Miller Electric NSPR 8989 User manual

Millerfi
November
1990
FORM: OM-135 582B
MODEL:
Robot
Interface
(per
NSPR
8989)
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
MIter
Group
Ltd..
Con~any
P.O.
Box
1079
Appleton,
WI
54912
USA
Tel.
414-734-9821
PRINTED
IN
U.S.A

Ui
ii
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
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

Accessory
Kits
MIg.
Co.,
Appleton,
Wisconsin.
warrants to
its
original
retail
purchaser
that
new 
Replacement
Parts
MIl.LER
equipment
sold
after the
effective date of
this
limited
warranty
is
tree
of
de
fects
in material
and
workmanship
at
the
tune
it
is
shipped by
MILLER.
THIS
WAR-
,
TM
PANTY IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES, EXPRESS
OR
MILLER
S
True Blue Limited
Warranty
shall
not
apply
to:
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS-
1
Items
fUrnished
by
MILLER,
but
manufactured
by
Others,
such
as
engines
or
trade
accessories.
These items
are
covered
by
the manufacturers
warranty,
if
Within
Inc
warranty
periods
listed
below,
MILLER
wilt
repair
or
replace
any
war-
any
ranted
parts
or
components
that
fail
due to
such detects
in
material
or
workmanship.
MILLER
must
be
notified
in
writing
within
thirty 30)
days
of
such
detector
failure, at
2
Consumable
components:
such
as
contact
tips,
cutting
noZzles.
contactors
which
time
MILLER
will
provide
instructions on
the
warranty
claim
procedures
lobe
and
relays
followed.
3.
Equipment
that has been
modified
by any
parry
other
than
MILLER,
or
equip-
MILLER
shall honor
warranty
claims
on
warranted
equipment
listed below
in
the
rnent
that has
been
improperly
installed,
improperly
Operated
or misused
event
of
such
a
failure
within
the
warranty
time
periods.
All
warranty
time
periods
based
upon
industry
standards, or
equiprnentwhich
has
not
had
reasonable
start
on
the date
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
and
necessary
maintenance, or
equipment
which has been used for
operation
and
are
as
follows:
outside
of
the
specifications
for
the
eQuipment
1.
5
Years
Parts
-3
Years Labor
MILLER
PRODUCTS
ARE
INTENDED FOR PURCHASE
AND
USE
BY
COMMER
CIAUINOUSTRIAL
USERS
AND
PERSONS
TRAINED AND
EXPERIENCED
IN
Original
main
power
rectifiers
THE USE
AND
MAINTENANCE OF WELDING
EQUIPMENT
2.
3 Years

Parts and
Labor
In
the
event
of
a
warranty
claim covered
by
this
warranty,
the
exclusive
remedies

Transformer/Rectifier
Power
Sources
shall
be.
at
MILLERS
option:
(I)
repair:
or
(2)
replacement:
Or,
where authorIzed
in

Plasma Arc
Cutting
Power Sources writing
by
MILLER
in
appropriate
cases.
(3)
the
reasonable
cost
of
repair
or
replace-

Semi-Automatic
and
AutOrr~atic
Wire Feeders
Went
St
an
authorized
MILLER
service
station: or
(4)
payment
of
or credIt
for
the
pur

Robots
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
3. 2
Years

Parts and Labor
will
be
F
0
B
,Factory
at
Appleton,
Wisconsin,
or
F
0
B
at
a
MILLER
authorized
ser
-
vice
facility
as
determined
by
MILLER
Therefore
no
compensation
or
reimburse.
Engine
Driven
Welding
Generators
merrt
for
transportation
costs
of
any
kind
will
be
allowed
(NOTE
Engines
are
warranted
separately
by
the
engine
manufacturer)
4
I
Year

Parts
and
Labor
TO THE
EXTENT PERMITTED
BY
LAW,
THE
REMEDIES PROVIDED
HEREIN
-
ARE THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO EVENT
SHALL
MILLER
BE
Motor Driven
Guns
LIABLE
FOR
DIRECT, INDIRECT, SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL

Process Controllers
DAMAGES
)INCLUDfNG
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CON-
*
Water
Coolant
Systems
TRACT,
TORT
OR
ANY
OTHER
LEGAL THEORY.
*
HF
Units
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN AND
ANY
IMPLIED
WAR.

