Miller KA600000 Owner's manual

Miller
Brand
Miller
Model
KA600000
Type
Owner's manual

This manual is also suitable for

Millerfi
August
1990
FORM:
OM-135
583A
MODEL:
Robot
Interface
(per
NSPRS
8933
And
9184)
Gas/Current
Sensing
Control
Hub
And
Spindle
~
~
OWNERS
MANUAL
IMPORTANT:
Read
and
understand
the
entire
contents
of
both
this
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
on
the
safety
material
throughout
both
manuals,
before
installing,
operating,
or
maintaining
this
equipment.
This
unit
and
these
instructions
are
for
use
only
by
persons
trained
and
experienced
in
the
safe
operation
of
welding
equip.
ment.
Do
not
allow
untrained
persons
to
Install,
operate,
or
maintain
this
unit.
Contact
your
distributor
if
you
do
not
fully
understand
these
instructions.
MILLER
ELECTRIC
Mfg.
Co.
A
Miller
Group
Ltd..
Con~any
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
PRINTED
IN
U.S.A
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.
i]
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
tree
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
thewarranties
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.
Exceptas
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,
Ml
LLERMATIC
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-
mentor,
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
Customers
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
FITNESS
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
COMMERCIAL/INDUSTRIAL
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.
I
OM.
135
583A&90
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
and/or
the
equipment
manufactur-
Model
_______________________________
ers
Transportation
Department.
Serial
or
Style
No.
___________________
When
requesting
information
about
this
equipment,
al
ways
provide
the
Model
Description
and
Serial
or
Style
Date
of
Purchase
_____________________
Number.
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
General
Information
And
Safety
1
1-2.
Safety
Alert
Symbol
And
Signal
Words
1
SECTION
2
SPECIFICATIONS
2-1.
Description
1
SECTION
3INSTALLATION
3-1.
Site
Selection
2
3-2.
Equipment
Installation
2
3-3.
Gas/Current
Sensing
Control
Interconnections
3
3-4.
Weld
Control
Motor
Connections
3
3-5.
Robot
Interface
Welding
Power
Source
Connections
3
3-6.
Robot
Interface
Robot
Control
Unit
Connections
4
3-7.
Arc
Failure
Light
Terminal
Strip
Connections
5
3-8.
Preset
Controls
5
3-9.
Peak
Amps/inductance
Control
6
3-10.
Pref
low,
Postf
low,
And
Bumback
Time
Presets
6
3-11.
Welding
Wire
Installation
6
SECTION
4OPERATOR
CONTROLS
4-1.
Power
Switch
7
4-2.
1Jog
Push
Buttons
7
4-3.
Purge
Push
Button
7
4-4.
Voltmeter
7
4-5.
Wire
Speed
Meter
7
4-6.
Peak
Amps/Inductance
Meter
7
4-7.
Indicator
Lights
7
SECTION
5
SEQUENCE
OF
OPERATION
5-1.
Input
Signals
From
Robot
Control
Unit
8
5-2.
Output
Signals
From
Robot
Interface
8
Section
No.
Page
No.
SECTION
6
MAINTENANCE
&
TROUBLESHOOTING
6-1.
Routine
Maintenance
8
6-2.
Overload
Protection
9
6-3.
Reinstallation
Of
Hub
Assembly
9
6-4.
Display
Board
PC4
Meter
Check
9
6-5.
Circuit
Board
Handling
Precautions
10
6-6.
Troubleshooting
11
6-7.
Use
Of
Indicator
Lights
For
Troubleshooting
13
SECTION
7
ELECTRICAL
DIAGRAMS
Diagram
7-1.
Circuit
Diagram
For
Robot
Interface
14
Diagram
7-2.
Circuit
Diagram
For
Voltage
Control
Board
PCi
16
Diagram
7-3.
Circuit
Diagram
For
Motor
Control
Board
PC2
17
Diagram
7-4.
Circuit
Diagram
For
Interface
Board
PC3
18
Diagram
7-5.
Circuit
Diagram
For
Meter
Display
Board
PC4
19
Diagram
7-6.
Circuit
Diagram
For
Isolation
Board
PC5
19
Diagram
7-7.
Circuit
Diagram
For
Isolation
Amp
Board
PC6
20
Diagram
7-8.
Circuit
Diagram
For
Preset
Board
PC7
20
Diagram
7-9.
Circuit
Diagram
For
Gas/Current
Sensing
Control
21
Diagram
7-10.
Circuit
Diagram
For
Gas/Current
Sensing
Control
Feedback
Board
PC6
21
SECTION
8
PARTS
LIST
Figure
8-1.
Circuit
Card,
Voltage
Control
PCi
25
Figure
8-2.
Circuit
Card,
Motor
Speed
Digital
PC2
27
Figure
8-3.
Circuit
Card,
Relay
PC3
29
Figure
8-4.
Circuit
Card,
Meter
PC4
31
Figure
8-5.
Circuit
Card,
Isolation/Amptlifier
PC5
32
Figure
8-6.
Circuit
Card,
Isolation
PC6
33
Figure
8-7.
