEACH-EDlTkeyonce,
andthedis
appears
as
shown:
play
P000
S000
5.
Press
the
SYSTEM
DATA
key,
and
the
display
ap
pears
as
shown:
SYSTEM
DATA
SET
NO.
6.
Press
the
numerical
4
key,
press
the
RECO
RD
key,
and
the
display
appears
as
follows:
WELDING
METHOD
SET
7.
Press
the
numerical
3
key,
press
the
RECORD
key,
and
the
display
appears
as
shown:
8.
Press
the
RECORD
key
again,
and
the
display
appears
as
shown:
1;
GMAW
STANDARD
DATA
INPUT
OM-141
182
Page
8
9.
Press
the
forward
DISPLAY
SELECT
key
to
Se-
16.
Press
the
RECORD
key,
and
the
display
appears
17.
Press
the
forward
DISPLAY
SELECT
key
twice
to
select
4.Ov.
Press
the
DEC
key
to
decrease
4.Ov
to
2.Ov.
*3:
50A
5.Ov
19.
Press
the
forward
DISPLAY
SELECT
key
to
se
lect
50A.
Press
the
INC
key
to
increase
50A
to
57A.
*3:
57A
5.Ov
20.
Press
the
RECORD
key,
and
the
display
appears
as
shown:
*4:
60A
6.Ov
21.
Press
the
forward
DISPLAY
SELECT
key
to
se
lect
60A.
Press
the
INC
key
to
increase
60A
to
73A,
and
the
display
appears
as
shown:
*4:
73A
6.Ov
22.
Press
the
forward
DISPLAY
SELECT
key
to
select
6.Ov.
Press
the
INC
key
to
increase
6
Ov
to
8.0
v.
*4
:
73A
8.Ov
lect:
as
shown:
*2:
40A
4.Ov
*2:
40A
2.Ov
1
8.Press
the
RECORD
key,
and
the
display
appears
as
shown:
2:
GTAW-100
10.
Press
the
READ
key,
and
the
display
appears
as
shown:
1:
MIG
11.
Press
the
forward
DISPLAY
SELECT
key
to
se
lect
*2:
TIG.
Press
the
RECORD
key,
and
the
dis
play
appears
as
shown:
*RATING
100A
12.
Press
the
DEC
key
to
decrease
the
rating
to
80A.
*RATING
80A
13.
Press
the
RECORD
key,
and
the
display
appears
as
shown:
*1:
20A
2.Ov
14.
Press
the
forward
DISPLAY
SELECT
key
to
se
lect
20A
(the
A
flashes).
Press
the
INC
key
to
in
crease
20A
to
30A,
and
the
display
appears
as
shown:
*1:
30A
2.Ov
15.
Press
the
forward
DISPLAY
SELECT
key
to
se
lect
2.Ov
(the
v
flashes).
Press
the
DEC
key
to
de
crease
2.Ov
to
0.Ov.
The
display
appears
as
shown:
*1:
30A
0.Ov
OM-141
182
Page9
23.
Press
the
RECORD
key,
and
the
display
appears
as
shown:
*5:
80A
8.Ov
24.
Press
the
forward
DISPLAY
SELECT
key
twice
to
select
8.Ov.
Press
the
INC
key
to
increase
8.Ov
to
1O.Ov.
*5:
80A
10.Ov
25.
Press
the
RECORD
key,
and
the
display
appears
as
shown:
1
:
MIG
26.
Pressthe
END
key,
and
the
dIsplay
appears
as
shown:
3
:
GTAW300
27.
Press
the
RESET
key,
and
the
display
appears
as
shown:
28.
Press
the
RESET
key
again,
and
th
pears
in
the
sequence
shown:
e
display
ap
COMP
L
ETED
S
YSTEM
DATA
SET
NO._
29.
Press
the
numerical
4
key,
press
the
RECORD
key,
and
the
display
appears
as
shown:
WELDING
METHOD
SET_
30.