Grids
PANTY,
GUARANTY OR
REPRESENTATION
AS
TO
PERFORMANCE.
AND
ANY
Spot
Welders
REMEDY FOR
BREACH
OF
CONTRACT TORT
OR
ANY
OTHER
LEGAL

Load
Banks
THEORY
WHICH.
BUT
FOR THIS
PROVISION,
MIGHT ARISE
BY
IMPLICATION.

SOX
Transformers
OPERATION
OF
LAW,
CUSTOM
OF TRADE
OR COURSE
OF
DEALING,
IN.
-
. .
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR FITNESS
unning
,
ear
rai
era
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT TO
ANY
AND
ALL EQUIPMENT

Field
Options
FURNISHED BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
(NOTE.
Field
options
are
covered under
True
Blue for
the
remaining
warranty
period
of the
product
they
are
installed
in,
or
for
a
minimum ~t
Some
states
in
the
U.S.A.
do
not
allow limitations of
how
long
an
implied
warranty
one
year

whichever
is
greater.)
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
ape
5. 6
Months

Batteries
cifiC
legal
rights,
and
Other
rights
may
be
available,
but
may
vary
from
state to
state.
6. 90
Days

Paris
and
Labor
In
Canada,
legislation
in
some
provincea provides
for
certain additional
warranties

MIG
Guns/TIC
Torches
or remedies other
than
as
stated
herein,
and
to
the
extent
that
they may
not
be
Waived,
the limitations
and
exclusions
set out
above
may
not
apply.
This
Limited
*
Plasma
Cutting
Torches
Warranty
provides
specific
legal
rights.
and
olher
rights
may
be
available,
but
may

Remote
Controls
vary
from
province
to
province.
~1~

ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet lists
exceptions
to
data
appearing
later
in
this manual.
AMENDMENT
TO
SECTION
3
INSTALLATION
Amend
Section
3-5B.
ROBOT INTERFACE
-
WELDING POWER
SOURCE CONNECTIONS:
REMOTE
17
Connections
3. For units
used
with
Pulstar
450
welding
power
source,
it
is
necessary
to
change
internal
connections
in
the
robot
interface.
Proceed
as
follows:
tk
WARNING:
ELECTRIC
SHOCK
can
kill.
______

Do
not
touch
live
electrical
parts.

Shut
down
unit,
welding
power
source,
and
robot,
and
disconnect
input
power
employing
lockouVtagging
procedures.
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.
a.
Open
front
panel
access
door.
b.
Locate
lead
72
at
pin
F
of
REMOTE
17
receptacle
RC16.
c.
Cut
lead
72
as
close
to
receptacle
as
possible.
d.
Splice
lead
72
to
lead
77
at REMOTE
14
receptacle
RC13
pin
D.
e.
Cover
splice
with
electrical
tape
or
other
insulation.
f.
Close
and
secure
front
panel
access
door.
a
CAUTION:
WELDING POWER SOURCE
may
not
respond
with
output
corresponding
to
set value.

Be
sure
welding
power
source
main
control
board
has
been
modified
to
use a
0
to
+
10 volt
command.
See
welding
power
source
Owners
Manual for
modification
procedure.
Add
Figure
3-7.
Voltage
Control
Board
DIP
Switch
Setting
Label
a
CAUTION: INCORRECT
DVC BOARD
DIP
SWITCH POSITION
can cause
equipment
malfunction.

DVC
DIP
switch is
factory
set
for
operation
with
Delta
weldfi
451
welding
power
source.
See
Figure
3-7
for
DVC
DIP
switch
setting
when
using
another
welding
power
source.

