Miller
September
1994
Form:
OM-150
577B
Effective
With
Serial
No.
KE709896
OWNER!S
MANUAL
Robot
Floppy
Disk
Drive
And
Robot
Floppy
Disk
Drive
Interface
Kit
Read
and
follow
these
instructions
and
all
Give
this
manual
to
the
operator.
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
For
help,
call
your
distributor
Call
your
distributor
if
you
do
not
understand
I~J
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
the
directions.
Appleton,
WI
54912
414-734-9821
Floppy
Disk
Drive
For
Cl
And
C2
Robot
Control
File
Data
Storage
And
Transfer
For
CPU
Memory
Requires
3-1/2
in
Floppy
Disk
2HD
Uses
100/115
Volts
AC
Single-Phase
Input
Power
Fuse
Overload
Protection
cover
5~94
ST.1
52592-A
'
1994
MILLER
Electric
Mig.
Co.
PRINTED
IN
USA
Within the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war-
ranted
parts
or
components
that
fail
due
to
such
defects
In
material
or
worlimanship.
MILLER
must
be
notified
in
writing
within
thirty
(30)
days
ot
such
defect
or
failure,
at
which
time
MILLER
wilt
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
evenl
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
retell
purchaser,
or
one
year
after
the
equipment
is
sent
to
the
distributor.
1.
5YearsParts-3YearsLabor
Original
main
power
rectifiers
2.
3
Years
Parts
and
Labor
Transformer/Rectifier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
SemiAutomatic
and
Automatic
Wire
Feeders
Robots
3.
2
Years
Pens
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer
for
a
period
ot
two
years.)
Air
Compressors
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/Trailers
Field
Options
(NOTE:
Field
options
are
covered
under
True
BtueTM
for
the
remaining
warranty
period
of
the
product
they
are
installed
in.
or
for
a
minimum
of
one
year
whichever
is
greater.)
5.
6
Months
Battenes
6.
90
Days
Parts
and
Labor
MIG
Guns/fiG
Torches
Plasma
Cutting
Torches
MILLERS
True
BIueTM
Limited
Warranty
shall
not
apply
to:
1.
Items
furnished
by
MILLER.
but
manufactured
by
others.
sucr
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactos
and
relays
or
parts
that
fail
due
to
normal
wear.
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip
ment
that
has
been
improperly
inatailed,
improperly
operated
or
misused
based
upon
induatry
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
CIALJ1NDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT.
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be.
at
MILLERS
option:
(1)
repair,
or
(2)
replacement;
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replace
ment
Stan
authorized
MILLER
se,vice
station;
or
(4)
payment
of
or
ci
odit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
ala
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
PERMITrED
BY
LAW.
THE
REMEDIES PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
LiABLE
FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL
DAMAGES
(INCLUDING
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
0
IHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
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
tS
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 exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
state
to
state.
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
Other
than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
iimitations
and
exclusions
set
out
above
may
not
apply.
This
Limited
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
:J~.
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial
number
preface
of
KC
or
newer)
This
limited
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
below,
MILLER
Electric
Remote
Controls
Mtg.
Co..
Appleton,
Wisconsin,
warrants
to
its
original
retail
purchaser
that
new
~
Kits
MILLER
equipment
sold
after
the
effective
date
of
this
limited
warranty
is
free
of
de-
Re
lacement
Pans
(acts
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.
I
I
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
tiling
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
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
9/93
TABLE
OF
CONTENTS
SECTION
1
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1
1-1.
General
Information
And
Safety
1
1-2.
Safety
Alert
Symbol
And
Signal
Words
1
SECTION
2
SPECIFICATIONS
1
2-1.
Description
2
SECTION
3
INSTALLATION
3
3-1.
Installation
Of
Floppy
Disk
Drive
Interface
Kit
3
3-2.
Connections
For
Floppy
Disk
Drive
8
SECTION
4-OPERATION
9
4-1.
Floppy
Disk
Write
Protection
9
4-2.
Inserting
Floppy
Disk
Into
Floppy
Disk
Drive
10
4-3.
Ejecting
Floppy
Disk
From
Floppy
Disk
Drive
10
4-4.
Procedure
For
Using
Floppy
Disk
Drive
10
4-5.
Precautions
For
Using
Floppy
Disk
Drive
11
4-6.
Initialization
Of
Floppy
Disk
11
4-7.
Saving
Data
To
Floppy
Disk
19
4-8.
Loading
Data
From
Floppy
Disk
42
4-9.
Verification
Of
Transfer
Data
65
4-10.
Deleting
Data
From
Floppy
Disk
For
C2
Robot
Control
75
4-11.
Listing
Files
On
Floppy
Disk
For
C2
Robot
Control
81
SECTION
5
TROUBLESHOOTING
86
SECTION
6
ELECTRICAL
DIAGRAMS
87
SECTION
7-
PARTS
LIST
Figure
7-1.
