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

0
~
I
p5~(
AiPS/
I
C.)
I
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2
3
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G
C
0
A
B
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18311
8910
657
PC
I
VTLTAGE
80*80
U
1-18
124
RCI/PL0I4 RC6/PLG2S
CIS4TP12..
88
ITO
0
I
4
14
C
0
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E
F
75
72
75
0
0
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H
0
84
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A
B
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52
52
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AA-AIJ
ON
RCI9
PCI
7
56
B
H
on 99
9
r
vu
ARC
VI3T5
G
A
P
a
N
L
RC9
I
2
3
10
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H
K
C
p
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A
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A
-
A
-
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-
A
F
J
P
P
B
C
E
S.
PC6
ARt/T~Lu
B
<
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u
A-S
ON
9d00/REGSO
IIJCH
SENRE/WIRE
STICK
1/05
SENSE
c<
~
j<)(L
PCI
2
___________
CS,~jC41j~,
0
H
I
v____v____v_.J
~
184
U
S
Y
WIRE
FEED
SPEED
Circuit
Diagram
No.
SC-i
54
230
Diagram
7-i.
Circuit
Diagram
For
Robot
Interface
Effective
With
Serial
No.
KC231859