Y8y7?~i
IMPORTANT: Read and understand the entire
contents of both this manual and the power source
manual used with this unit, with special eutiphasis
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 equipment. Do not allow
untrained persons to install, operate, or maintain
this unit. Contact your distributor if you do not fully
understand these instructions.
Effe~ti.E With SanE I Fic.
..
H1:33:~’ I
MODEL
MR-5/ARC PAKTM 350
COMPUTER INTERFACE
GAS/CURRENT SENSING
CONTROL
+5
OWNER’S
MANUAL
millER
MILLER ELECTRIC MFG. Co.
718 S BOUNDS ST, P 0 Box 1079
APPLETON, WI 54912 USA
ADDITIONAL COPY PRICE 95 CENTS
NWSA CODE NO. 4579
PRINTED IN U S A
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May 31,1990
~OM.882j
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 2— INSTALLATION
IMPORTANT: A 25 ft. (8m) interconnectingcordwith a five-pin Amphenoiplug issuppliedwith thisunitbutis notused
in this installation. Retain cordfor future use.
Add the foliowing IMPORTANT block to the end of Section 2-3A. COMPUTER INTERFACE
SOURCE CONNECTIONS: Wire Stick Sensing Connections
-
WELDING POWER
IMPORTANT: If dc electrode negative welding is desired, reverse connections so the lead with ring terminal is
connected to the negative weld output terminal and the lead with a clamp is connected to the positive weld output
terminal.
Amend Section 2-3C. COMPUTER INTERFACE
AC/Contactor Control Connection
-
WELDING POWER SOURCE CONNECTiONS: 115 Volts
IMPORTANT: Cords are supplied that may notbe used in this installation. Match cordto weldingpower source and
computer interface available.
1. Align keyways, insert 4-socket Amp plug into matching receptacle on computer interface, and rotate threaded
collar fully clockwise.
2. Align keyway, insert 14-pin Amphenol plug into matching receptacle on welding power source, and rotate
threaded collarfully clockwise.
3. Place appropriate remote control switch(es) on the welding power source in the proper position for use of a
remote control device.
Amend Section 2-5. COMPUTER INTERFACE TERMINAL STRIP CONNECTIONS
WARNING: ELECTRIC SHOCK can kill.
0
Do not touch live electricalparts.
A
0
Shutdownunit, weldingpowersource, and robot,and disconnect inputpoweremployinglockout/tag-
ging procedures before making interconnections.
Lockout/taggingprocedures consist of padlocking line disconnect switch in open position, removingfuses
from fuse box, or shutting off and red-tagging circuit breaker orother disconnecting device.
There are several terminal strips inside the computer interface for control connections. Remove unittopcover, loosen
screws on strain relief on unit rear panel if necessary, and locate appropriate terminal strip for connections. Tighten
screws on strain relief if necessary, and reinstall top cover when procedure is finished.
A. CVICC Connections
WARNING: Read and follow safety information at beginning of Section 2-5 before proceeding.
A
1. Locate terminal Strip 2T.
2. For CC operation, remove jumper link between terminal E and F on 2T.
IMPORTANT: The Inductance control is disabled when operating in the CC (constantcurrent) mode.
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B. ARC FAILURE Light Connections (Figure 2-4)
WARNING: Read and follow safety Information at beginning of Section 2-5 before proceeding.
A
The ARC FAILURE lightorlthe computerinterface front panelis turnedon and offby asignalfromthe robot control unit.
Locate supplied length of 18 gauge/2-conductor cord for this connection, and proceed as follows:
1. For robot control units with no other connections at jig terminal strip 2:
a. Open robot control unit door, and locate jig terminal strip 2.
b. Route cord under cross member below door.
c. Make cord connections to terminal strip common and the Weld Alarm terminal.
d. Close robot control unit door, and route cord through strain relief on rear panel of computer interface.
e. Connect cord to 2TF and 2TG.
2. For robot control Units when 115 or 24 vac, or 24 vdc is used at jig terminal strip 2T:
a. Obtain a 115 or 24 vac, or 24 Vdc isolation relay, and install into jig interface.
b. Open robot control unit door, and locate jig terminal strip 2.
c. Route customer supplied 18 gauge/2-conductor cord undercross member belowdoor.
d. Make cord connections to terminal strip common and the Weld Alarm terminal.
e. Close robot control unitdoor, and route cord to jig interface.
f. Connect cord to isolation relay coil and voltage source.
g. Cut off terminals from one end of supplied 18 gauge/2-conductor cord, and install terminals to connect to
contacts on isolation relay.
h. Connectone end of cord to a set of normally-open contacts on isolation relay.
i. Route cord through strain relief on rear panel of computer interface.
j. Connect cord to 2TF and 2TG.
OM-882 Page 2
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Add Figure 2-4. Arc Failure Light Connections
Jig Terminal
Strip 2
Common
Computer Interface
2TF
+24VDC
Robot
control
Unit
2TG
weld Alarm
Arc Failure
Indicator
Light
2TL
To Voltage Source
(115VAC, 24VAC, 24VDC)
-rj
2TF
~—
Robot
Control
Unit
Arc Failure
Indicalor
Light
Weld
Alarm
Jig Interface
TA-il5 648
Figure 2-4. Arc Failure Light Connections
AMENDMENT TO SECTION 5 - MAINTENANCE & TROUBLESHOOTING
Add the following Step to Section 5-1
-
INSPECTION AND UPKEEP
3. Inspect motor control relay, CR2, and clean or replace as required.
Amend Figure 5-3. Circuit Diagram For Computer Interface (see Page 4 on this Errata)
Amend Figure 5-4. Circuit Diagram For Voltage Control Board PCi (see Page 5 on this Errata)
Amend Figure 5-6. Circuit Diagram For Interface Board PC3 (see Page 6 on this Errata)
Add Figure 5-9. Wiring Diagram (see Pages 7 and 8 on this Errata)
OM-882 Page 3
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AMENDMENT TO SECTION 5
-
MAINTENANCE & TROUBLESHOOTING
Amend Figure 5-3. Circuit Diagram For Computer Interface
0 0 0 0 ~
0 0 0 0 0 0
U
K
U
N
k ~ ,
~000
0 0
0
0
0
0
0
C
-
~
-,
C 0 C W L .~ C I~ N
= 0 C L ,L t,~ tj7 ~ ~ liU
d
K
-~
~
z
E
Cu
0
cc
to
0
(3
C~J
6
z
w
U
0)
0)
U
0)
‘N
0)
S~~CNN
0.