Floppy
Disk
Drive
88
OM-150
577B
-9/94
S
SECTION
1
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
labels,
tags,
and
plates
on
the
unit
pertains
to
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
troubleshooting
of
robotic
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
installed,
operated,
and
main
tained
only
by
qualified
persons
in
accordance
with
this
manual and
all
applicable
codes
such
as,
but
not
limited
to,
those
listed
in
Section
1
Safety
of
the
robot
Owners
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
identify
different
levels
of
hazard
and
special
instructions.
a
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
attention
to
the
safety
statements.
a
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
serious
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
equipment.
SECTION
2
SPECIFICATIONS
Table
2-1.
Optional
Floppy
Disk
Drive
Item
Specification
Input
Power
Requirement
100/115
Volts
AC
(Input
Power
Supply
Available
From
Interface
Kit
Receptacle
Installed
On
Robot
Control)
Memory
Element
3-1/2
in.
Floppy
Disk
2HD*
Operating
Temperature
Range
410
To
95
F
(5
To
350
C)
Temperature
Range
For
Data
Retention
On
Floppy
Disk
-4
To
140
F
(20
To
60
C)
~
Humidity
Range
20%
To
80%
(Without
Condensation)
Operation
Time
Operation
Standard
Memory
Extended
Memory
Save
Data
26
sec.
52
sec.
Load
Data
26
sec.
52
sec.
Verify
Data
Initialization**
26
sec.
102
sec.
52
sec.
102
sec.
*
Save
function
of
entire
memory
data
from
only
one
Robot
Control
is
permitted
on
a
single
floppy
disk.
**
Initialization
is
necessary
before
using
a
new
floppy
disk;
however,
once
initialization
is
performed
on
a
floppy
disk
it
is
not
necessary
again.
CM-i
50
577
Page
1
2-1.
DESCRIPTION
The
floppy
disk
drive
provides
a
data
storage
function
for
the
Robot
Control
memory
by
saving
or
loading
and
verifying
alt
programs
and
jobs.
A
standard
3-1/2
in.,
2t-ID
floppy
disk
is
capable
of
storing
the
entire
contents
of
Robot
Control
memory.
The
floppy
disk
drive
and
interface
kit
together
make
a
dedicated
system
for
use
with
the
Robot
Control.
Firmware
for
the
floppy
disk
drive
is
a
proprietary
protocol
type
not
compatible
for
use
with
a
PC
or
PC
Data
Storage
software.
Figure
2-1.
Floppy
Disk
Drive
Dimensions
FRONT
VIEW
ST-152
592-A
Floppy
Disk
Slot
~
Operation
Light
~
Eject
Button
Power
Light
Power
Switch
Power
Supply
Cord
Figure
2-2.
Floppy
Disk
Drive
Components
Connector
S-0685
125/16
In.
(313
mm)
Add
13/16
in.
(21
mm)
for
fuse
holder
at
rear
of
unit.
~JIj
II~ft
Fuse
REAR
VIEW
OM-150
577
Page
2
SECTION
3
INSTALLATION
IMPORTANT:
If
installing
a
floppy
disk
drive
interface
kit
in
an
MRH
Robot
Control
prior
to
Serial
No.
KB136982
or
MRV-6
Robot
Control
prior
to
Serial
No.
KB
129527,
contact
the
nearest
Facto,y
Authorized
Service
Station
for
CPU
board
update.
INSTALLATION
OF
FLOPPY
DISK
DRIVE
INTERFACE
KIT
(Figure
3-1)
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
Robot
Control,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
be
ginning
this
installation.
Lockout/tagging
procedures
consist
of
padlocking
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnecting
device.
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit
boards.
Put
on
properly
grounded
wrist
strap
BEFORE
handling
circuit
boards.
Transport
circuit
boards
in
proper
static-shielding
carriers
or
packages.
Perform
work
only
at
a
safe
static-safe
work
area.
INCORRECT
INSTALLATION
or
misaligned
plugs
can
damage
circuit
boards.
Be
sure
that
plugs
are
properly
installed
and
aligned.
EXCESSIVE
PRESSURE
can
break
circuit
board.
Use
only
minimal
pressure
and
gentle
movement
when
disconnecting
or
connecting
board
plugs
and
re
moving
or
installing
board.
A.
Interface
Kit
Installation
For
Cl
Robot
Control
a
Centronics
Flat
Ribbon
Cable
Flat
Connector
FC2
Interlace
CircuIt
Board
Flat
Connector
FC1
Robot
Control
Cpu
Board
Flat
Connector
FC3
Figure
3-1.
Floppy
Disk
Drive
Interface
Kit
Installation
For
Cl
Robot
Control
ST-152
588
OM-150
577
Page
3
1.