DVC SWITCH
SETTINGS
S2
Si
1
2
1
2
3
4
5
DELTAWELD
300
ON ON
ON
DELTAWELD
451
0ON
ON
DELTAWELD
651
0
ON ON
MAXTRON
300,
400
ON
ON
MAXTRON
450
ON
ON
ON
XMT200/300
ON ON
ON
ARC
PAK35O
ON ON
ON
SHOPMASTER
300
ON ON ON
DIMENSION
400
ON
ON
Figure
3-7.
DVC
DIP
Switch
Setting
Label
Add
Section
3-10.
SETTING
DIP
SWITCHES
ON VOLTAGE
CONTROL
BOARD
PCi
DIP
switch
Si
and
S2
on
voltage
control board
PCi
allow
setting
the
proper
command
signal
voltage
level
for
control
ling
voltage
output
at
a
welding
power
source.
To
change factory
set
position
of
DIP
switches
from
a
Deltaweldfi
451
to
another
welding
power
source,
proceed
as
follows:
a
WARNING:
ELECTRIC
SHOCK
can
kill.

Do
not
touch live electrical
parts.

Shut
down
unit,
welding
power
source,
and wire
feeder,
and
disconnect
input
power employing
lockout/
tagging
procedures
before
setting
DIP
switches.
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
static-safe
work
area.
1.
Loosen
screws
securing
front
access
door,
and
open
door.
2.
Locate
voltage
control
board
PCi
in
lower
left
portion
of
component
mounting
panel
inside
robot
interface
con
trol.
3.
Set
position
of
DIP
switches
Si
and
S2
according
to
label
inside unit
and
Figure
3-7
for
appropriate welding
power
source.
4. Close
and
secure
access
door.
Add
Section
3-11.
VOLTAGE
CONTROL
BOARD
MODIFICATION
FOR
EARLY
MODEL
WELDING POWER
SOURCE
If
the robot
interface control is
to
be
used
with
an
early
model
Deltaweld 450
or
650
welding
power
source
prior
to
serial
number
JJ400026,
proceed
as
follows:
O

On
For
Optional
Soft Start.
Turn
Off Si
-3.

On For
Optional
Hot
Start.
S~15o864A
OM-135
5828
Page
2

a
WARNING:
ELECTRIC SHOCK
can
kill.

Do
not
touch
live
electrical
parts.

Shut
down
unit,
welding
power
source,
and
wire
feede~
and disconnect
input
power
employing
Iockout/
tagging
procedures
before
making
circuit
board
modifications.
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.
i
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
static-safe
work
area.
IMPORTANT:
A
customer-supplied
cord
(Miller #042562)
is
required
to
connect
the
welding
power
source
to
the
weld
control.
1.
Loosen
screws
securing
front
access
door,
and
open
door.
2.
Locate
voltage
control
board
PCi
in
lower
left
portion
of
component
mounting
panel
inside robot
interface
con
trol.
3. Mark and
disconnect leads
from
voltage
control board
PCi.
4.
Mark
and disconnect
plugs
from
PCi.
5.
Note
position
of
circuit
board
and
remove
from
unit.
6. Place circuit board
on
a
stationary
work
surface
so
that
component
side is
facing
up.
7.
Locate
jumpers
Ji thru
J8
on
surface of board
(see
Figure
3-8).
8.
Use
a
sharp
tool
to
remove
sealant
coating
from
all
jumper
locations,
and
remove
foil
jumper
between
pads
at
J2,
J4,
J6,
and
J8.
9.
Apply
a
small
amount
of solder
to
bridge
the foil
pads
at
jumper
Ji, J3,
J5,
and J7.
10.
Apply
a
sealant
coating
over
all
jumper
locations.
11.
Reinstall
circuit
board
into
unit
in
its
original
position.
12.
Reconnect
marked leads and
plugs
to
appropriate
locations.
Receptacle
RC1
6
leads
76,
77,
and
78
must
be
changed
at
plug
PLG1 4
connected
to
receptacle
RC1
on
voltage
con
trol
board
PCi
as
follows:
IMPORTANT:
See
receptacle
RC1
pin
designations
etched
on
circuit
board
to
identify
plug
openings.
1.
Locate and disconnect
plug
PLG14
from
receptacle
RC1
on
voltage
control
board
PCi.
2.
Mark
and
remove
leads
76, 77,
and
78
from
plug
PLG1 4
by
inserting
end of
a
small,
flat-tip
screwdriver into
window
on
side
of
plug
to
bend down
locking
tab,
and
pull
contact
attached
to
lead from
plug.
3. Bend
locking
tabs
on
lead
contacts
Out
50
thatthey
secure
contacts
when
inserted
into
plug.
4.
Insert
lead
contacts
into
plug
as
follows:
a.
Lead
76
to
plug
opening
10.
b.
Lead
77
to
plug
opening
8.