Press
the
numerical
1
key,
press
the
RECORD
key,
and
the
display
appears
as
shown:
WELDING
METHOD
SET1
PWR
SPLY*
GMAW
STANDARD
DATA
INPUT
31.
Press
the
forward
DISPLAY
SELECT
key
until
GTAW-1
00
appears.
Press
the
RECORD
key,
and
the
display
appears
as
shown:
WELDING
METHOD
SET1
PWR
SPLY*
GTAW-100
32.
Press
the
RESET
key,
and
the
display
appears
as
shown:
WELDING
METHOD
SET_
33.
Press
the
numerIcal
6
key,
press
the
RECORD
key,
and
the
display
appears
in
the
sequence
shown:
COMP
L
ETED
SYSTEM
DATA
SET
NO._
34.
Press
the
RESET
key,
and
the
display
appears
as
shown:
P000
S000
35.
Press
the
TEACH-EDIT
key,
and
the
łway
ap
pears
as
shown:
SERVO
POWER
IS
OFF
OM-141
182
Page
10
1
Cl)
m
C)
-1
T2O~1Th
0
z
UI
m
r
Ill
C,
-I
I
0
C)
AOa
S
0
~
coa
U)
Circuit
Diagram
No.
SC-141
074-A
21
*
0
W
o
a
C
0
~
o
o
zi
£
0
.~
Jo
Diagram
5-1.
Circuit
Diagram
For
Robot
PAC
System
RC2-6>>~60
<<RCI-6
______
r)
<<RCI-5
I
_______
cfl
PCIO
~RCI-3
FILTER
BOARD
I
RCI/PLGII
I
RC2/PLGI2
I
~(RCI-8
RC3/GRN
LEAD
<<Rd-I
I\) I~)
<<RCI-4
L
~
RC2-3>)
I________
I
Circuit
Diagram
No.
SA-141
073-A
Diagram
5-2.
Circuit
Diagram
For
Robot
PAC
interface
Panel
Diagram
5-3.
Circuit
Diagram
For
Filter
Board
PC1O
Circuit
Diagram
No.
SB-i
40
513
26
COMMAND
p
RC2O
B>
C>-
/02
/03
COMMAND
COMMAND
COMMON
/0d
~
/05
CONTACTOP
~.
/06
E>
F>
G>
L~
CPN
SHIELD
H>~
RC26
6QN
wCp
/PNT
WCR
1i~60
PLG2I
<C
<B
PLO
0
/
<4
/
<2
CONT
ACTOR
OM-141
182
Page
12
PLG2
I
FLTR
BRD
Wiring
Diagram
No.
SB-141
195-B
Diagram
5-4.
Wiring
Diagram
For
Robot
PAC
interface
Panel
PC2O
bOA
GRD
PLGIO
TO
INTERcACE
ca~r~a.
BOX
OM-141
182
Page
13
SECTION
6
PARTS
LIST
PC1O
140510
110
375
PLG1O
115094
113
746
PLGI1
115092
113
746
PLG12
115093
113
746
PLG21
047
544
039
828
049
455
139
040
RC2O,26
145706
139
455
139
454
134
241
126
147
126
084
115
135
109
770
116964
097
426
141
224
094 482
073
296
604
825
073
690
141
348
602
173
140
987
141
218
602
004
128
189
604
433
141
563
049 028
141
407
141
408
143
352
089
799
089
800
143
990
143
996
602
177
141
445
141
409
141
449
+139
465
+140
125
134
464
CIRCUIT
CARD,
RF
filter
STAND-OFF
SUPPORT,
PC
card
No.
6
screw
HOUSING
PLUG
&
SOCKETS,
(consisting
of)
TERMINAL,
female
lskt
24-18
wire
HOUSING
PLUG
&
SOCKETS,
(consisting
of)
TERMINAL,
female
lskt
24-18
wire
HOUSING
PLUG
&
SOCKETS,
(consisting
of)
TERMINAL,
female
lskt
24-18
wire
PLUG,
4skt
MS-3106A-14S-2SX
CLAMP,
cable
AN-3057-6
CABLE,
port
No.