Remove
and
retain
hardware
securing
rectangular
cover
plate,
located
on
left
side
panel
in
the
upper
right-hand
corner,
on
Robot
Control.
IMPORTANT:
Position
Interface
circuit
board
so
that
connector
FC2
is
at
top
of
circuit
board
when
installed
inside
Robot
ControL
2.
Open
cabinet
door,
and
install
supplied
Interface
circuit
board
to
left
side
panel
inside
cabinet,
just
below
rectan
gular
opening
where
cover
plate
was
removed
in
Step
1.
Use
supplied
screws
to
secure
circuit
board
to
side
panel
(see
Figure
3-1).
3.
Locate
supplied
multi-lead
cord
with
flat
connector
plugs
at
each
end,
and
connect
one
end
to
flat
connector
FC3
on
CPU
board
(see
Figure
3-1).
4.
Connect
remaining
end
of
cord
to
flat
connector
FC1
on
Interface
board
installed
in
Step
2.
5.
Locate
supplied
flat
ribbon
cable
with
Centronics
connector
on
one
end.
Insert
Centronics
connector
through
rectangular
opening
in
supplied
mounting
plate,
and
use
supplied
screws
to
secure
connectorto
mounting
plate
(see
Figure
3-2).
6.
Insert
flat
ribbon
cable
through
rectangular
opening
from
outside
cabinet,
and
use
hardware
removed
in
Step
1
to
secure
mounting
plate
to
side
panel.
7.
Connect
remaining
end
of
flat
ribbon
cable
to
flat
connector
FC2
on
Interface
board
(see
Figure
3-1).
8.
Remove
a
cover
plate
from
one
of
the
openings
in
the
lower
portion
of
left
side
panel.
9.
Locate
supplied
single
receptacle,
circuit
breaker,
and
mounting
plate
(see
Figure
3-3),
and
install
supplied
cord
as
follows:
a.
Connect
friction
terminal
on
black
lead
to
terminal
on
circuit
breaker.
b.
Connect
friction
terminals
on
supplied
jumper
lead
to
remaining
terminal
on
circuit
breaker
and
to
brass
termi
nal
on
receptacle.
c.
Connect
friction
terminal
on
white
lead
to
silver
terminal
on
receptacle.
d.
Connect
ring
terminal
on
green
lead
to
green
grounding
screw
on
receptacle.
10.
Insert
plug
on
end
of
cord
through
square
opening
from
outside
cabinet,
and
use
hardware
removed
in
Step
8
to
secure
mounting
plate
to
side
panel
(see
Figure
3-3).
11.
Connect
plug
to
100
volts
ac
receptacle
in
lower
portion
inside
cabinet
on
rear
panel
(see
Figure
3-3).
12.
Close
and
secure
Robot
Control
cabinet
door.
Figure
3-2.
Centronics
Receptacle
Installation
For
Cl
Robot
Control
ST-152
589-A
Flat
Ribbon
Cable
Screw
(2)
From
Cover
Plate
Fiat
Connector
FC2
Interface
Circuit
Board
Dust
Cover
Robot
Control
Left
Side
Panel
OM-150
577
Page
4
Duplex
Receptacle
On
Rear
Panel
Inside
Robot
Control
ST-800
903
Figure
3-3.
100
Volts
AC
Receptacle
Installation
For
Cl
Robot
Control
B.
Interface
Kit
Installation
For
C2
Robot
Control
1.
Install
Interface
board
onto
mounting
plate
as
shown
in
Figure
3-4.
2.
Remove
and
retain
hardware
securing
rectangular
cover
plate,
located
in
the
upper
left-hand
portion
of
cabinet
door,
on
Robot
Control.
IMPORTANT:
Position
Interface
circuit
board
so
that
connector
FC2
is
at
right
side
of
circuit
board
when
installed
on
inside
Robot
Control
cabinet
door.
Screw
(4)
interface
Circuit
Board
Mounting
Plate
Fiat
Connector
FC1
ST-181
118
Figure
3-4.
Installation
Of
Interface
Board
Onto
Mounting
Plate
For
C2
Robot
Control
OM-150
577
Page
5
Screw
(2)
And
Washers
From
Cover
Plate
Single
Receptacle,
Circuit
Breaker,
And
Mounting
Plate
Lock
Washer
(4)
Washer
(4)
Screw
(4)
....~
~~~~Stand.Off
(4)
Washer
(4)
Connector
FC2
Robot
Control
Figure
3-5.
Floppy
Disk
Drive
Interface
Kit
Installation
On
C2
Robot
Control
ST-161
116
3.
Open
cabinet
door,
and
install
mounting
plate/Interface
board
to
inside
of
cabinet
door,
just
to
left
of
rectangular
opening
where
cover
plate
was
removed
in
Step
2.