Circuit
Card,
Feedback
PC6
34
LIST
OF
CHARTS
AND
TABLES
Table
2-1.
Specifications
1
Table
6-i.
Troubleshooting
12
SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual
and
on
various
la
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which
should
be
read,
understood,
and
followed
for
the
safe
and
effective
use
of
this
equipment.
B.
Safety
The
installation,
operation,
maintenance,
and
trouble
shooting
of
arc
welding
equipment
requires
practices
and
procedures
which
ensure
personal
safety
and
the
safety
of
others.
Therefore,
this
equipment
is
to
be
in
stalled,
operated,
and
maintained
only
by
qualified
per
sons
in
accordance
with
this
manual
and
all
applicable
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1
Safety
Rules
For
Operation
Of
Arc
Weld
ing
Power
SOurce
in
the
welding
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
a
a
This
safety
alert
symbol
is
used
with
the
signal
words
WARNING
and
CAUTION
to
call
atten
tion
to
the
safety
statements.
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
sen
ous
personal
injury
or
loss
of
life.
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify
special
instructions
necessary
for
the
most
efficient
operation
of
this
equip
ment.
SECTION
2-
SPECIFICATIONS
Table
2-1.
SpecIfications
~1
Component
Dimensions
Weight
Height
Width
Depth
Net
Ship
Robot
Interface
22-1/2
in.
(572
mm)
16-1/2
in.,
(419
mm)
6-1/4
in.
(159
mm)
38
lbs.
(17
kg)
Total
61
lbs.
(27.7
kg)
Gas/Current
Sensing
Control
4-1/2in.
(108
mm)
5-1/2
in.
(140
mm)
10-1/2
in.
(267
mm)
5
lbs.
(2.3
kg)
Spool
Support
Assembly+
13-3/4
in.
(349
mm)
8-3/4
in.
(222
mm)
8-1/2
in.
(216
mm)
6
lbs.
(2.7
kg)
Add
2-1/4
in.
(57
mm)
for
brake
resistor.
+Spool
Support
without
optional
wire
reel.
Add
7/8
in.
(22
mm)
for
front
panel
knob.
2-1.
DESCRIPTION
The
robot
interface
control
is
designed
to
interface
with
a
GMF
robot
and
an
Arc
Pak
350,
Deltaweld,
Maxtron,
or
Pulstar
450
welding
power
source.
This
unit
provides
digital
display
of
weld
votts,wire
feed
speed,
and
peak
amperage
or
inductance.
The
gas/current
sensing
control
contains
the
gas
valve,
shunt,
and
current
sensing
reed
relay.
These
components
function
with
the
robot
system
when
using
the
Gas
Metal
Arc
Welding
(GMAW)
process.
OM-135
583
Page
1
SECTION
3-INSTALLATION
3-1.
SITE
SELECTION
Select
an
installation
site
which
provides
the
following:
1.
Correct
input
power
supply
(see
unit
nameplate)
2.
Shielding
gas
supply
(if
applicable)
3.
Water
supply
(if
applicable)
4.
Adequate
ventilation
and
fresh
air
supply
5.
No
flammables
6.
A
clean
and
dry
area
7.
Proper
temperature
that
avoids
extremes
of
heat
or
cold
8.
Proper
airflow
around
unit
9.
Adequate
space
to
open
and
remove
cover
and
wrapper
for
installation,
maintenance,
and
repair
functions.
Mounting
holes
provide
the
capability
to
install
and
se
cure
the
system
components
in
a
permanent
location.
Table
2-1
gives
overall
dimensions.
3-2.
EQUIPMENT
INSTALLATION
A.
Supplied
Equipment
The
following
equipment
is
supplied
as
standard
and
re
quires
installation
or
assembly:
1.
Weld
Control
with
Gas/Current
Sensing
Control
Cord
and
Motor
Cord
2.
Gas/Current
Sensing
Control
3.
Hub
and
Spindle
Assembly
4.
Spindle
Support
5.
Weld
Control
Welding
Power
Source
Intercon
necting
Cords
6.
Gas
Hose
7.
Voltage
Sensing
Cord
B.
EquIpment
Location
When
deciding
on
equipment
location,
consider
the
fol
lowing:
1.
The
equipment
must
be
mounted
to
a
structure
ca
pable
of
supporting
the
weight
of
the
equipment.
2.
The
lead
lengths
of
the
cords
supplied
with
the
equipment
will
limit
the
area
in
which
the
equipment
can
be
located.
Some
cords
can
be
extended
by
us
ing
optional
extension
cords
(check
with
welding
equipment
distributor).
3.
The
interconnecting
cords
must
be
routed
so
that
they
are
not
caught,
pinched,
or
strained
during
welding
operations.
4.
One
weld
output
cable
must
be
routed
to
the
Gas!
Current
Sensing
control.
5.
Welding
wire
must
be
routed
so
that
it
does
not
con
tact
the
weld
control
or
any
other
grounded
equip
ment.
C.
Equipment
Installation
Obtain
appropriate
mounting
brackets
or
adapter
plates
as
necessary
and
mounting
hardware.
Prepare
struc
ture
for
equipment
installation.