E
0
C.)
I -
0
U -
E
I -
0)
N.FS
0
SN-CCN(
srNso~
I..
(3
JOG ~EV
0)
~
~
1~
c i
9E’EC’
Ua’AGE
OM-882 Page 4
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a
I
C.’J
to
C~4
1 ~
6
6
z
E
Cu
Cu
•~ ‘
to
o
.~
—
to
U,
o
( 3 - ,
6
z
1~
0)
C/)
0)
0
0)
w
5
0.
•0
I-
Cu
0
3
0
C.)
0)
C)
Cu
3
I -
0
IL
E
Cu
IC- )
Cu
4
U
I-
(3
0)
C)
OM-882 Page 5
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-
5V
,24V
06
AR
AL
4ELD START
JOG F~C
CR
2
C ON-S
REF EEC
CR5
ACTOR
WELD
CURRENT
RELA’
AL
~
AJ
JOG (RE.
A
6050’
CJRRE’.’
CECXCT
RE.. RE.A’
4
CR4
CON’N-C’CR
AC
Circuit Diagram No. B-128 016-A
FIgure 5-6. CIrcuit Diagram For interface Board PC3 Effective With Serial No. JK588314 Thru KA819026
‘LO
A
‘24
CC
.24 C.
AC
6
06
~ELC S’ART AR
AE
CR
6
UDO (L(~fl(
—
C SE L FEC
045
AC’CR
RELO
AL
CURRENT
RELAY
A.
406 (RE6I
A
C66
T
6080’
CLPREN
CECEO C
OR?
C07R40N,
ALA
REV. RELAX
1<
CR4
0C7,’4C’CR
AC
Circuit Diagram No. B-i 37 905
Figure 5-6.Circuit Diagram For interface Board PC3 Effective With Serial No. KABi9027
OM-882 Page 6
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Add Figure 5-9. Wiring Diagram
cc
r-.
I”-
1 ~
‘N
0
6
z
E
Cu
C)
0
C)
cc
U,
to
to
1..
I -
cc
to
0
c,,J
6
z
h..
0)
U)
0)
C.)
0)
w
E
Cu
IC..)
Cu
0
C)
C
U,
0)
iCr)
OM-882 Page 7
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c~J
1 ~
6
z
E
Cu
IC- )
0
C
to
U,
to
to
6
2
I0-)
U)
0)
0)
w
E
Cu
C)
0
C
0)
L..
OM-e82 Page 8
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AMENDMENT TO PARTS LIST
Amend Parts List as follows:
Dia.
Mkgs
Part
Replaced
Description
Quantity
No.
With
111 992
117 724 CONTROL PANEL, (Elf w/JH290689 thru
JK636568)
129 952 CONTROL PANEL, (Effw/JK636569)
123 154 LABEL, warning general precautionary
118 676 CABLE, volt sensing (Eff w/HJ304076)
604 109 WIRE, (qty chg)
028 291 CAPACITOR, (qty chg)
135 304 CABLE, port No. 18 8/c (order by ft)
117836 CIRCUITOARD, meter
2-1
1
1
117724
070 634
049 989
604 109
028 291
090 890
iii 564
011 622
Added
2-1
2-4
2-17
2-20
2-
2-39
2-48
3-56
3-
1
1
26ft
7
61t
1
1
C2,3,6-10
PC4
011 609 SWITCH, tgl SPDT iSA 125V
110 438 CABLE, interconnecting 25ft (Eff w/JK678982)
(consisting of)
51
1
1
048 284
079 534
079 531
604 571
iii 122
109 770
HOUSING PLUG & SOCKETS, (consisting of)
.
TERMINAL, female iskt 14-18w
4
1
CLAMP, cable strain relief sz 11
25ft
1
CABLE, port No. 184/c (order by ft)
HOUSING PLUG & PINS, (consisting of)
TERMINAL, female 1 pin sz 45 16-22w
.
14
1
2
2
4-
6-2
6-5
Ri-S
044 635
083 147
035 914
034 841
110375
111 065
111 408
113 221
128014
073 730
073 739
030 028 RESISTOR, C .5W 1.5K ohm
083 147 GROMMET, (qty chg)
SR1,2
CR1
035 704 RECTIFIER, (qty chg) integ 30A 600V
109 006 RELAY, end 24VAC DPDT (Effw/JK636569)
110375 STANDOFF, (qtychg)
6-12
6-15
6-16
6-25
6-26
6-26
6-28
8-
1
7
121 313 PANEL, rntg-components (Elf w/JJ377225)
1
PCi
PC3
PC3
RC5
1
131 247 CIRCUIT CARD, Voltage control (Effw/JK655454)
128 014 CIRCUIT CARD, interface (Effw/JK588314)
128014 CIRCUITCARD,interface, (Effw/KA819027)
073 730 TERMINAL, hdr 22 pin
073 739 CAPACITOR, (qty chg added C25-30)
(EU w/JK655454)
000 88S RESISTOR, (qty chg added R46,47)
(Elf w/JK655454)
049 015 RESISTOR, CF .25W 10 meg ohm
(Eff w/JK655454)
072 130 CAPACITOR, (qty chg deleted C6, 9, 10)
(Elf w/JK588314 thru KA819026)
1
1
1
25
ii
000 885
Added
8-
8-
R48,49
2
11—
072 130
11—
11-
11-
C3
C4
072 130
005023
073 739
Deleted Elf w/KA819027
Deleted Elf w/KA819027
073739 CAPACITOR (qty chg deleted Cli
(Elf w/ JK5883 14)
11—
13-
13-3
13-6
028 3S1
109 936
079682
010 610
028351 DIODE, (qty chg added D16) (Elf w/JK588314)
117 617 CONTROL BOX, gas/current sensor
136 59S RELAY,current
115 104 CONNECTOR CLAMP, cable 1/2 in
110386 RELAY,encI24VACDPDT
REED
CR5
Ti
117725 TRANSFORMER,control
117 726 CAPACITOR/RESISTOR, (consisting of)
OM-582 Page 9
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Parts Lists Continued
• CAPACITOR, eIctlt 220uf 35VDC
601 394 •RESISTOR,C2WlOKohm
2
C4,S
R4
000 859
Added
Added
136584 BRACKET, mtg reed relay
1
2
13-
13-
WASHER, flat nyl .265 ID x .437 OD
007501
~First digit represents page no digits following dash represent item no.