Use
supplied
screws
to
secure
mounting
plate
to
cabinet
door
(see
Figure
3-5).
4.
Locate
supplied
multi-lead
cord
with
flat
connector
plugs
at
each
end,
and
connect
one
end
to
flat
connector
FC3
on
CPU
board
(see
Figure
3-5).
5.
Connect
remaining
end
of
cord
to
flat
connector
FC1
on
Interface
board
installed
in
Step
3.
6.
Locate
supplied
flat
ribbon
cable
with
Centronics
connector
on
one
end.
Insert
Centronics
connector
through
rectangular
opening
in
supplied
mounting
plate,
and
use
supplied
screws
to
secure
connector
to
mounting
plate
(see
Figure
3-6).
From
Flat
Ribbon
Cable
Cabinet
Door
Rear
Of
Cabinet
Door
Figure
3-6.
Centronics
Receptacle
Installation
On
C2
Robot
Control
Flat
Connector
FC2
Flat
Connector
FC1
Multi-Lead
Cord
Flat
Connector
FC3
Interface
Circuit
Board
CM-i
50
577
Pago
6
7.
Connect
remaining
end
of
flat
ribbon
cable
to
flat
connector
FC2
on
lntertace
board
(see
Figure
3-6).
8.
Insert
flat
ribbon
cable
through
rectangular
opening
from
outside
of
cabinet
door,
and
use
hardware
removed
in
Step
2
to
secure
mounting
plate
to
side
panel.
9.
Remove
a
cover
plate
from
one
of
the
openings
in
the
lower
portion
of
left
side
panel.
10.
Locate
supplied
single
receptacle,
circuit
breaker,
and
mounting
plate
(see
Figure
3-7),
and
install
supplied
cord
as
follows:
a.
Connect
friction
terminal
on
black
lead
to
terminal
on
circuit
breaker.
b.
Connect
friction
terminals
on
supplied
jumper
lead
to
remaining
terminal
on
circuit
breaker
and
to
brass
termi
nal
on
receptacle.
c.
Connect
friction
terminal
on
white
lead
to
silver
terminal
on
receptacle.
d.
Connect
ring
terminal
on
green
lead
to
green
ground
screw
on
receptacle.
ii.
Insert
leads
with
attached
ring
terminals
on
end
of
cord
through
square
opening
from
outside
cabinet,
and
use
hardware
removed
in
Step
9
to
secure
mounting
plate
to
side
panel
(see
Figure
3-7).
12.
Connect
ring
terminals
at
end
of
leads
as
follow:
a.
Remove
clear
plastic
cover
from
terminal
block
TF1,
located
just
below
Constant
Voltage
Power
Supply
Unit
Psi,
on
rear
panel
inside
Robot
Control
(see
Figure
3-7).
IMPORTANT:
Be
sure
that
existing
leads
are
connected
to
original
terminals
on
terminal
block
TF1
and
ground
bus
after
connecting
leads
from
receptacle
cord.
b.
Connect
ring
terminal
on
end
of
black
lead
to
100
V
terminal
on
TF1
(empty
side
of
jumper
link
where
existing
lead
10
is
connected).
c.
Connect
ring
terminal
on
end
of
white
lead
to
0
V
terminal
on
TF1
(empty
side
of
jumper
link
where
existing
lead
11
is
connected).
d.
Connect
ring
terminal
on
end
of
green
grounding
lead
to
ground
bus
on
base
of
cabinet
at
rear
main
input
power
transformer.
13.
Close
and
secure
Robot
Control
cabinet
door.
ST.800
902
Screw
(2)
And
Washers
From
Cover
Plate
Robot
Control
Left
Side
Panel
Green
Grounding
Lead
Figure
3-7.
100
Volts
AC
Receptacle
Installation
On
C2
Robot
Control
OM-150
577
Page
7
3-2.
CONNECTIONS
FOR
FLOPPY
DISK
DRIVE
(Figure
3-8)
a
CAUTION:
IMPROPER
VOLTAGE
can
damage
auxiliary
equipment.
Do
not
use
100
VAC
receptacle
for
equipment
designed
to
operate
at
a
different
voltage.
1.
Locate
supplied
cord
with
Centronics
connectors
at
each
end
of
cord.
Remove
dust
cover
from
receptacle
(left
side
panel
of
cabinet
on
Cl
Robot
Control;
cabinet
door
on
C2
Robot
Control),
and
connect
plug
at
one
end
of
cord
to
receptacle.
Use
bail
locks
on
receptacle
to
secure
plug
(see
Figure
3-8).
IMPORTANT:
Whenever
Centronics
connector
is
removed
from
receptacle
on
Robot
Control,
be
sure
to
place
dust
cover
over
the
receptacle.