Secure
weld
control,
Gas/Current
Sensing
control,
and
all
other
equipment
onto
structures
in
the
welding
area.
D.
Hub
installation
(Figure
3-1)
The
hub
assembly
is
supplied
with
the
robot
interface.
Remove
the
hub
asse
rnbly
from
the
shipping
carton,
and
install
it
as
follows:
1.
Remove
hex
nut
from
end
of
hub
support
shaft.
2.
Align
keyway
and
insert
hub
support
shaft
through
selected
hole
in
hub
support.
Hole
selection
in
hub
support
depends
on
wire
spool
size.
Be
sure
the
brake
washers
are
properly
seated
in
the
hub.
3.
Reinstall
hex
nut
onto
support
shaft.
lighten
hex
nut
until
a
slight
drag
is
felt
while
turning
hub.
4.
Install
welding
wire
according
to
Section
3-11.
Hub
Support
FIgure
3-1.
Hub
Assembly
Installation
SA-126
870
I.
Hub
Support
Shaft
Hub
Assembly
Hex
Nut
OM-135
583
Page
2
2.
Align
keyway,
insert
17-pin
plug
into
matching
re
ceptacle
on
welding
power
source,
and
rotate
thread
collar
fully
clockwise.
C.
REMOTE
10
ConnectIons
1.
Align
keyway,
insert
10-socket
plug
into
matching
receptacle
RC15
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyway,
insert
plug
into
matching
receptacle
on
the
welding
power
source,
and
rotate
threaded
collar
fully
clockwise.
Voltage
Sensing
Lead
Ring
Terminal
Location
Wire
Drive
Assembly
Ret:
TA-109
093
Figure
3-3.
Voltage
Sensing
Connections
At
WIre
DrIve
Assembly
D.
Voltage
Sensing
Connections
1.
Align
keyway,
insert
4-socket
plug
into
matching
re
ceptacle
RC12
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Connect
lead
with
ring
terminal
to
wire
drive
assem
bly,
along
with
the
weld
cable
from
the
welding
pow
er
source,
as
shown
in
Figure
3-3.
3.
Connect
lead
with
clamp
to
the
workpiece.
3-6.
ROBOT
INTERFACEROBOT
CONTROL
UNIT
CONNECTIONS
(Figure
3-2)
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
making
inter
connections.
LockoutIta~ging
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.
CAUTION:
IMPROPER
USE
OF
SOCKET
r
can
cause
equipment
damage.
Use
socket
ronly
when
using
a
Karel
Control
ler.
Activating
+24
volts
dcatsocketrcandamage
other
brand
equipment
connected
to
receptacle
RC17.
1.
Obtain
a
proper
cord
and
37-pin
Amphenol
plug
(not
supplied).
2.
Connect
conductors
at
one
end
of
cord
to
appropri
ate
sockets
in
plug.
3.
Align
keyway,
insert
37-pin
plug
into
matching
re
ceptacle
on
robot
interface,
and
rotate
threaded
col
lar
fully
clockwise.
4.
Route
and
connect
conductors
at
remaining
end
of
cord
to
the
robot
control
unit.
The
input
and
output
signals
at
the
sockets
of
receptacle
RC17
by
means
of
the
robot
interface
control
circuitry
are
as
follows:
Socket
A:
+
Arc
Volts;
0-10
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
A
(ana
log
common)
equals
0-50
volts
dc
output.
Socket
B:
Arc
Volts;
analog
common
for
Socket
B
(+
Arc
Volts).
Socket
C:
+
Peak
Amps;
0-10
volts
dc
input
from
ro
bot
control
unit
with
respect
to
Socket
D
(analog
common)
equals
0-500
amperes
dc
output.
Socket
D:
Peak
Amps;
analog
common
for
Socket
C
(+
Peak
Amps).
Socket
E:
+
Wire
Feed
Speed;
0-10
volts
dc
input
from
robot
control
unit
with
respect
to
Socket
F
(analog
common)
equals
0-1000
1PM.
Socket
F:
Wire
Feed
Speed;
analog
common
for
Socket
E
(+
Wire
Feed
Speed).
SocketJ:
Voltage
Feedback;
100V
(arc
voltage)
=
1OV
(feedback
signal)
with
respect
to
Socket
K.
Socket
K:
Voltage
Feedback;
analog
common
for
Socket
J.
Socket
L:
Current
Feedback;
500A
(weld
current)
=
1OV
(feedback
signal)
with
respect
to
Socket
M.
Socket
M:
Current
Feedback:
anaiog
common
for
Socket
L.
Wire
Stuck
Signal;
return
for
Socket
P.
Wire
Stuck
Signal
output
to
robot
control
unit
with
respect
to
Socket
N;
indicates
wire
is
stuck
to
work.
So~ket
R:
Contactor
Control;
contact
closu
refrom
ro
bot
control
unit
with
respect
to
Socket
a,b
(Circuit
Common).
Socket
5:
Gas
Control;
contact
closure
from
robot
control
unit
with
respect
to
Socket
a,b
(Cir
cuit
Common).
Socket
U:
Jog
Forward;
contact
closure
from
robot
control
unit
with
respect
to
Socket
a,b
(Cir
cuit
Common).