c.
Lead 78
to
plug opening
9.
5.
Reconnect
plug
PLG14
to
receptacle
RC1
on
voltage
control board
PCi.
6.
Close
and
secure access
door.
Add
Figure
3-8.
Jumper
Locations
On
Voltage
Control
Board PCi
OM-1355828Page3

Ret.
SD148
322
AMENDMENT
TO SECTION
7
ELECTRICAL
DIAGRAMS
Amend
Diagram
7-1.
Circuit
Diagram
For
Robot
Interface
(see
page
8
on
this
Errata
Sheet)
Delete
Diagram
7-2.
Circuit
Diagram
For
Voltage
Board
PCi
This
diagram
no
longer
applies
effective
with
Serial
No.
KC231
859
Amend
Diagram
7-3.
Circuit
Diagram
For Motor
Control
Board
PC2
(see
pages
6 and
7
on
this
Errata
Sheet)
Amend
Diagram
7-4.
Circuit
Diagram
For
Interface Board
PC3
(see
page
9
on
this Errata
Sheet)
Figure
3-8.
Jumper
Locations
On
Voltage
Control
Board
PCi
OM-135
582B
Page
4

AMENDMENT
TO
SECTION
8
PARTS LIST
Amend Parts
List
as
follows:
**First
digit
represents
page
no

digits
following
dash
represent
item
no.
+Eff
w/KB1
13874.
Parts
on
page
27
may
not
represent
actual board.
BE
SURE TO
PROVIDE
MODEL
AND
NSPR
NUMBER
WHEN
ORDERING REPLACEMENT
PARTS.
Dia.
Part
Replaced
Mkqs.
No.
With
Description
Quantity
.
19-
CR4
.
028 291
.
. .
Added
.
.
028 291
..
.
095 521
. .
CAPACITOR,
(qty chg
&
dia.
mkg.
chg)
(C2-4
is
now
C6-10)
RELAY,
end
24VDC
4PDT
.
5
1
.
.
.
.
.
.
.
.
19-
19-
19-
19-
19-
19-
.
19-
.
20-
.
..
PCi
.
..
PC4
.
.
PLG25
049
970
.
079 844
.
027811
.
048 029
.
026 202
.
.
137695
.
.
117
836
.
..
Added
.
.
048
588
..
.
079 844
..
.
027811
..
.
048 029
..
.
026 202
..
.
148320
..
+149
339
..
.
117
037
..
BRACKET,
mtg
relay
SPRING,
(qty
chg)
SOCKET,
(qtychg)
CLIP,
(qty chg)
DIODE,
(qty
chg)
(added D4)
CIRCUIT
CARD,
(qtychg)
CIRCUIT
CARD,
meter
(Eff
w/KB113874)
HOUSING,
term
hdr
2skt
1
2
2
2
3
1
1
1
.
.
.
.
20-
.
20-
20-
20-
.
RC13
. .
109
768
.
111
122
.
.
094
480
..
.
141
162
..
134
731
. .
073 739
..
RECEPTACLE,
14
pin
MS-3102A-20-27P
(Effw/KC217109)
HOUSING
PLUG &
PINS,
(consisting
of)
..
TERMINAL,
male
1
pin
sz
16
18-14 wire
..
CLAMP,
cable
strain
relief
sz
17
.
1
1
14
2
.
.
.
20-
20-
20-
116
964
.
111
123
.
.
Deleted
. .
.
152 370
..
079 534
. .
CLAMP,
(now
md.
w/housing
plug
&
pins)
HOUSING
PLUG &
SOCKETS,
(consisting
of)
..
TERMINAL,
female
lskt 18-14
wire
1
14
.
20-
079 739
..
..
CLAMF~
strain relief
sz
17
2
.
21-
072 292
. .
154 098
..
SHAFT,
spool
support
1
.
.
21-
21-
Added
.
Added
.
.
141
700
..
.
605941
..
RING,
retaining
ext
.625shaftx
.O5Othk
(mci.
w/hub
&
spindle
assy)
WASHER,flatstl.64OIDx1.OOD
1
(md.
w/hub
&
spindle
assy)
1
OM-135
582B
Page
5