2.
Connect
plug
at
remaining
end
of
cord
to
receptacle
on
rear
of
floppy
disk
drive
(see
Figure
3-8).
3.
Connect
plug
on
end
of
power
cord
to
100
volts
ac
receptacle
installed
in
lower
portion
of
left
side
panel.
An
optional
mounting
bracket
is
supplied
with
the
floppy
disk
drive
to
allow
securing
the
unit
on
top
of
the
cabinet.
1.
Install
mounting
bracket
onto
bottom
of
floppy
disk
drive
case
(see
Figure
3-9).
Use
supplied
screws
to
secure
mounting
bracket
to
case.
2.
Remove
lifting
eye
or
bolt
from
right
front
corner
of
Robot
Control
top
cover.
3.
Align
hole
in
mounting
bracket
with
hole
in
top
cover,
and
reinstall
lifting
eye
or
bolt.
Figure
3-8.
Floppy
Disk
Drive
Connections
C2
Robot
Control
Floppy
Centronics
Disk
Drive
Connector
Plug
And
Single
Receptacle
ST.152
590
Cl
Robot
Control
ST-161
115
OM-150
577
Page
8
51-152
591-8
SECTION
4-OPERATION
a
CAUTION:
INCORRECT
HANDLING
can
damage
floppy
disk
and
cause
toss
of
stored
data.
Keep
ferromagnetic
substances
such
as
magnets
away
from
floppy
disk.
Keep
magnetic
field
generating
devices
such
as
TV
sets
and
radios
away
from
floppy
disk.
Do
not
touch
magnetic
disk.
Do
not
drop
floppy
disk.
Protect
floppy
disk
from
extreme
changes
in
temperature
and
humidity.
Avoid
using
floppy
disk
in
dusty
or
ditty
environment.
Use
proper
case
to
store
floppy
disk.
Store
floppy
disk
with
write
protection
applied.
4-1.
FLOPPY
DISK
WRITE
PROTECTION
(Figure
4-1)
A
slide
type
key
is
provided
for
write
protection
to
prevent
unexpected
erasure
of
stored
data.
Always
store
floppy
disk
with
key
set
for
write
protection,
and
place
floppy
disk
in
a
proper
storage
case.
f
Write
Enable
Write
Disable
5-0882
Figure
4-1.
Write
Protection
On
Floppy
Disk
Mounting
Bracket
Hole
In
Right
Front
Corner
Of
Robot
Control
Top
Cover
Figure
3-9.
Optional
Mounting
Bracket
Installation
lop
View
Botton
View
OM.150
577
Page
9
4-2.
INSERTING
FLOPPY
DISK
INTO
FLOPPY
DISK
DRIVE
a
CAUTION:
IMPROPER
POWER-UP
PROCEDURES
can
damage
floppy
disk
and
cause
loss
of
stored
data.
Turn
off
Robot
Control
input
power
before
connecting
and
disconnecting
floppy
disk
drive.
Place
floppy
disk
drive
power
switch
in
the
ON
position
before
turning
on
Robot
Control
input
power.
1.
Open
case
cover
on
floppy
disk
drive.
2.
Place
floppy
disk
drive
power
switch
in
ON
position.
3.
Turn
on
Robot
Control
input
power.
4.
Remove
floppy
disk
from
storage
case,
check
position
of
write
protection
key
(the
write
enable
position
is
for
transfer
of
data
to
the
floppy
disk,
see
Figure
4-1),
and
insert
floppy
disk
fully
into
floppy
disk
slot
on
drive
unit
(see
Figure
2-2)
until
disk
clicks
into
slot
and
eject
button
pops
out.
5.
The
floppy
disk
is
operative
once
it
is
properly
inserted
into
the
floppy
disk
slot.
4-3.
EJECTING
FLOPPY
DISK
FROM
FLOPPY
DISK
DRIVE
a
CAUTION:
IMPROPER
EJECTING
PROCEDURE
can
cause
loss
of
data
being
transferred
to
or
from
floppy
disk.
Be
sure
that
operation
light
on
floppy
disk
drive
is
NOT
illuminated
before
ejecting
floppy
disk.
1.
If
case
cover
is
closed
on
disk
drive,
open
cover.
2.
Check
that
operation
light
is
not
illuminated
and
press
the
eject
button
on
the
floppy
disk
drive
(see
Figure
2-2).
The
floppy
disk
should
pop
out
one-half
to
two-thirds
of
the
way
from
inside
the
floppy
disk
slot.
3.
Remove
floppy
disk
from
slot,
place
write
protection
key
in
the
write
disable
position
(see
Figure
4-1),
and
place
floppy
disk
in
a
proper
storage
case.
4-4.