-
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-882 Page 10
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TABLE OF CONTENTS
Section No.
Page No.
SECTION 1
-
INTRODUCTION
1
1
I
-
-
-
1. General Information And Safety
2. Receiving-Handling
3. Description
2
2
2
SECTION 2
-
INSTALLATION
2-1. Location
2
3
3
4
5
2
2
2
2
-
-
-
-
2. Gas/Current Sensing Control Connections
3. Computer Interface
4. Computer Interface
5. Computer Interface Terminal Strip Connections
-
Welding Power Source Connections
-
Welding Power Source Interface Connections.
SECTION 3
-
FUNCTION OF CONTROLS
3 -1 . PowerSwitch
6
6
6
6
6
6
6
3
3
3
-
2. Inductance Control
3. Overload Protection
4. Voltmeter
-
-
3 -5 . WireSpeedMeter
3
3
-
6. Ammeter
-
7. Indicator Lights
SECTION 4 SEQUENCE OF OPERATION
-
4
4
-
1. input Signal From Welding Power Source
2. Output Signals From Computer Interface
6
7
7
-
4 -3 . Wire Stick Check
SECTION 5
-
MAINTENANCE 8 TROUBLESHOOTING
5
5
5
5
5
-
1. Inspection And Upkeep
2. Overload Protection
7
7
8
8
10
-
-
3. Display Board Meter Check
-
-
4. Board Replacement Procedures
5. Troubleshooting Chart
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SECTION 1
-
INTRODUCTION
Model
Weight
31 lbs. (14 kg)
I-
MR-5AP
Control 5 lbs. (2.3 kg)
I Gas/Current Sensing
TB-i 14346
+ 16.5 in. (419 minI case only
2-7/8 in.
(73.0 minI
In.
mm)
16 in. (7.9 mm)
Diameter 2 Holes
TB-i 10320
Figure 1 1. Specifications
-
OM-882 Page 1
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1
-
1. GENERAL INFORMATION AND SAFETY
carefully followed could result in minor personal injury
or damage to this equipment.
A. General
A third signal word,
• s • s ,
highlights instruc-
tions which need special emphasis to obtain the most
Information presented in this manual and on various
labels, tags, and plates on the unit pertains to equip-
ment design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
efficient operation of this equipment.
1
-
2. RECEIVING-HANDLING
-
Before installing
this equipment, clean all packing material from around
the unit and carefully inspect for any damage that may
have occurred during shipment. Any claim for loss or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill
of lading will be furnished by the manufacturer on re-
quest if occasion to file claim arises.
followed for the safe and effective use of this equip-
ment.
B. Safety
The installation, operation, maintenance, and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
When requesting information concerning this equip-
ment, it is essential that Model Description and Serial
Number of the equipment be supplied.
be installed, operated, and maintained only by qualified
persons in accordance with this manual and all ap-
plicable codes such as, but not limited to, those listed at
1
-
3. DESCRIPTION The computer interface con-
-
the end of Section 1 Safety Rules For Operation Of
-
trol contains wire feed speed, weld voltage, and weld
amperage control circuitry, digital ammeter, voltmeter,
and wire feed speed meter, and circuitry to interface
with the robot control. The control isshipped for opera-
tion in the constant voltage mode but has constant cur-
rent capabilities.
Arc Welding Power Source in the welding power source
Owner’s Manual.
Safety instructions specifically pertaining to this unitap-
pear throughout this manual highlighted by the signal
CAUTION
words WARNING and
different levels of hazard.
which identify
The gas/current sensing control contains the gas valve
and current sensing reed relay.
WARNING statementsinclude installation, operation,
and maintenance procedures or practices which if not
carefully followed could result in serious personal injury
or loss of life.
These components function with the robot system
when using the Gas Metal Arc Welding (GMAW) pro-
cess.
statements include installation, operation,
CAUTION
and maintenance procedures or practices which if not
INSTALLATION
SECTION 2
-
Normally the computer interface is mounted on top of
the robot control unit. The gas/current sensing control
should be mounted in line between the welding power
source and wire drive assembly. See installation section
of robot manual for specific information.
2
-
1. LOCATION (Figure 1-1)
The location should allow room to open and remove
covers and wrappers for installation, maintenance, and
repair. Lead lengths must be considered when locating
components.
The service life and efficiency of the system are reduced
when it is subjected to high levels of dust, dirt,
moisture, corrosive vapors, and extreme heat.
Mounting holes are provided in each component for
mounting purposes. Figure 1-1 gives unit dimensions.
Wire Stick Sensing
Strain
Gas/current Sensing
control Receptacle RC9
Receptacle RC12 Inductance Relief
control
Welding Power Source
Interface Receptacle
RC17
115 Volts Ac/contactor
control Receptacle Rd 1
Voltage control
Receptacle RC13
re-114 347
Figure 2 1. Rear Panel View
-
OM-882 Page 2
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2
-
2. GAS/CURRENT SENSING CONTROL CON-
D. Gas Connections
NECTIONS (Figures 2-1 And 2-2)
Connect hose from gas regulator/flowmeter (customer
N -.
ELECTRIC SHOCK can kill.
supplied) at gas source to IN fining on gas/current sen-
•
•
Do not touch live electrical parts.
sing 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.
Shut down unit, welding power source, and
robot, and disconnect input power employing
“lockout/tagging procedures” before making in-
terconnections.
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.
E. Touch Sensor Connections
Connect cord with two friction connectors coming from
gas/current sensing control to touch sensor leads com-
ing from outlet cable. Polarity is not important for this
connection.
A. Computer Interface
Control Connections
-
Gas/Current Sensing
2
-
3. COMPUTER INTERFACE
-
WELDING
1. Align keyways, insert 14-pin Amp plug into mat-
ching receptacle on computer interface, and
rotate threaded collar fully clockwise.