Socket
V:
Jog
Reverse;
contact
closure
from
robot
control
unit
with
respect
to
Socket
a,b
(Cir
cuit
Common).
Nut
Lock
Washer
Flat
Washer
Location
Socket
N:
Socket
P:
a
OM-135
583
Page
4
To
Voltage
Source
(1I5VAC,
24VAC,
24VDC)
~rc
Failure
2TM
Indicator
Light
Arc
Failure
IndIcator
Ught
.
Sockets
a,b:
Circuit
Common
for
Sockets
A,
S,
U,
and
b.
Obtain
a
115
or
24
vac,
or
24
vdc
isolation
relay
V;
all
circuit
voltages
referenced
to
this
CR1,
and
install
into
robot
control.
point.
c.
Route
and
connect
remaining
end
of
cord
to
one
Socket
d:
Current
Detect
output
to
robot
control
unit
side
of
the
normally-open
robot
control
relay
with
respect
to
Socket
m.
contact
and
ground.
Socketh:
Weld
Standby
output
to
robot
control
unit
d.
Connect+24vdctoremainingsideof
normally-
with
respect
to
Socket
m
(Digital
Corn-
open
robot
control
relay
contact.
mon);
indicates
robot
interface
is
in
stand-
e.
Connect
a
lead
from
one
side
of
robot
control
by.
This
is
a
normally-open
contact.
coil
to
weld
alarm
terminal.
Socket
m:
Digital
Common
for
Sockets
d
and
h.
1.
Connect
proper
voltage
source
(115
vac,
24
Socket
r:
+24
volts
dc.
(Option
For
Karel
Controller)
Socket
s:
Chassis
ground.
vac,
or
24
vdc)
between
common
terminal
and
remaining
side
of
robot
control
relay
coil.
Robot
Control
Unit
Robot
interface
IMPORTANT:
The
remaining
sockets
in
the
receptacle
are
not
used.
3-7.
ARC
FAILURE
LIGHT
TERMINAL
STRIP
CON-
NECTIONS
(FIgure
3-4)
There
are
two
terminal
strips
inside
the
robot
interface
for
control
connections.
Loosen
screws
on
strain
relief
on
unit
right
side
panel
if
applicable,
open
front
panel
ac
cess
door,
and
locate
appropnate
terminal
strip
torcon-
nections.
Tighten
screws
on
strain
relief
if
necessary,
Weld
Alarm
Terminal
Common
Terminal
It
So
Equipped
If
So
Equipped
+24VDC~~1lJ
21
~
-
and
close
and
secure
front
panel
access
door
when
pro-
Robot
Control
Unit
cedure
is
finished.
The
ARC
FAILURE
light
on
the
robot
interface
front
pan
el
is
turned
on
and
off
by
a
signal
from
the
robot
control
unit.
Obtain
proper
length
of
18
gauge/2-conductor
cord
for
this
connection,
and
proceed
as
follows:
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Isolation
Relay
CR1
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockouttagging
procedures
before
making
inter-
Robot
Controi
Robot
Interface
connections.
Lockout/tagging
procedures
consist
of
padlock-
+24VDC
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
.
.
1.
For
robot
control
units
when
24
vdc
is
used
(Figure
3-4):
a.
Route
cord
through
strain
relief
on
right
side
panel
of
robot
interface,
and
make
proper
con
S-0292
Figure
3-4.
Arc
Failure
Light
Connections
nections
to
2TL
and
2TM.
3-&
PRESET
CONTROLS
(FIgure
3-5)
b.
Route
and
connect
remaining
end
of
cord
to
weld
alarm
terminal
and
ground
connection
at
The
unit
isshippedfromthefactorywith
presetvalues
of
wire
feed
speed
and
voltage
(300
ipm
at
20
volts).
If
a
the
robot
control
unit.
value
is
not
preset
for
the
voltage
and
wire
feed
speed,
c.
Connect
+24
vdc
to
common
relay
contact
ter-
minal.
the
robot
system
will
not
start.
To
change
preset
values,
proceed
as
follows:
2.
Forrobotcontrolun,tswhen
ll5or24vac,
or24vdc
is
used
(Figure
3-4):
WARNING:
ELECTRIC
SHOCK
can
kIll.
~
Do
not
touch
live
elect
rica!
parts.
a.
Route
cord
through
strain
relief
on
right
side
panel
of
robot
interface,
and
make
proper
con
Power
is
applied
to
the
weld
control
during
the
following
procedure.
nections
to
2TL
and
2TM.
1.
Open
interface
control door.
Common
Terminal
Weld
Alarm
Terminal
If
So
E~UIPP_~_,_~,/
If
So
Equipped
2TM
OM-135
583
Page
5
2.
Locate
Preset
circuit
board
PC7
on
inside
of
door
(see
Figure
3-5).
3.
Locate
WFS
Preset
R3
and
Voltage
Preset
R4
on
PC7.
4.
While
watching
VOLTS
and
WIRE
FEED
meters,
adjust
potentiometers
to
desired
preset
conditions.
5.
Close
and
secure
interface
control
door.
Figure
3-5.