PROCEDURE
FOR
USING
FLOPPY
DISK
DRIVE
a
CAUTION:
IMPROPER
POWER-UP
PROCEDURES
can
damage
floppy
disk
and
cause
loss
of
stored
data.
Turn
off
Robot
Control
input
power
before
connecting
and
disconnecting
floppy
disk
drive.
Place
floppy
disk
drive
power
switch
in
the
ON
position
before
turning
on
Robot
Control
input
power.
1.
Connect
floppy
disk
drive
to
Robot
Control.
2.
Place
floppy
disk
drive
power
switch
in
ON
position.
3.
Turn
on
Robot
Control
input
power.
4.
Insert
floppy
disk
into
floppy
disk
drive.
IMPORTANT:
See
Sections
4-6
through
4-8
for
instructions
to
perform
Steps
5
through
7.
5.
Initialize
new
floppy
disk.
6.
Transfer
data.
IMPORTANT:
Do
not
touch
Program
Module
keypad
during
a
data
transfer
operation
or
a
data
error
may
occur.
7.
Verify
data.
8.
If
an
error
message
appears
on
the
Program
Module
display,
see
Section
5Troubleshooting
to
check
the
error
code
before
continuing
operation.
OM-150
577
Page
10
4-5.
PRECAUTIONS
FOR
USING
FLOPPY
DISK
DRIVE
1.
Make
sure
Robot
Control
input
power
is
OFF
before
connecting
or
disconnecting
cable
between
floppy
disk
drive
and
Robot
Control.
Damage
to
the
floppy
disk
drive
may
result
from
connecting
or
disconnecting
cable
when
Robot
Control
input
power
is
ON.
2.
Place
floppy
disk
drive
power
switch
in
the
ON
position
before
placing
the
Robot
Control
power
switch
in
the
ON
position.
This
sequence
for
energizing
the
floppy
disk
drive
and
Robot
Control
sets
the
operational
timing
for
data
transfer
between
the
two
units.
3.
Insert
a
floppy
disk
into
the
floppy
disk
slot
only
after
energizing
the
floppy
disk
drive
and
Robot
Control.
4.
Immediately
after
transferring
data
between
the
Robot
Control
memory
and
a
floppy
disk,
the
verity
function
should
be
used
to
check
if
transferred
data
matches
the
stored
data.
IMPORTANT:
The
verify
function
must
be
performed
immediately
after
a
transfer
operation.
If
other
operations
are
performed
using
the
Program
Module
keys
to
change
any
transferred
data
before
the
verify
function,
an
error
will
result
during
data
verification.
Some
possible
causes
for
an
error
during
a
transfer
operation
or
in
verifying
data
are
as
follows:
1.
The
verify
function
was
not
performed
immediately
after
the
transfer
of
data
and
stored
data
was
changed
caus
ing
a
mismatch
during
verification.
2.
The
cable
connection
between
the
floppy
disk
drive
and
Robot
Control
is
not
secure.
3.
The
floppy
disk
write
protection
key
is
in
the
write
disable
position
preventing
data
from
being
transferred
to
the
floppy
disk.
Additional
error
code
information
is
provided
in
Section
5
Troubleshooting.
4-6.
INITIALIZATION
OF FLOPPY
DISK
IMPORTAN1~
Whenever
the
transferoperation
is
to
be
done
using
a
new
floppy
disk
ora
floppy
disk
that
contains
old
data
no
longernecessary,
initialize
the
floppy
disk
to
erase
all
stored
data
and
begin
the
transferoperation
with
a
blank
floppy
disk
a
WARNING:
ELECTRIC
SHOCK
can
kill;
ROBOT
ARM
MOVEMENT
can
cause
serious
Injury
and
death;
INCORRECT
PROCEDURE
can
cause
serious
personal
injury.
Do
not
touch
live
electrical
parts.
Press
an
EMERGENCY
STOP
button
before
entering
robot
work
envelope.
Do
not
enter
robot
work
envelope
with
servo
power
on
unless
a
watchperson,
with
an
EMERGENCY
STOP
button
in
hand,
is
nearby
and
ready.
Press
and
reset
an
EMERGENCY
STOP
button
to
turn
off
servo
power,
and
check
that
there
is
no
illumina
tion
at
the
servo
power
warning
light(s)
on
manipulator
and
the
SERVO
ON
button
on
the
Operation
Module
is
not
illuminated
before
entering
the
robot
work
envelope.
IMPORTANT
See
Section
3Installation
forinformation
about
installing
and
preparing
floppy
disk
drive.
A
floppy
disk
should
NOT
be
inserted
into
the
floppy
disk
slot
prior
to
energizing
floppy
disk
drive
and
Robot
ControL
A.
Initialization
For
Cl
Robot
Control
To
prepare
the
robot
system
for
floppy
disk
initialization,
proceed
as
follows;
1.