POWER SOURCE CONNECTIONS (Figures 2-1 And
2-2)
ELECTRIC SHOCK can kill.
2. Align keyways, insert 16-pin Amp plug into mat-
ching receptacle on gas/current sensing control,
and rotate threaded collar fully clockwise.
•
•
Do not touch live electrical parts.
Shut down unit, welding power source, and
robot, and disconnect input power employing
“lockout/tagging procedures” before making in-
terconnections.
B. Gas/Current Sensing Control
nections
-
Motor Con-
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.
Align keyways, insert 14-pin plug from motor into mat-
ching receptacle on gas/current sensing control, and
rotate threaded collar fully clockwise.
There are several cords used for interconnections bet-
ween the computer interface and welding power
source. Examine and select the proper cord for the
following connections.
C. Weld Cable Connections
Route cable from welding power source positive weld
output terminal, through the gas/current sensing con-
trol, to the wire drive assembly and connect cable to
weld cable terminal (see Motor/Drive Assembly
Owner’s Manual for location).
115 Volts AC/Contactor
Computer
Interface
control Cord
Arc Pak Welding
Power Source
RC17 Rd
Sensor
GaslCurrent
Sensing Control
Arc Failure
Connection In
Robot Control UnIt
Motor Control-
Cord
TB-i 14 357
Figure 2 2. Interconnection Diagram
-
OM-882 Page 3
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2. Connect the twistlock receptacles to the mat-
ching plugs, and rotate plugs clockwise.
A. Wire Stick Sensing Connections
1. Align keyway, insert four-socket Amphenol plug
into matching receptacle on computer interface,
and rotate threaded collar fully clockwise.
3. Align keyway, insert 14-pin Amphenol plug into
matching receptacle on welding power source,
and rotate threaded collar fully clockwise.
2. Connect lead with ring terminal to welding
power source positive output terminal.
3. Connect lead with clamp to welding power
source negative output terminal.
2
-
4. COMPUTER INTERFACE
-
WELDING
POWER SOURCE INTERFACE CONNECTIONS
(Figures 2-1, 2-2, And 2-3)
WARNING: ELECTRIC SHOCK can kill.
B. Voltage Control Connections
•
•
Do not touch live electrical parts.
1. Align keyway, insert 17-socket plug into mat-
ching receptacle on computer interface, and
rotate threaded collar fully clockwise.
Shut down unit, welding power source, and
robot, and disconnect input power employing
‘lockout/tagging procedures” before making in-
terconnections.
2. Align keyway, insert 17-pin plug into matching
receptacle on welding power source, and rotate
threaded collar fully clockwise.
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.
C. 115 Volts AC/Contactor Control Connec-
tions
1. Align keyway, insert 24-socket plug into mat-
ching receptacle on computer interface, and
rotate threaded collar fully clockwise.
Two cords are necessary for this connection. One cord,
supplied with the welding power source, has a 14-pin
Amphenol plug and two twistlock receptacles. The se-
cond, supplied with the robot, has two twistlock plugs
2. Align keyways, insert four-, six-, and ten-pin
plugs from interconnecting cord into matching
receptacles on bottom of welding power source
interface, and rotate threaded collars fully
and a four-pin Amp plug.
1. Align keyways, insert four-pin Amp plug into
matching receptacle on computer interface, and
rotate threaded collar fully clockwise.
clockwise.
Power Source
Welding
Current
(WCR) Detect
Figure 2 3. Welding Power Source Interface Connections
-
OM-882 Page 4
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3. Remove welding power source interface side
panel.
There are several terminal strips inside the computer in-
terface for control connections. Remove unit top cover,
loosen screws on strain relief on unit rear panel if
necessary, and locate appropriate terminal strip for con-
nection. Tighten screws on strain relief if necessary,
and reinstall top cover when procedure is finished.
4. Route remaining cord from computer interface
through strain relief in bottom of welding power
source interface, to 14-position terminal strip.
A. ARC FAILURE Light Connections
5. Connect leads as follows:
a. Red lead to terminal 52.
b. Blue lead to terminal 50.
c. White lead to terminal 35.
d. Green lead to terminal 36.
The ARC FAILURE light on the computer interface front
panel is turned on and off by a signal from the robot
control unit. The robot control unit mustsupply 24 volts
dc to the computer interface arc failure circuit when arc
failure occurs. Locate supplied length of 18 gauge/2
conductor cord for this connection, and proceed as
follows:
1. Open robot control unit door, and locate jig ter-
minal strip 2.
e. Long green lead with ring terminal connects
to chassis ground.
6. Reinstall and secure side panel.
2. Route cord under cross member below door.
2 -5. COMPUTER INTERFACE TERMINAL STRIP
CONNECTIONS
3. Make cord connections to terminal strip com-
mon and the Weld Alarm terminal.
IMPORTANT:
A 25 ft. (8m) interconnecting cable
4. Close robot control unit door, and route cord
through strain relief on rear panel of computerin-
terface.
with a five-pin Amphenol plugis supplied with this unit
but is not used in this installation. Retain cable for
future use.
5. Connect cord common to 2TL and positive to
WARNING:
2TG.
ELECTRIC SHOCK can kill.
•
•
Do not touch live electrical parts.
Shut down unit, welding powersource, and robot
and disconnect input power employing
“lockout/tagging procedures” before making in-
terconnections.
B. CV/CC Connections
1. Locate terminal strip 2T.
Lockout/tagging procedures consist of padlocking line
disconnect switch in open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
2. For CC operation, remove jumper link between
terminals E and F on 2T.
IMPORTANT:
breaker or other disconnecting device.
The Inductance control is disabled
when operating in the CC (constant current) mode.
SECTION 3
-
FUNCTION OF CONTROLS
Ta-i 14 436
Arc Failure
indicator
Light
Figure 3
-
1. Front Panel View
OM-882 Page 5
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3
-
4. VOLTMETER (Figure 3-1)
3
-
1. POWER SWITCH (Figure 3-1)
The voltmeter displays weld voltage to the nearest tenth
of a volt while welding and preset voltage while idling.