Preset
Board
PC7
R~:
SA-139
296
3-9.
PEAK
AMPS/INDUCTANCE
CONTROL
This
unit
is
shipped
for
use
with
a
two
analog
channel
robot.
This
means
that
peak
amperage
or
inductance
can
be
set
at
the
interface
using
potentiometer
R4.
R4
is
located
beneath
the
snap-in
blank
on
the
lower
left
cor
ner
of
the
interface
front
door.
This
unit
can
be
used
with
a
three
channel
robot
where
the
robot
control
sets
peak
amperage.
A
jumper
link
must
be
moved
on
terminal
strip
iT
to
accomodate
the
three
channel
robot.
4A
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
changing
in
ternal
connections.
Lockout/tagging
procedures
consist
of
padlock
ing
line
disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
1.
Open
interface
control
door.
Locate
terminal
strip
11.
2.
Move
the
jumper
from
between
1
TE
and
1
TF
to
be
tween
lTD
and
1TE.
3.
Close
and
secure
interface
control
door.
3-10.
PREFLOW,
POSTFLOW,
AND
BURNBACK
TIME
PRESETS
On
the
left
side
of
the
interface
control
there
are
three
snap-in
blanks.
Beneath
these
snap-in
blanks
are
screwdriver
adjustable
potentiometers.
The
top
poten
OM-t35
583
Page
6
tiometer
sets
pref
low
time
from
0
to
6
seconds.
The
middle
potentiometer
sets
postf
low
time
from
0
to
6
sec
onds.
The
bottom
potentiometer
sets
burnback
time
from
approximately
5
to
250
milliseconds.
3-11.
WELDING
WIRE
INSTALLATION
(Figure
3-6)
Wire
Retainer
SC-127
~OB
Figure
3-6.
Optional
Wire
Reel
And
Reel-Type
Wire
Installation
A.
Installation
Of
Spool-Type
Wire
1.
Remove
retaining
ring.
2.
Slide
spool
of
wire
onto
hub
so
that
wire
feeds
off
bottom
of
spool.
3.
Rotate
spool
until
hole
in
spool
aligns
with
pin
in
hub.
Slide
spool
onto
hub
until
it
seats
against
back
flange
of
the
hub.
4.
Reinstall
retaining
ring
onto
hub.
B.
Installation
Of
Optional
Wire
Reel
And
Reel-
Type
Wire
1.
Remove
retaining
ring
and,
if
applicable,
wire
reel
assembly
from
hub.
2.
Lay
wire
reel
assembly
flat
on
a
table
or
floor.
3.
Remove
spanner
nut
from
wire
reel
assembly.
4.
Remove
wire
retainer,
and
install
wire
onto
wire
reel.
Be
sure
that
wire
feeds
off
bottom
of
reel.
5.
Reinstall
wire
retainer
and
spanner
nut
onto
wire
reel.
6.
Slide
wire
reel
assembly
onto
hub,
and
rotate
as
sembly
until
hub
guide
pin
is
seated
in
reel.
7.
Reinstall
retaining
ring
onto
hub.
C.
Adjustment
Of
Hub
Tension
(Figure
3-1)
Check
the
hub
tension
by
slowly
rotating
the
wire
spool
or
reel.
The
wire
should
unwind
freely,
but
hub
tension
should
be
sufficient
to
keep
wire
taut
and
prevent
back
lash
when
the
wire
feed
stops.
If
adjustment
is
required,
loosen
or
tighten
the
hex
nut
on
the
end
of
the
hub
sup
port
shaft
accordingly.
Retaining
Ring
SECTION
4-
OPERATOR
CONTROLS
Gas
Indicator
Light
Contactor
Indicator
Light
Voltmeter
Wire
Speed
1PM
Meter
Peak
Amps/
Inductance
Meter
Circuit
Breaker
(See
Section
6-2)
Power
Switch
Purge
Push
Button
Switch
Jog
REV
Push
Button
Switch
Location
Ref.
TB-119
645
4-1.
POWER
SWITCH
(Figure
4-1)
Placing
the
POWER
switch
in
the
ON
position
energizes
the
robot
interface.
The
interface
must
be
on
for
the
ro
bot
to
weld.
Placing
the
POWER
switch
in
the
OFF
posi
tion
shuts
down
the
interface.
4-2.
JOG
PUSH
BUTTONS
(Figure
4-1)
The
JOG
FWD
and
JOG
REV
push
buttons
are
momen
tary-contact
switches.
4-3.
PURGE
PUSH
BUTTON
(Figure
4-1)
The
PURGE
push
button
is
a
momentary-contact
switch.
This
switch
energizes
the
gas
solenoid
and
purges
the
shielding
gas
line
of
the
gun.
The
PURGE
push
button
allows
the
flow
meter
to
be
adjusted
without
energizing
the
welding
circuit.
4-4.
VOLTMETER
(Figure
4-1)
The
voltmeter
displays
weld
voltage
to
the
nearest
tenth
of
a
volt
while
welding
and
preset
voltage
while
idling.
4-5.
WIRE
SPEED
METER
(FIgure
4-1)
The
wire
speed
meterdisplays
preset
wire
feed
speed
to
the
nearest
inch
per
minute
while
welding
and
idling.
