Miller KE709896 Owner's manual

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

MILLERS

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

manufacturers

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

MILLERS

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

customers

risk

and

expense.

MILLERS

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~.

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1992

(Equipment

with

a

serial

number

preface

of

KC

or

newer)

This

limited

warranty

supersedes

all

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

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

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

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

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

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

5Troubleshooting

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

3Installation

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

LEDs

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

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

010010010010010

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

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

LEDs

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

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

A505010001

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.

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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