3 -5. WIRE SPEED METER (Figure 3-1)
Placing the POWER switch in the ON position applies
input power to the interface. The interface must be on
for the robot to weld. Placing the POWER switch in the
OFF position shuts down the interface.
Thewire speed meter displays preset wire feed speed to
the nearest inch per minute while welding and idling.
Actual and preset wire feed speed are the same due to
the wire feed speed feedback circuit.
3 -2. INDUCTANCE CONTROL (Figure 2-1)
The INDUCTANCE control is a digital pushbutton con-
trol which can be set for inductance levels 1 through 7.
As the level of inductance increases, the rate of change
of the weld output or speed of response slows down.
The slower response time produces a softer arc, more
fluid welding puddle, and flatter, smoother bead.
3
-
6. AMMETER (Figure 3-1)
The ammeter displays weld amperage to the nearest
amp while welding and preset amperage while idling.
The 0 (zero) setting gives minimum inductance, i.e., a
stiff, fast-responding arc, and a small, fast-freezing
puddle. The 7 setting gives maximum inductance
characteristics, i.e., a soft, slow-responding, low spat-
ter arc, and high weld puddle fluidity.
3
-
7. INDICATOR LIGHTS (Figure 3-1)
There are five indicator lights on the interface. These
are visual indications of various process functions.
The GAS light turns on when the gas valve is energized
to indicate shielding gas flow.
Select a setting best suited for the application.
3
-
3. OVERLOAD PROTECTION (Figure 3-1)
The CONTACTOR light turns on when the welding
power source contactor is energized to indicate that
weld output is available.
A. Fuse Protection
The interfaceis protected from damage due to an inter-
nal short or excessive overload by fuse Fl. If fuse Fl
opens, the interface shuts down. See Section 5-2 for
replacement procedures.
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.
B. Wire Drive Motor Circuit Breaker
The ARC FAILURE light turns on when there is an arc
outage while welding.
The wire drive motor is protected from damage due to
overload bycircuit breaker CB1. If CB1 opens, the inter-
face shuts down. Manually depress the reset button to
reset the circuit breaker.
SECTION 4
-
SEQUENCE OF OPERATION
Arc Initiation
4 -1. INPUT SIGNAL FROM WELDING POWER
SOURCE (Figure 4-1) The welding power source
and wire drive motor send signals to the computer inter-
face. These signals are used to determine weld
parameters. During welding these signals are compared
to preset welding values and compensations are made
to keep weld parameters at preset levels.
Welding Current
No-Load
-
H-
Crater
WeldingT~
Voltage
0 to 50V
— F
WeldAbnormal
—
D ~ L Y Open when abnormality occurs.
Time
TA-i 14 379
Start
Figure 4
-
1. Input Signal Timing Chart
OM-882 Page6
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4
-
2. OUTPUT SIGNALS FROM COMPUTER IN-
TERFACE (Figure 4-2) The interface interprets the
-
input signals from the welding power source, wire drive
motor, robot, and wire stick check circuit. The output
of the computer interface regulates the welding power
source and wire feed functions while welding.
1OVDC
5VDC
2.5VDC
I
I
Arc Initiation
Voltage 1 .25VDC
Command
I
Open
Close
Wire Start Relay
I
I
Close
I
~~chlng~
Open
TA~1 14 379
I
I
I
Output To Motor
Figure 4 3. Wire Stick Check
-
If the feedback indicates the wire is stuck, the welding
power source is sent a 1 .25 VDC command signal to
provide minimum welding power source output. The
contactor is pulsed on. If the wire was stuck, the pulsed
voltage should be enough to free the wire. Feedback is
used to determine if the wire is now free of the weld. If
the feedback indicates the wire isfree, the robot can cy-
cle to its next sequence.
Start
TA-i 14 378
If the feedback indicates the wire is still stuck, a higher
voltage command is given, and the contactor pulsed to
Figure 4
-
2. Output Signal Timing Chart
free the welding wire. The check is performed and two
more voltage increases are used to try and free the
welding wire (see Figure 4-3).
4
-
3. WIRE STICK CHECK (Figure 4-3)
-
After the
weld is completed, the wire stick check is performed to
determine if the welding wire has burned back out of
the weld puddle.
If the wire remains stuck, the robot will shut down, a
Weld Abnormal error will be displayed on the robot pro-
gram module, and the wire must be physically removed
from the weld.
Feedback is used to determine if the wire is free of the
weld. If the feedback indicates the wire is free of the
weld, the robot can cycle to its next sequence.
SECTION 5
-
MAINTENANCE & TROUBLESHOOTING
•~ j~ j~ ~ j5
Every six months inspect the labels on
1. Repair or replace, as required, all hoses, cords,
and cables; give particular attention to frayed
and cracked insulation and areas where it enters
equipment.
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See the Parts List forpart number of
precautionary labels.
2. Remove grease and grime from components;
moisture from electrical parts and cables.
5
-
1. INSPECTION AND UPKEEP
ELECTRIC SHOCK can kill.
5
-
2. OVERLOAD PROTECTION (Figure 3-1)
WARNING:
•
•
Do not touch live electrical parts.
WARNING:
•
•
Shut down unit, welding powersource, and robot
and disconnect input power employing
‘lockout/tagging procedures” before internally
inspecting or servicing.
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 internally
inspecting or servicing.
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.
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.
Usage and shop conditions will determine the frequency
and typeof maintenance. Inspectequipment as follows:
OM-882 Page 7
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Figure 5 1. Display Board Meter Checks
-
CAUTION: IMPROPER FUSES can damage this
3. Check voltage according to Figure 5-1.
unit.
4. If a meter power supply and command voltage is
correct and the meter is not working, replace the
meter (see Section 5-4).
If replacementbecomes necessary, use only fuses
of the proper size, type, and rating (see Parts
List).
5. If the power supply or command voltage is incor-
rect, replace display board PC4 (see Section
5-4).
To replace the fuse, proceed as follows:
1. Depress and rotate fuse holder cover
counterclockwise.
5
-
4. BOARD REPLACEMENT PROCEDURES
(Figure 5-2)
2. Pull out fuse with cover when fuse holder cover
is free.
WARNING: ELECTRIC SHOCK can kill.
•
•
Do not touch live electrical parts.