Ac
tual
and
preset
wire
feed
speed
are
the
same
due
to
the
wire
feed
speed
feedback
circuit.
4-6.
PEAK
AMPS/INDUCTANCE
METER
(Figure
4-1)
When
used
with
the
Puistar
welding
power
source,
the
meter
displays
preset
peak
weld
amperage
to
the
near
est
ampere
while
welding
and
idling.
When
used
with
the
Arc
Pak
welding
power
source,
in
ductance
is
displayed
in
percentage.
4-7.
INDICATOR
LIGHTS
(Figure
4-1)
There
are
five
indicator
lights
on
the
interlace.
These
are
visual
indications
of
various
process
functions.
The
GAS
light
turns
on
when
the
gas
valve
is
energized
to
indicate
shielding
gas
flow.
The
CONTACTOR
light
turns
on
when
the
welding
pow
er
source
contactor
is
energized
to
indicate
that
weld
ou~ut
is
available.
The
WIRE
FEED
light
turns
on
when
the
wire
drive
motor
is
energized
to
indicate
that
wire
is
feeding.
The
CURRENT
light
turns
on
when
the
current
detect
relay
is
energized
to
indicate
that
an
arc
is
established.
The
ARC
FAILURE
light
turns
on
only
when
properly
connected
according
to
instructions
in
Section
3-7,
and
there
is
an
arc
outage
while
welding.
Fuse
(See
Section
6-2)
Wire
Feed
indicator
Light
Figure
4-1.
Front
Panel
Controls
OM-135
583
Page
7
Wire
Feed
Speed
01OV
=
0-1000
1pm
Output
Volts
0-IOV
=
0-50V
Peak
Amps
0-500
Amps
Output
~
On,
S~.ndby
Weld
Control
J
Cnr,.flt
D.,.ct
To
Robot
(,~Wir.
S,cck
5-1.
INPUT
SIGNALS
FROM
ROBOT
CONTROL
UNIT
(Figure
5-1)
The
robot
interlace
receives
input
signals
for
contactor
control,
gas
control,
jog,
welding
volts,
and
wire
speed.
5-2.
OUTPUT
SIGNALS
FROM
ROBOT
INTERFACE
(Figure
5-1)
The
robot
interface
sends
output
signals
to
the
robot
control
unit
for
current
sense,
wire
stuck,
and
weld
standby.
SECTION
6
MAINTENANCE
&
TROUBLESHOOTING
6-1.
ROUTINE
MAINTENANCE
IMPORTANT:
Every
six
months
inspect
the
labels
on
this
unit
for
legibility.
All
precautionary
labels
must
be
maintained
in
a
clearly
readable
state
and
replaced
when
necessaiy
See
Parts
List
for
part
number
of
precautionary
labels.
Usage
and
shop
conditions
determine
the
frequency
and
type
of
maintenance.
At
minimum,
inspect
equip
ment
every
three
months
as
follows:
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit;
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
inspecting,
maintaining,
or
servicing.
Lockout/tagging
pt~cedures
consist
of
pad
Iockin~
line
disconnect
switch
in
open
position,
removing
fuses
from
fuse
box,
or
shutting
off
and
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
SECTION
5
SEQUENCE
OF
OPERATION
Robot
To
Weld
Control
Jog
Adc.nc
Jog
R.rr.ct
0..
On
Arc
On
Ootpcr
VoI1.g.
ShI.Iding
0..
WI,.
E..d
No,m.I
Abnorrn&
Figure
5-1.
Input
And
Output
Signal
Timing
Chart
Ret.
TA-095
014
OM-135
583
Page
8
MOVING
PARTS
can
cause
serious
Injury.
interface
shuts
down.
if
the
fuse
opens,
correct
the
prob
Keep
away
from
moving
parts.
lem
and
replace
Fl
as
follows:
HOT
SURFACES
can
cause
severe
burns.
1.
Depress
and
rotate
fuse
holdercovercounterclock
wise.
Allow
cooling
period
before
servicing.
Maintenance
to
be
performed
only
by
qualified
2.
Pull
out
fuse
with
cover
when
fuse
holder
cover
is
free.
persons.
3.
Insert
new
fuse
into
fuse
holder
cover.
1.
Repair
or
replace,
as
required,
all
hose
and
cable;
give
particular
attention
to
frayed
and
cracked
insu-
4.
Install
fuse
with
fuse
holder
cover
back
into
unit.
lation
and
areas
where
it
enters
equipment.
5.
Depress
and
rotate
fuse
holdercoverclockwise
until
2.
Remove
grease
and
grime
from
components;
mois-
cover
is
secure.
ture
from
electrical
parts
and
cable.
6-3.
REINSTALLATION
OF
HUB
ASSEMBLY
(FIg
6-2.
OVERLOAD
PROTECTION
ure
6-1)
WARNING:
ELECTRIC
SHOCK
can
kill.
If
it
becomes
necessary
to
replace
part
or
all
of
the
hub
Do
not
touch
live
elect
rical
parts.
assembly,
reinstall
the
new
hub
assembly
as
follows:
Shut
down
unit,
welding
power
source,
and
1.