W
S
ALL
WAVEFOPIlS
AT
300
IPW-MOTOP PUNNING
ALL
VOLTAGES
MEASIJPED WITH PESPECT
TO
fi~
COM)OJ
POINT
J.
EXCEPT
~4. MEASURE
H
WITH
RESPECT
TO
POINT
~I(.
'111_
_nrL
fi
ft_ill
fi~
VV
A A
L~i
052
~
R s J
B
3V.
Diagram
7-3.
Circuit
Diagram
For Motor
Control
Board PC2
OM-135 582B
Page
6

M
D
F
C P
C??
Circuit
Diagram
No.
SD-083
388-B
OM-135
5828
Page
7
150

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S
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Circuit
Diagram
No.
SC-i
54
230
Diagram
7-i.
Circuit
Diagram
For
Robot
Interface
Effective
With
Serial
No.
KC231859

Diagram
7-4.
Circuit
Diagram
For
Interface
Board
PC3
POIJER/GROUHO NETS FOR
CHIPS
RI
i~GND 8 IS)
UI
8.5140 I6~ISU
Circuit
Diagram
No. SB-141
311-A
OM-135
5828
Page
9

OM-135
5829-11/90
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
manutactur-
Model
_______________________________
ers
Transportation
Department.
Senal
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.
Voltage
Sensing
Connections
3
3-5.
Robot
Interface

Welding
Power
Source
Connections
4
3-6.
Robot
Interface

Robot
Control
Unit
Connections
4
3-7.
Arc
Failure
Light
Terminal
Strip
Connections
5
3-8.
Welding
Wire
Installation
6
3-9.
Burnback Control
6
SECTION
4-
OPERATOR
CONTROLS
4-1.
Power Switch
7
4-2.
Jog
Push
Buttons
7
4-3.
Purge
Push
Button
7
4-4.
Voltmeter
7
4-5.
Wire
Speed
Meter
7
4-6.
Amps/lnductanc~
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
Board PCi
15
Diagram
7-3.
Circuit
Diagram
Motor Control
Board
PC2
16
Diagram
7-4.
Circuit
Diagram
For
Interface
Board
PC3
17
Diagram
7-5.
Circuit
Diagram
For
Display
Board
PC4 17
Diagram
7-6.
Circuit
Diagram
For
Arc Failure Board
PC5
18
Diagram
7-7.
Circuit
Diagram
For Touch
Sense/Wire
Stick
Board
PC6
. . . .
18
SECTION
8
-
PARTS LIST
Figure
8-1.
Circuit
Card,
Voltage
Control PCi
22
Figure
8-2.
Circuit
Card,
Motor
Speed
Digital
PC2
24
Figure
8-3.
Circuit
Card,
Interface PC3
26
Figure
8-4.
Circuit
Card,
Meter
PC4
27
Figure
8-5.
Circuit
Card,
Interface PC5
28
Figure
8-6.
Circuit
Card,
Wire Touch PC6
29
LIST
OF
CHARTS
AND
TABLES
Table
2-1.
Specifications
1
Table
6-1.
Troubleshooting
12

SECTION
1
-
SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL
INFORMATION
AND
SAFETY
1-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
AG
I
WORDS
enera
The
following
safety
alert
symbol
and
signal
words
are
Information
presented
in this
manual
and
on
various
Ia-
used
throughout
this
manual
to
call
attention
to
and
iden
bels,
tags,
and
plates
on
the
unit
pertains
to
equipment
tify
different
levels
of
hazard
and
special
instructions.
design,
installation,
operation,
maintenance,
and
~
This
safety
alert
symbol
is used with
the
signal
troubleshooting
which
should
be
read,
understood,
and
words
WARNING and
CAUTION
to
call
atten
followed
for the safe
and
effective
use
of
this
equipment.
tion
to
the
safety
statements.
B.
Safety
WARNING
statements
identify
procedures
or
The
installation,
operation,
maintenance,
and trouble- practices
which
must
be followed
to
avoid
seri
shooting
of
arc
welding
equipment
requires
practices
ous
personal
injury
or
loss of
life.
and
procedures
which
ensure
personal
safety
and the
safety
of others.
Therefore,
this
equipment
is
to
be
in-
CAUTION
statements
identify
procedures
or
stalled,
operated,
and
maintained
only
by
qualified
per-
practices
which
must
be followed
to
avoid minor
Sons
in
accordance
with this
manual
and all
applicable
personal
injury
or
damage
to
this
equipment.
codes
such
as,
but
not
limited
to,
those
listed
at
the
end
of
Section
1