Install
floppy
disk
drive
according
to
instructions
in
Section
3
Installation.
2.
Place
floppy
disk
drive
power
switch
in
the
ON
position.
3.
Turn
on
input
power
for
the
Robot
Control
by
placing
the
power
switch
handle
in
the
ON
position.
The
Program
Module
display
will
appear
as
shown
momentarily,
and
all
the
key
pad
LEDs
will
illuminate
during
the
display
time:
I
H A N
K
Y
OU
WA
K
E
M
E
UP
!
WE
L
C
OME
TO
M
ILL
ER!
OM-150
577
Page
11
4.
The
next
display
will
be
for
automatic
self-diagnosis
of
the
Robot
Control
functions
and
connections.
The
dis
play
during
self-diagnosis
will
appear
as
shown:
Main
Cpu
Software
Version
Number
SELF
DIAGNOSIS
VOlO
1
t
Step
Number
SELF
DIAGNOSIS
VOlO
10
IMPORTANT:
After
first
turning
on
power
to
the
Robot
Control,
automatic
self-diagnosis
will
follow
the
sequence
of
steps
from
Ito
10.
Do
the
absolute
offset
adjustment
if
any
one
of
the
following
alarm
or
error
code
messages
appear
on
the
Program
Module
display
before
continuing
the
operation
mode
selection:
1)
Error2
100000
2)Alarm2
110000
3)
Error
6280000
4)
Error
6290000
lithe
DIAGNOSIS
button
is
pressed
on
the
Operation
Module,
the
sequence
of
steps
will
be
from
0
to
8
because
no
checking
is
done
for
absolute
offset
adjustment.
Checking
absolute
offset
adjustment
is
only
performed
in
automatic
self-diagnosis
after
turning
on
power
to
the
Robot
Control.
5.
Once
automatic
self-diagnosis
is
completed,
the
display
will
appear
as
shown:
SERVO
POWER
IS
OFF
010010010010010
6.
Press
TEACH-EDIT
key
on
the
Program
Module
to
select
the
Edit
mode,
check
appropriate
key
LED
for
illumi
nation,
and
the
display
will
appear
as
shown:
P000
S000
7.
Press
the
EXTERNAL
MEMORY
key,
and
the
display
will
appear
as
shown:
P000 S000
PREPARE
MT
OPERATION
8.
Insert
floppy
disk
into
floppy
disk
slot.
9.
Press
PROGRAM
NO.
key
and
START
NO.
key
at
the
same
time,
and
the
display
will
appear
as
shown:
P000
S000
INITIALIZE?
Y:
1
N:
0
OM-150
577
Page
12
If
floppy
disk
drive
is
not
connected
to
the
Robot
Control,
the
display
will
remain
as
shown
in
Step
6.
Pressing
the
RESET
key
after
Step
8
will
cause
the
robot
system
to
return
to
the
point
of
selecting
Edit
mode,
and
the
display
will
appear
as
shown
in
Step
5.
IMPORTANT:
A
new
floppydiskmustbe
initialized
before
transferring
data
to
it.
When
initialization
is
assigned(Y:1),
al/data
currently
stored
on
floppy
disk
is
erased,
and
the
transfer
operation
begins
with
the
floppy
disk
blank
When
initiallzation
is
notassigned
(N:O),
all
data
currentlystoredon
floppydiskis
retained,
and
the
transferdata
is
savedafter
the
last
data
stored
on
the
floppy
disk
When
using
the
data
loading
operation
(see
Section
4-8),
a//data
on
the
floppy
disk
is
transferred
to
Robot
Control
memory.
10.
To
select
initialization
of
floppy
disk,
press
the
numerical
1
key
and
RECORD
key,
and
the
display
will
appear
as
shown:
P
0 0
0
S
0
0
0
DEALING
WI
TH
DATA
To
retain
data
currently
stored
on
floppy
disk,
initialization
is
not
assigned
by
pressing
the
numerical
0
key
and
RE
CORD
key.
If
initialization
is
assigned
and
successfully
completed
or
if
initialization
is
not
assigned
the
display
will
appear
as
shown:
P000
S000
PROGRAM
SAVING
If
initialization
is
assigned,
but
the
erasing
operation
is
not
completed
successfully,
the
display
will
appear
as
shown:
P000 S000
SAVING
ERROR
IMPORTANT
If
SAVING
ERROR
appears
on
the
display,
press
the
MODIFY
key,
and
initialization
selection
display
will
appearas
shown
in
Step
8.
Assign
the
initialization
again
according
to
Step
9.
If
initialization
is
completed
success
fully
PROGRAM
SAVING
will
appearon
the
display;
otherwise,
SAVING
ERROR
willagain
appear
on
the
display,
and
pressing
the
MODIFY
key
will
cause
the
display
to
change
to
the
one
that
appeared
at
the
moment
of
selecting
the
Edit
mode.