Removehubassemblyfromhubsupportanddisas
robot,
and
disconnect
input
power
employing
semble
discarding
worn
or
broken
parts.
lockout/tagging
procedures
before
inspecting,
2.
Slide
the
following
items
onto
the
hub
support
shaft
maintaining,
or
servicing.
in
order
given.
Lockoutltagging
procedures
consist
of
pad
locking
line
disconnect
switch
in
open
position,
a.
Spring
removing
fuses
from
fuse
box,
or
shutting
off
and
b.
Keyed
Washer
red-tagging
circuit
breaker
or
other
disconnect
ing
device.
c.
Fiber
Washer
INCORRECT
FUSE
can
damage
unit.
d.
Brake
Washer
Use
only
replacement
fuse
of
same
size,
type,
e.
Hub
and
rating
(see
Parts
List).
1.
Brake
Washer
A.
Wire
Drive
Motor
Circuit
Breaker
CB1
(Figure
g.
Fiber
Washer
4-1)
4A
WARNING:
Read
and
follow
safety
informa-
3.
Align
keyway,
and
insert
hub
support
shaft
through
tion
at
beginning
of
Section
6-2
before
pro-
selected
hole
in
hub
support.
ceeding.
4.
Install
hex
nut
onto
hub
support
shaft.
Tighten
hex
Circuit
breaker
CB1
protects
the
wire
drive
motor
from
nut
until
a
slight
drag
is felt
while
turning
hub.
overload
.
If
CB1
opens,
the
wire
feed
motorwould
stop.
5.
Install
welding
wire
according
to
Section
3-11.
Should
a
motor
overload
occur
and
CB1
open,
proceed
as
follows:
6-4.
DISPLAY
BOARD
PC4
METER
CHECK
(Figure
6-2)
1.
Check
for
jammed
wire
or
clogged
gun
liner,
and
correct
problem.
If
wire
jams
often,
replace
gun
liner.
Check
points
are
provided
on
the
display
board
PC4
for
checking
power
supply
and
input
command
for
the
me-
2.
If
motoroverload
occurs
often,
repair
or
replace
wire
ters.
drive
motor.
WARNING:
ELECTRIC
SHOCK
can
kill.
3.
Check
for
binding
drive
gear
or
misaligned
drive
4~.
Do
not
touch
live
electrical
parts.
rolls,
and
correct
problem.
-
Be
sure
that
personnel
performing
testing
4.
Reset
circuit
breaker
by
depressing
the
button.
A
procedures
are
familiar
withandfollowstandard
cooling
period
may
be
necessary
before
the
circuit
safety
practices.
breaker
can
be
reset.
Shut
down
unit
before
making
or
changing
5.
Resume
operation.
meter
or
test
equipment
lead
connections.
ELECTROSTATIC
DISCHARGE
(ESD)
can
B.
Main
Fuse
Fl
(Figure
4-1)
damage
electronic
components.
a
WARNING:
Read
and
follow
safety
Informa-
Put
on
a
properly
grounded
wrist
strap
tion
at
beginning
of
Section
6-2
before
pro-
BEFORE
handling
circuit
boards.
ceedlng.
Transport
all
static-sensitive
components
in
Fuse
Fl
protects
the
robot
interface
from
an
internal
proper
static-shielding
carriers
and
packages.
short
or
excessive
overload.
If
fuse
Fl
opens,
the
robot
Perform
work
only
at
a
static-safe
work
area.
OM-135
583
Page
9
Ring
Wire
Retainer
FIgure
6-1.
Hub
And
Reel
Assemblies
Locate
display
board
PC4.
3.
Check
voltage
according
to
Figure
6-2.
4.
If
a
meter
power
supply
and
command
voltage
is
correct
and
the
meter
is
not
working,
replace
the
me
ter
(see
Section
6-5
and
contact
nearest
Factory
Au
thorized
Service
Station).
5.
If
the
power
supply
orcommand
voltage
is
incorrect,
replace
display
board
PC4
(see
Section
6-5
and
contact
nearest
Factory
Authorized
Service
Sta
tion).
6-5..
CIRCUIT
BOARD
HANDLING
PRECAUTIONS
a
WARNING:
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockout/tagging
procedures
before
inspecting,
maintaining,
or
servicing.
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.
Wire
Reel
Spring
Spanner
Nut
Hub
Support
Shaft
OPTIONAL
Brake
Washer
Hub
Fiber
Washer
Fiber
Washer
Hub
Support
Rear
View
Of
Display
Board
PC4
I~et.
SC-127
328
Input
Command
For
Volts
Meter
O.5V
50V
1.
Open
robot
inteilace
access
door.
2.
Figure
6-2.
Display
Board
Meter
Checks
OM-135
583
Page
10
Table
6-1.
TroubleshootIng
TROUBLE
PROBABLE
CAUSE
REMEDY
No
arc
voltage
control.
Output
control
connections.
Check
and
secure
connections
(see
Section
3-4).
Arc
sensing
connections.
Check
and
secure
connections
(see
Section
3-4).
Voltage
Board
PCi
not
working.