18
2/c
(order
by
ft)
BUSHING,
strain
relief
.231/.394
ID
x
.733mtg
hole
CIRCUIT
CARD,
rcpt
8
pin
CASE
SECTION,
front/bottom
PANEL,
rear
NAMEPLATE,
(order
by
model
and
serial
number)
CABLE,
port
No.
18
2/c
(order
by
ft)
HOUSING,
term
plug
nyl
2cont
1
row
TERMINAL,
male
1
pin
20-14
wire
HOUSING
PLUG
&
PINS,
(consisting
of)
TERMINAL,
male
1
pin
20-16
wire
CLAMP,
cable
97-3057-1012
CABLE,
shld
No.
1
8ga
10/c
(order
by
ft)
CABLE,
pwr
interface
(consisting
of)
PLUG,
l4skt
MS-3106A-20-27S
CLAMP,
cable
97-3057-12-6
CABLE,
port
No.
18
3/c
(order
by
ft)
PLUG,
str
grd
armd
2P3W
15A
125V
SHOCK
SENSOR,
w/heavy
spring
SCREW,
set
stl
sch
10-32
x
.250
cup
point
BRACKET,
mtg
bottom
BRACKET,
PAC
SCREW,
cap
stl
sch
.250-20
x
.750
SCREW,
cap
stl
hexhd
.312-18
x
1.750
NUT,
stl
slflkg
hex
hvy
.312-18
CABLE,
grd
manipulator
to
rod
SCREW,
cap
stl
hexhd
12mm
x
20mm
GAUGE,
electrode
brass
HOLDER,
gauge
PAC
CLAMP,
cable
SCREW,
cap
stl
hexwhd
.250-20
x
.500
NUT,
stl
fig
lkd
hex
.250-20
BRACKET,
support
gun
cable
ROD,
strain
relief
SCREW,
set
stl
sch
.250-20
x
.250
knr
cup
point
BAR,
delrin
.500dia
x
lOft
INSULATOR,
plate
torch
PANEL,
side
COVER,
(used
with
1
option)
COVER,
(used
with
2
options)
LABEL,
warning
general
precautionary
1
1
4
4
1
1
4 4
1
1
8 8
1
1
6
6
1
1
1
1
3ft
3ft
1
1
1 1
1 1
1
1
1
1
lOft
lOft
1 1
2
2
1
1
8
8
1
1
5ft
5ft
1
1
1
1
1 1
l6ft
l6ft
1
1
1
1
2
2
1
1
1
1
2
1
1
1 1
1 1
4
4
4
4
1
1
1
1
4
4
1
1
1
1
1 1
1
1
1
1
Dia.
Part
Mkgs.
No.
Description
Quantity
Spectrum
Interface
042
591
042
592
OM.141
182
Page
14
Dia.
Mkgs.
134
048
134
054
135
937
135
936
109
526
124
778
127
815
127
878
128
008
601
977
602
216
602
246
602
969
Quantity
042
591
042
592
1
1
1
1
1
1
1
4
1
4
4
4
2
+When
ordering
a
component
originally
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Part
No.
Description
Spectrum
Interface
(Continued)
TRAY,
support
BASE,
support
tray
BRACKE1
lift
eye
RH
BRACKET
lift
eye
LH
PEDESTAL,
robot
controls
KNOB,
plstc
T
1.000
lg
x
.312-18
x
2.000
bar
INSULATOR
INSULATOR,
shoulder
pedestal
INSULATOR,
pedestal
SCREW,
cap
stl
hexhd
.500-13
x
3.000
.
WASHER,
lock
stl
split
.500
WASHER,
flat
stl
std
.500
PLUG,
protective
No.
6
plastic
OM.141
182
Page
15
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Miller KB049104 Owner's manual

Miller
Brand
Miller
Model
KB049104
Category
Welding System
Type
Owner's manual
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