3. Insert new fuse into fuse holder cover.
Shut down unit, welding power source, and
robot, and disconnect input power employing
“lockout/tagging procedures” before inspecting
or servicing.
4. Install fuse with fuse holder cover back into unit.
5. Depress and rotate fuse holder cover clockwise
until cover is secure.
Lockout/tagging procedures consist of padlocking line
disconnect switch in the open position, removing fuses
from fuse box, or shutting off and red-tagging circuit
5
-
3. DISPLAY BOARD METER CHECK (Figure
breaker or other disconnecting device.
ELECTROSTATIC DISCHARGE (ESD) can damage
circuit board components.
5-1) Check points are provided on the display board
-
for checking power supply and input command for the
meters.
•
Put on properly grounded wrist strap BEFORE
handling circuit boards.
~
•
•
ELECTRIC SHOCK can kill.
•
Transport all static-sensitive components in pro-
per static-shielding carriers or packages.
Perform work only at a static-safe work area.
Do not touch live electricalparts.
Be sure that personnel performing testing pro-
cedures are familiar with and follow standardsafe-
ty practices.
•
INCORRECTLY INSTALLED PLUGS can damage
circuit boards.
•
Shut down unit before making or changing meter
or test equipment lead connections.
•
Be sure that plugs are properly alignedand install-
ed onto connectors before resuming operation.
ELECTROSTATIC DISCHARGE (ESD) can damage
electronic components.
•
•
•
IMPORTANT: All directions, such as left orright, are
with respect to the operator facing the unit frontpanel.
Retain all hardware removed during this procedure for
reinstallation.
Put on a properly grounded wrist strap BEFORE
handling circuit boards.
Transport all static-sensitive components in pro-
per static-shielding carriers and packages.
Perform work only at a static-safe work area.
A. Display Board PC4 And Meter Replacement
1. Remove computer interface top cover.
2. Locate display board PC4.
1. Remove unit top cover.
OM-882 PageS
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5. To replace meter(s) proceed as follows:
2. Removescrews securing board to stand-offs. Do
not remove stand-offs.
a. Remove nuts and lock washers from meter
support.
3. Disconnect plugs PLG2O and PLG24 from mat-
ching receptacles on PC4.
b. Gently pull meter straight out of socket. Re-
tain spacers.
4. Gently pull board straight away from front panel.
Do not pull up or down; otherwise, the meters
and LED’s may be damaged.
Digital Motor
Speed
Circuit
Receptacles RC2O And RC24
Receptacle RCS
Interface
RF Filter Circuit
Board PCS
Receptacles R021 And RC22
Receptacle RC19
Receptacle R(
Voltage
Circuit Board PCi
Ret TO-i 14 344
Figure 5 2. Circuit Board Replacement
-
OM-882 Page 9
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c. Slide spacers onto new meter support.
4. Slide new board into retaining rail and latch stan-
doffs.
d. Push meter into socket with meter supports
protruding through to rear of PC4.
5. Connect plug(s) to matching receptacle(s) on
new board.
e. Reinstall lock washers and nuts to secure
meter to board. Do not overtighten nuts or
meter may be damaged.
6. Reinstall unit top cover.
5 -5. TROUBLESHOOTING CHART
6. To install replacement display board, carefully
line board up with front panel openings for
meters and LED’s.
ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Shutdown unit, welding powersource, and robot
and disconnect ,nput power employing
‘lockout/tagging procedures” before internally
inspecting or servicing.
WARNING:
•
•
7. Reinstall securing screws.
8. Reconnect PLG2O and PLG24 to matching
receptacles on new PC4.
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.
9. Reinstall unit top cover.
B. Motor Board PC2 Replacement
1. Remove unit top cover.
MOVING PARTS can cause serious injury.
•
Keep clear of moving parts.
HOT SURFACES can cause severe burns.
Allow cooling periodbefore servicing.
•
2. Remove securing screw and unlatch standoff.
3. Gently pull board from receptacle RC5.
4. Insert new board into RC5.
Troubleshooting to be performed only by qualified per-
sons.
It is assumed that the computer interface was properly
installed according to Section 2 of this manual, the
operator is familiar with the function of controls, the
unit was working properly, and that the trouble is not
related to the welding process. The following chart is
designed to diagnose and provide remedies for some of
the troubles that may develop in this unit.
5. Reinstall securing screw and latch standoff.
6. Reinstall unit top cover.
C. Replacement Procedure For Remaining
Boards
Use this chart in conjunction with the circuit diagrams
while performing troubleshooting procedures. If the
trouble is not remedied after performing these pro-
cedures, the nearest Factory Authorized Service Sta-
tion should be contacted. In all cases of equipment
malfunction, the manufacturer’s recommendations
should be strictly followed.
1. Remove unit top cover and locate board.
2. Disconnect plug(s) from board.
3. Unlatch standoffs and
ing rail.
slide board out of retain-
TROUBLE
PROBABLE CAUSE
REMEDY
Unit does not operate.
Fuse Fl open.
Check Fl, and replace if necessary (see Section
5-2). Correct overload problem before continuing
operation.
Circuit breaker CB1 tripped. Check CBl, and reset if necessary. Correct
overload problem before continuing 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
5-3). If check points are okay, replace meter (see
Section 5-4).
Display board PC4 not Use check points to determine if power is available
working. (see Section 5-3). If check points do not test
okay, replace PC4 (see Section 5-4).
OM-882 Page 10
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TROUBLE
No wire feed.
PROBABLE CAUSE
REMEDY
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 work- Replace PC2 (see Section 5-4).
ing.
Wire feeds at maximum.
No arc voltage control.
Tach board PC5 at wire Replace PC5.
drive motor not working.
Voltage control connec- Check and secure connections (see Section 2-3).
tions.
Wire stick sensing connec- Check and secure connections (see Section 2-3).
tions.
Voltage board PCi not Replace PCi (see Section 5-4).
working.
Incorrect robot command Check robot command voltage at voltage board
voltage.
PCi. Command voltage should be 0-10 vdc bet
ween pins BB and CC (common) at RC25.
Robot shuts down due to Touch Sensor connections. Check continuity of leads between gun/torch and
Touch Sensor error.
gas/current sensing control. Repair or replace.