Safety
Rules
For
Operation
Of Arc
Weld-
IMPORTANT
statements
identify special
instructions
ing
Power
Source
in
the
welding
power
source
Owners
necessary
for the
most
efficient
operation
of
this
equip
Manual.
ment.
SECTION
2 SPECIFICATIONS
Table
2-1.
SpecIfications
Component
Dimensions
Weight
Height
Width
Depth
Net
Ship
Robot Interface
22-1/2
in.
(572
mm)
16-1/2in.
(419
mm)
6~1/4in.*
(159
mm)
38
lbs.
(17
kg)
Total
61 lbs.
(27.7
kg)
Gas/Current
Sensing
Control
4-1/2
in.
(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
and
peak
amperage
or
inductance.
The
robot
interface
control is
designed
to
interface
with
The
gas/current
sensing
control contains
the
gas
valve
and
current
sensing
reed
relay.
a
Panasonic
robot and
an
Arc
Pak
350,
Deltaweld,
Maxtron,
or
Pulstar 450
welding
power
source.
This
unit These
components
function with
the robot
system
when
provides digital display
of weld
volts,wire
feed
speed,
using
the
Gas
Metal Arc
Welding
(GMAW)
process.
OM-135
582
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. 10
ft.
(3 m)
Weld
Control

Welding
Power
Source
Interconnecting
Cords
6.
lOft.
(3m)
Gas
Hose
7.
10
ft.
(3
m)
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).
OM-135
582
Page
2
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
assembly
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.
Tighten
hex
nut
until
a
slight drag
is
felt
while
turning
hub.
4.
Install
welding
wire
according
to
Section
3-8.
Hex Nut
Hub
Support
Shaft
Hub
Assembly
Washer
Hub
Support
SA-126
870
Figure
3-1.
Hub
Assembly
Installation

3-3.
GAS/CURRENT
SENSING
CONTROL
INTER
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.
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.
A.
Robot
Interface

Gas/Current
Sensing
Control
Connections
1.
Align keyways,
insert
14-pin
Amp
plug
into
matching
receptacle
RC9
on robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Align keyways,
insert
16-pin Amp
plug
into
matching
receptacle
RC16
on
gas/current
sensing
control,
and
rotate
threaded
collar
fully
clockwise.
B.
Gas/Current
Sensing
Control

Motor Connec
tions
1.
Align
keyways,
insert
14-pin
plug
from
motor
cord
into
matching
receptacle
RC7
on
gas/current
sens
ing
control,
and
rotate
threaded
collar
fully
clock
wise.
2.
Align
keyways,
insert
14-socket
plug
from
motor
control cord into
matching
free-hanging
receptacle
from
motor,
and
rotate
threaded
collar
fully
clock
wise.
C.
Weld
Cable
Connections
For Electrode
Positive/Reverse
Polarity,
route
cable
from
welding
power
source
POSITIVE
weld
output
ter
minal,
through
the
gas/current
sensing
control,
to
the
wire
drive
assembly,
and
connect
cable
to
weld
cable
terminal
(see
Motor/Drive
Assembly
Owners
Manual for
location).
D.
Gas Connections
Connect
hose
from
gas regulator/flowmeter
(customer
supplied)
at
gas
source
to
IN
fitting
on
gas/current
sens
ing
control.
Connect
gas
hose from
wire
drive
assembly
to
fitting
on
gas/current
sensing
control. The
gas
flow
must
be
accurately
controlled
by
a
regulator/flowmeter
at
the
source.
3-4.
VOLTAGE
SENSING
CONNECTIONS
(Figures
3-2
And
3-3)
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.
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.
Figure
3-2.
Right
Side
View
TG-tt9
646
There
are
several cords
supplied
for
gas/current
sens
ing
control interconnections.
Examine
and
select
the
proper
cord for
the
following
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
weld cable
termi
nal
on
the wire
drive
assembly
as
shown
in
Figure
3-3.
3.
Connect
lead with
clamp
to
workpiece.
Gas/Current
SensIng
Control
Receptacle
RC9
14-PIn
115
Volts
AC/Contactor
Control
Receptacle
RC13
OM-135
582
Page
3