Replace
PCi
(see
Section
6-5
and
contact
near
est
Factory
Authorized
Service
Station).
Incorrect
robot
command
voltage.
Check
robot
command
voltage
at
Isolation
Board
PC5.
Command
voltage
should
be
0-10
vdc
be
tween
sockets
A
()
and
B
(common)
at
RC17.
Incorrect
robot
peak
command
cur-
rent.
Check
robot
peak
command
current
at
Isolation
Board
PC5.
Peak
command
current
should
be
0-10
vdc
between
sockets
C
and
D
(common)
at
RC17.
Robot
moveswhenwelding
wire
is
stuck.
Wire
stick
connection.
Be
sure
that
leads
from
robot
are
connected
to
sockets
P
and
N
at
RCI7.
Wire
speed
(1PM)
meter
goes
to
zero.
Incorrect
robot
command
voltage.
Check
robot
command
voltage
at
Motor Board
PC2.
Signal
should
be
0-10
vdc
between
pins
K
and
B
(common)
at
RC5.
Motor
Board
PC2
not
working.
Replace
PC2
(see
Section
6-5
and
contact
near
est
Factory
Authorized
Service
Station).
Unit
does
not
operate.
Fuse
Fl
Open.
Check
Fl,
and
replace
if
necessary
(see
Section
6-2).
Correct
overload
problem
before
Continu
ing
operation.
Circuit
breaker
CB1
tripped.
Check
CB1,
and
reset
if
necessary
(see
Section
6-2).
Correct
overload
problem
before
continu
ing
operation.
No
meter
display.
Meter
not
working.
Use
check
points
on
Display
Board
PC4
to
deter
mine
if
power
is
available
to
meter
(see
Section
6-4).
If
check
points
are
okay,
replace
meter
(see
Section
6-5
and
contact
nearest
Factory
Autho
rized
Service
Station).
Display
Board
PC4
not
working.
Use
check
points
to
determine
if
power
is
avail
able
(see
Section
6-4).
If
check
points
do
not
test
okay,
replace
PC4
(see
Section
6-5
and
contact
nearest
Factory
Authorized
Service
Station).
No
wire
feed.
.
~
Robot
signal.
:
Check
input
signal
from
robot
to
Motor
Board
PC2.
Signal
should
be
0-10
vdc
between
pins
K
and
B
(common)
on
RC5.
Relay
CR1
not
working.
Replace
CR1.
Motor
Board
PC2
not
working.
Replace
PC2
(see
Section
6-5
and
contact
near
est
Factory
Authorized
Service
Station).
Wire
feeds
at
maximum
only.
Tach
board
at
wire
drive
motor
not
working.
Replace
tach
board
(see
motor/drive
assembly
Owners
Manual).
OM-135
583
Page
12
6-7.
USE
OF
INDICATOR
LIGHTS
FOR
TROUBLESHOOTING
on4
Gas
flows:
System
normal
(on.)
Gas
Indicator
Light
Gas
does
not
flow
Gas
flows:
Check
gas
valve
operation.
Check
gas
valve
operation
and
gas
line
for
leaks.
Check
interface
board
PC3.
DOff
Gas
does
not
flow
System
normal
(oft).
On4
Contactor
closed:
System
normal
(on).
Contactor
closed:
Check
display
board
PC4.
Current
Indicator
Light
Wire
does
not
feed:
System
normal
(off).
No
arc:
System
normal
(off).
No
arc:
Arc
started:
Check
weld
parameters.
Check
signal
from
robot.
Signal
should
be
24
vdc
between
terminals
2TL
and
2TM.
Check
display
board
PC4.
Contactor
Indicator
Light
Contactor
open:
Check
interconnecting
cords.
Check
interface
board
PC3.
Off
le
Contactor
open:
System
normal
(off).
On
Wire
Feed
Indicator
Light
~
Off
~
I
~Ir
Wire
does
not
feed:
Check
circuit
breaker
CB1
Check
relay
CR1.
Check
interface
board
PC3.
Wire
feeds:
System
normal
(on).
On4
Wire
feeds:
Check
input
signal
from
robot
to
motorboard
PC2.
Signal
should
be
0-10
vdc
between
pins
K
and
B
(common)
at
RC5.
Check
motor
board
PC2
ll~
Arc
started:
No
arc:
Arc
started:
System
normal
(on).
Replace
reed
relay.
Replace
reed
relay.
Off
On
Arc
Failure
Indicator
Light
Off
No
arc:
Normal
during
idling.
Arc
started:
Normal
while
welding.
OM-135
583
Page
13
SECTION
7-
ELECTRICAL
DIAGRAMS
A
IC
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DIagram
7-1.
CIrcuit
Diagram
For
Robot
Interface
N
N
0
A
6
7
a
I
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OM-135
583
Page
14
Circuit
Diagram
No.
SD-i
39
396
OM-135
583
Page
15
b
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Circuit
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518
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DIagram
7-2.
CIrcuit
Diagram
For
Voltage
Control
Board
PCi
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Miller KA600000 Owner's manual

Miller
Brand
Miller
Model
KA600000
Type
Owner's manual
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