Secure all connections.
Robot moves when welding Wire stick connection.
wire is stuck.
Be sure that red lead is connected to terminal 52
and blue lead is connected to terminal 50 on
welding power source interface 14 position ter
minal strip.
Wire stick sensing connec- Check and secure connections (see Section 2-3).
tions.
Wire speed (1PM) meter Incorrect robot command Check robot command voltage at motor board
goes to zero.
voltage.
PC2. Signal should be 0-10 vdc between pins K
and B (common) at RC5.
Motor board PC2 not work- Replace PC2 (see Section 5-4).
ing.
No wire retract.
Control relay CR2 not work- Replace CR2.
ing.
Interface board PC3 not Replace PC3 (see Section 5-4).
working.
Incorrect robot command Check robot command voltage at motor board
voltage.
PC2. Signal should be 0-10 vdc between pins K
and B (common) at RC5.
Robot shuts down.
Loose weld output connec- Clean and tighten connections.
tions.
Interconnecting cords.
Check all interconnecting cords for breaks; repair
or replace. Check and secure all connections.
Interface board PC3 not Replace PC3 (see Section 5-4).
working.
OM-882 Page 11
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5
-
6. USE OF INDICATOR LIGHTS FOR TROUBLESHOOTING
On
Ga~ Indicator Light
Off
IF
IF
I
Gas flows:
Gas dodes not flow:
System normal (off).
Gas flows:
Gas does not flow:
Check gas valve operation. Check gas valve operation
and gas line for leaks.
System normal (on).
Check interface board PC3.
Off
On
-Contactor Indicator Light
IF
IF
I,
Contactor open:
Contactor closed:
Contactor closed:
Contactor Open:
Check interconnecting
Check display board PC4.
System normal (off).
System normal (on).
cords.
Check interface board PC3.
Wire Feed Indicator L.~,1
,~.1
On
IF
Wire feeds:
Wire does not feed:
Wire feeds:
Wire does not feed:
Check circuit breaker CB1.
Check relay CR1.
System normal (on).
Check input signal from
robot to motor board PC2.
Signal should be 0-10 vdc
between pins K and B
System normal (off).
Check interface board PC3. (common) at RC5.
Check wire feed board PC2.
I
—
•Off
On
Current Indicator Light
V
Arc started:
No arc:
Arc started:
No arc:
System normal (on).
Replace reed relay.
System normal (off).
Replace reed relay.
II
Arc Failure Indicator Ligl~
-Off
On
Arc started:
No arc:
Arc started:
No arc:
Normal while welding.
Normal during idling.
Check weld parameters.
Check signal from robot.
Signal should be 24vdc
between terminals 2TL and
2TG.
Check display board PC4.
OM-882 Page 12
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0 0 0 0
0 t 0 0 ~ N -
0 0 0 0 0
A
0 U
O
0
U
J L .0 Z N - 0 4 0
I -
0 0
0
0
0
0
0
~ t.0 ~ 0
8
I -
I -
~
I -
;
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- 0 0
O cP ~ 0 0 0 0 0 0
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cy~
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OM-882 Page 13
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I
&
1
N
LI)
I -
I -
6
S
2
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C
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OM-882 Page 14
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0
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cv)
0
C
Ca
0
z
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C
0
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h.
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OM-882 Page 15
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•15 V.
•24 V.
07
0
F
•24 V.
G
A
WELD START AS
AS
, . ~
(FAD)
J
~CGAS
~F~-*B~
.fl3 (REV)
N
R~UOT
~2
~4
~T
c ~
AX
REV. RELAY
K
cGJTACT~
Circuit Diagram No. B-113 431
6. Circuit Diagram For Interface Board PC3
Figure 5
-
OM-882 Page 16
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N-B V. AA
VR2
I :
V .
.1
IN LOW
1dj
co.~ 4 AS -~
1ST
IN H I
WS I~F~JT K
N-24 V.
C
I
cOWTACTOW
DETECT
GAS F
.~
.~G (REV)
IFWO)
A
B
COW
RFL
L
ROW
D3
N-12
V
H
V .
IN LOW
191
coeu~ 4
AD
IN HI
V~TS
i~eu•r
C
0 4
c’J c~J
U
~
V .
IN LOW
(ST
0.
LL.
IN HI
M 5
I~UUT
~
ROW
RFH
RFL
DOW
Circuit Diagram No. B-ill 341
7. Circuit Diagram For Display Board PC4
Figure 5
-
OM-882 Page 17
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AP
AE
A.A
As
AG
AF
AD
AC
AJ
AN
AL
~
AM
,~.
AN
, ,
AN
AR
AS
N-,
N-
A
, .