Figure
3-3.
Voltage
Sensing
Connections
At Wire
Drive
Assembly
3-5.
ROBOT
INTERFACE

WELDING
POWER
SOURCE
CONNECTIONS
(Figure
3-2)
There
are
three cords
supplied
for interconnections
be
tween
the robot
interface
and
welding
power
source.
Ex
amine and select the
proper
cords for the
following
con
nections.
A.
REMOTE
14
Connections
1.
Align keyway,
insert
14-socket
plug
into
matching
receptacle
RC13
on
robot
interface,
and
rotate
threaded
collar
fully
clockwise.
2.
Align
keyway,
insert
14-pin
plug
into
matching
re
ceptacle
on
welding
power
source,
and
rotate
threaded collar
fully
clockwise.
B.
REMOTE
17
Connections
1.
Align
keyway,
insert
17-socket
plug
into
matching
receptacle
RC16
on
robot
interface,
and
rotate
threaded collar
fully
clockwise.
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.
If
the
welding
power
source
is
equipped
with
a
14/17
switch,
be
sure
the switch is
in
the
14
position,
even
though
connections
are
made
to
both
REMOTE
14
and
REMOTE
17
receptacles.
3-6.
ROBOTINTERFACE-ROBOTCONTROLUNIT
CONNECTIONS
(Figures
3-2
And
3-4)
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.
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.
Obtain
a
proper
cord and
24-pin Amphenol
plug
(not
supplied).
2.
Connect
conductors
at
one
end of
cord
to
appropri.
ate
sockets
in
plug.
3.
Align
keyway,
insert
24-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:
Digital
common
for
output
signals
at
Sock
ets
B,
C,
and
G.
Arc
failure
output
signal.
Touch
Sense/Wire
stick
output
signal.
Socket
G: Current
detect
output
signal.
Socket
H:
Weld
start
input
signal.
Socket
J:
Circuit
Common
for Sockets
H,
K, M, P,
and
A;
all circuit
voltages
referenced
to
this
point.
Socket
K:
Gas
valve
input
signal.
Socket
L:
Circuit
common
for
input
signals
at Sockets
H,
K,
M, P,
and
R
Socket
M:
Touch
Sense/Wire
stick
input
signal.
Socket
N:
Circuit
common
for
input
signals
at
Sockets
H,
K, M, P~
and
A
Socket
P:
Wire inch
positive
(+)
input
signal.
Socket
0:
Circuit
common
for
input
signals
at Sockets
H,
K, M, P,
and
R.
Socket
R:
Wire inch
negative
()
input
signal.
Socket
S: Circuit
common
for
input
signals
at Sockets
H, K, M, P,
andR
Voltage
control
positive
(+)
connection.
Voltage
control
wiper
connection.
Nut
Sensing
Lead
Ring
Terminal
Location
Cable
Lug
Location
TA-109
093
Socket
B:
Socket
C:
Socket
T:
Socket
U:
OM.135
582
Page
4