Begin
the
procedure
again
starting
at
Step
6,
and
if
initialization
is
unsuccessful,
COPY
ERROR:
1
will
appear
on
the
display.
Press
the
RESET
key,
check
connections
between
Robot
Control
and
floppy
disk
drive,
and
follow
in
structions
again
starting
at
Step
6.
11.
Press
the
RESET
key,
and
the
display
will
appear
as
shown:
P000
S000
OM-150
577
Page
13
B.
Initialization
For
C2
Robot
Control
To
prepare
the
robot
system
for
floppy
disk
initialization,
proceed
as
follows:
1.
Install
floppy
disk
drive
according
to
instructions
in
Section
3
Installation.
2.
Place
floppy
disk
drive
power
switch
in
the
ON
position.
3.
Place
the
power
switch
handle
on
the
Robot
Control
door
in
the
ON
position.
The
automatic
self-diagnosis
mode
will
appear
on
the
Teach
Pendant
display,
and
all
the
keypad
LEDs
will
illuminate
momentarily.
WELCOME
TO
DIAGNOSIS
MILLER
COOPERATIVE
CONTROL
MILLER
ELECTRIC
Mfg.
Co.
START
DIAGNOSIS
1,2,3,4,5,
92-10-31
11:51
4.
Once
automatic
self-diagnosis
is
completed,
the
EPROM
software
version
numbers
may
appear
on
the
display
if
the
optional
user
parameter
is
set
to
ON
in
PARMTER/SYSTEM/DISPLAY
VERSION;
otherwise,
the
display
will
appear
as
shown
after
Step
5.
WELCOME
TO
DIAGNOSIS
MILLER
COOPERATIVE
CONTROL
MAIN
:
130
PRM
:
O1OA
I/O
:
120
WELD
:
013
MCON
:
130
LINE
:
000
92-10-31
T.B
:
040
11:51
CONTINU
ROLL
UP
5.
Press
the
Fl
key
for
the
CONTINUE
function
to
change
to
the
Teach
mode
display.
TEACH
TEACH
EDIT
FILE
ALLOT
LOCK
>
OM-150
577
Page
14
If
the
optional
user
parameter
is
set
to
AUTO
in
PARMTER/SYSTEM/INITIAL
MODE,
an
error
code
message
will
ap
pear
on
the
display
indicating
servo
power
is
off.
AXIS
ML4
IMPOSSIBLE
TO
AU
A505010001
AUTO
SERVO
OFF
Press
the
SERVO
ON
button
on
the
Operation
Module
or
Teach
Pendant
and
operation
begins
in
Automatic
mode.
AUTO.
START
READY
AUTO.
PUSH
START
PB.
SERVO
ON
TEACH
EDIT
FILE
ALLOT
LOCK
Press
the
TEACH
button
on
the
Operation
Module
and
the
display
will
appear
as
shown
after
Step
6.
6.
After
completion
of
the
automatic
self-diagnosis
mode,
press
the
SERVO
ON
button
on
the
Operation
Module
or
Teach
Pendant
and
operation
can
begin
in
the
Teach
mode.
AXIS
ML4
TEACH
SERVO
ON
TEACH
EDIT
FILE
ALLOT
LOCK
7.
Press
the
FUNCTION
APPLICATION
key
t~
for
additional
functions
to
appear
on
the
display.
PARMTER
CHECK
MANAGE
SYS.SET
MEMORY
OM-150
577
Page
15
SERVO
ON
EXT
.
MEMORY
The
functions
available
for
the
external
memory
operation
are
as
follows:
I
~
I
key:
Displays
a
file
list.
F2
key:
Saves
a
file
(writes
data
to
a
floppy
disk).
F3
J
key:
Loads
a
file
(reads
data
from
a
floppy
disk).
F4
J
key:
Verify
file
data
after
a
save
or
load.
F5
key:
Delete
a
file
from
floppy
disk.
Press
the
FUNCTION
APPLICATION
key
c::
for
additional
functions
to
appear
on
the
display.
AXIS
ML4
TEACH
8.
Press
thel__F5
key
for
the
MEMORY
function
to
select
external
memory
functions.
SELECT
FUNCTION
L
I
ST
SAVE
LOAD
VERIFY
DEL.
>
INITIAL
Fl
key:
Initialize
the
floppy
disk.
9.
Press
the
Fl
key
for
the
INITIAL
function
to
initialize
the
floppy
disk.
AX
I
S
TEACH
ML4
IN
IT
I
AL
I
ZAT
ION
FLOPPY
DISK
FORMAT
SELECT
KIND
OF
FLOPPY
DISK.
SERVO
ON
EXT
.
MEMORY
USER
S
Y
S
TE
M
OM-150
577
Page
16
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