Socket V:
Voltage
control
negative
()
connection.
Socket
W:
Wire
feed
speed
positive
(+)
connection.
Socket
X:
Wire
feed
speed
wiper
connection.
Socket
Y:
Wire
feed
speed
negative
()
connection.
IMPORTANT:
The
remaining
sockets
in
the
receptacle
are
not
used.
___________________________
S.0291
Figure
3-4.
Front
View
Of
24-Socket
Amphenol
Receptacle
With Socket
Designations
2.
For
robot
control units
when
115
or
24
vac,
or
24
vdc
is
used
(Figure
3-5):
a.
Route
cord
through
strain relief
on
right
side
panel
of
robot
interface,
and
make
proper
con
nections
to
1TL and 1TM.
b.
Obtain
a
115
or
24
vac,
or
24
vdc
isolation
relay
CR1,
and
install into robot
control.
c.
Route
and
connect
remaining
end
of
cord
to
one
side
of
the
normally-open
robot
control
relay
contact
and
ground.
d.
Connect
+24
vdc
to
remaining
side
of
normally-
open
robot
control
relay
contact.
e.
Connect
a
lead from
one
side of
robot
control
coil
to
weld alarm
terminal.
f.
Connect
proper
voltage
source
(115
vac,
24
vac,
or
24
vdc)
between
common
terminal
and
remaining
side of
robot
control
relay
coil.
3-7.
ARC
FAILURE LIGHT
TERMINAL
STRIP
CON
NECTIONS
(Figure
3-5)
j~
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.
Lockout/tagging
procedures
consist
of
padlock
ing
line disconnect
switch
in
open
position,
re
moving
fuses
from
fuse
box,
or
shuthng
off and
red-tagging
circuit breaker
or
other disconnect
ing
device.
(
0
0
Robot
Control
Unit
Robot
Interface
Common
Terminal
Weld
Alarm
Terminal
Ii
So
Equipped
If
So
Equipped
+24V0C
I
Arc
Failure
1TM
Indicator
Light
Robot
Control
Unit
Common
Terminal
Weld
Alarm
Terminal
If
So
Equipped
If
So
Equipped
To
Voltage
Source
(115VAC,
24VAC,
24VDC)
Isolation
Relay
CR1
Robot Control
Robot
Interface
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
appropriate
terminal
strip
for
con
nections.
Tighten
screws
on
strain
relief
if
necessary,
and
close and
secure
front
panel
access
door when
pro
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:
1.
For
robot control
units when 24
vdc
is used
(Figure
3-5):
a.
Route cord
through
strain relief
on
right
side
panel
of
robot
interface,
and
make
proper
con
nections
to
1TL
and
1TM.
b.
Route
and
connect
remaining
end
of
cord
to
weld alarm
terminal and
ground
connection
at
the robot
control unit.
c.
Connect
+24
vdc
to
common
relay
contact
ter
minal.
CR1
+24VDC
E-j
Arc
Failure
1TM
Indicator
Light
S-0292
Figure
3-5. Arc Failure
Light
Connections
OM-135
582
Page
5

3-8.
WELDING
WIRE
INSTALLATION
(Figure
3-6)
C.
Adjustment
Of
Hub
Tension
(Figure
3-1)
A.
Installation
Of
Spool-Type
Wire
1.
Remove
retaining
ring.
2.
Slide
spool
of
wire
onto
hub
so
that
wire
feeds
oft
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.
FIgure
3-6.
OptIonal
Wire Reel And
Reel-Type
Wire
Installation
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.
3-9.
BURNBACK
CONTROL
Burnback
is
provided by
potentiometer
R32
on
Interface
Circuit
Board
PC3
inside
the
unit. Burnback
can
be
set
between
0
and 0.25 seconds.
The burnback
circuitry
in
this unit
keeps
the
welding
wire
from
sticking
to
the
workpiece
after
the
arc
is
extin
guished.
The burnback
circuitry
keeps
weld
output
on
the
welding
wire from
0
to
0.25 seconds
after the wire
has
stopped
feeding.
This
delay
action
permits
the weld
ing
wire
to
burn
back
to
a
point
where it neither
sticks to
the
workpiece
or
the
contact
tube.
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
locko
ut/tagging procedures
before
inspecting
or
installing.
Lockout/tagging
procedures
consist
of
padlock
ing
line disconnect switch
in
open
position,
re
moving
fuses from
fuse
box,
or
shutting
off and
red-tag9ing
circuit breaker
or
other disconnect
ing
device.
CAUTION:
ELECTROSTATIC
DISCHARGE
(ESD)
can
damage
circuit boards.

Put
on
properly grounded
wrist
strap
BEFORE
handling
circuit boards.

Perform work
only
at
a
static-safe
work
area.
Retaining Ring
Retainer
Wire Reel
/
Spanner
Nut
a
Hub
Support
SC-1V
308
1.
Open
front
access
door
and locate
PC3.
2.
Locate
potentiometer
R32
in
upper
left
corner
of
PC3.
3.
Rotate R32
clockwise
to
increase
burnback
time.
4.
Close
and
secure
front
access
door.
OM-135
582
Page
6