A
N-~N-
A
C32
C30
C25
C24
C22
C20
- ~
H - ’
—
~
— -~ H -
—9 H -
- ~
H -
— i H -
~—9H -
PFL— Z~I IL IL IL ~
—
~
H -
—
~
H -
— ~ H -
- ~
H -
—9 H -
— 9
C21
C33
C31
C29
C25
C23
CAR
RC2I
~‘
~‘
V
N
‘
N
P
0
H
L
P4
D
C
,J
K
F
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S
•
A
Circuit Diagram No. B-ill 117
8. Circuit Diagram For RF Filter Board PC6
Figure 5
-
OM-882 Page 18
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Yay
-
Effe~tiv With Serial Nc. ~H13 ?.~i1
K
PARTS
LIST
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Fig C
1
TC-1 14 345
FigureA
-
Control Box
OM-882 Page 1
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Control Box
Figure A
111 992 CONTROL PANEL (Fig C Pg 6)
010 855 RETAINER, screw No. 2
010 853 FASTENER, screw-hd No. 2
1
4
4
1
1
1
1
4
2
1
1
1
1
14
2
18ft
1
1
2
3
4
070 634 LABEL, warning electric shock can kill etc
5
+ 109 026 COVER, top
079 683 HEAT SINK
6
RESISTOR, WWfixed 100 wattS ohm
030 941
7
R2
010 193 TUBING,3/BODxl8gawallxl/4
010 199 TUBING, .275 ID x .048 wall x 1
030 949 HEAT SINK
8
9
10
11
12
SHIELD, resistor
056 170
109 041 CABLE, interconnecting-motor/gas (consisting of)
13
HOUSING PLUG & PINS (consisting of)
PLG9
047 636
079 535 TERMINAL, male
14
15
079 739 • CLAMP, cable
096 813 CABLE, l8ga 15/c (order byft)
048 598 HOUSING PLUG & SOCKETS (consisting of)
079 534 TERMINAL, female
16 PLG16
16
1
1
1
CABLE, volt-sensing (consisting of)
17
049 989
PLG12
073 686 PLUG,4socketMS-3106A-145-25
18
19
039 328
604 109
600 848
• CLAMP, cable AN-3057-6
• WIRE, stranded 16 ga (order byft)
• WIRE, stranded 12 ga (order byft)
20
21
22
23
24
25
26
27
28
29
30
31
32
19ft
35ft
1
600 750 TERMINAL, ring tongue 1/2 stud
601 226 • INSULATOR
1
601 228 CLAMP, universal 25 amp
111 951 CABLE, control-interconnecting (consisting of)
1
1
PLUG, l7socketMS-3106A-20-295
1
097 868
039 734 CLAMP, cableAN-3057-12
2
20ft
1
090 263 CABLE, No. 18/c (order byft)
097 866 PLUG, 17 pin MS-3106A-20-29P
010 916 CONNECTOR, clamp-cable 3/4 inch
070 731 BLANK, snap-in 1-3/32 x 1-1/8 mtg hole
057 360 BLANK, snap-in 1-3/8 mtg hole
1
1
1
BLANK, snap-in 1 inch mtg hole
PLUG, Spin MS-3106A-165-8P
047 838
039 273
2
1
039 685 CLAMP, cable AN-3057-8
1
CABLE, No. 182/c (order byft)
25ft
1
049 455
33
RC11
048 283 RECEPTACLE W/PINS (consisting of)
079 535 TERMINAL, male
4
34
111 199 CABLE, interconnecting (consisting of)
109330 PLUG, 24 socket MS-3106A-24-285
091 100 CLAMP, cable AN-3057-16
604 910 CABLE, 20 ga 5/c (order byft)
1
3S PLG17
1
36
37
38
39
40
41
42
43
44
4S
1
6ft
6ft
6ft
1
CABLE, l8ga 4/c (order byft)
CABLE, No. 20 8/c (order byft)
604 571
090 890
ICN4
ICN2
109 159 CONNECTOR
109 157 CONNECTOR
1
604 825 CABLE, 183/c (orderbyft)
109 158 CONNECTOR
6ft
1
ICN3
113 736 CABINET, control
1
RC1 3
C2,3
097 867 RECEPTACLE, 17 pin MS-3102A-20-29P
028 291 CAPACITOR, ceramic 0.1 uf 500 voltsdc
1
2
RECEPTACLE, 24 pin MS-3102A-14S-2P
46 RC17
47
094 591
076 624
1
RC12
PC4
RECEPTACLE, 4 pin MS-3102A-145-2P
1
057 084 BUSHING, snap 1/4 ID x 3/8 mtg hole
111 564 CIRCUIT CARD, meter (Fig B Pg 4)
073 756 STAND-OFF, No. 6-32 x S/8 x 1/4 hex
081 380 HOUSING, terminal header 14 pin
1
48
49
1
7
50 PLG21,25
2
OM-882 Page 2
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Item
Dia.
Part
No.
No. Mkgs.
Description
Quantity
1
Figure A
Control Box (Cont’d)
51
52
53
54
55
56
57
58
59
112 254 LABEL, Miller robot computer interface
089 032 LENS, led 4341
5
1
1
046 432 HOLDER, fuse
Fl
*012 655 FUSE, miniature glass 10 amp250 volts
073 487 NUT, speed No. 2
4
51
CB1
S2
011 622 SWITCH, toggle 3PDT 15 amp 125 volts
011 991 CIRCUIT BREAKER, 1 pole 1 .5 amp250 volts
112392 SWITCH, code
1
1
1
1
14
1
1
1
HOUSING RECEPTACLE & SOCKETS (consisting of)
047 637
RC9
079 534 TERMINAL, female
Dl
026 202 DIODE, 1 amp 400 volts SP
079 760 HOUSING, terminal header 12 pin
079 798 HOUSING, terminal header 13 pin
PLG18
PLG19
PLG20,26
PLG22
PLG24
PLG27
HOUSING, terminal header 12 pin
HOUSING, terminal header 16 pin
HOUSING, terminal header 6 pin
CONNECTOR, plug 5 position
081 379
092 159
084 198
111 500
2
1
1
1
4.Recommended Spare Parts
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-882 Page 3
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Dia.
Part
No.
Mkgs.
Description
Quantity
2
Figure B 111 564 Circuit Card, Meter (FIg A Pg 2 Item 48)
Cl ,2
000 348 CAPACITOR, tantalum 0.47 uf 35 volts
C3-5
073 739 CAPACITOR, ceramic 0.1 uf 50 volts dc
028 351 DIODE, signal 0.020 amp 75 volts SP
108 453 METER, DCO-200MV
3
3
3
3
Dl,2
LCDl-3
LEDl,2,4,5 089 028 LED,5330A1040MCD
LED3
Ri-S
097 763 LED, 5330A19200MCD
044 635 RESISTOR, carbon film 0.25 watt 680 ohm
3
3
3
R6,8,l 1 030 140 POTENTIOMETER, cermet 15 turn 0.75 watt 220K ohm
R7,9,l0 003 272 RESISTOR, carbon film 0.25 watt 1 meg ohm
RC2O
081 382 TERMINAL, header 12 pin
RC21 -23 109 161 TERMINAL, header 13 socket
3
1
2
2
RC24
VR1,2
084 194 TERMINAL, header6 pin
071 248 IC, linear78M05
070 026 STAND-OFF, No.6-32 x7/16 xl /4 hex
ASSE~ABLY
1Y 564
cc
~
C02
LCD3
±
210
2C2 I
2C22
2223
J ~
122
W
I
23
LED
2
~ED3
LED
4
21
LED
~~UT)~4~
~U
~N-C<<.(<
O L d ~ .
~
02
2020
2024
~1LIDi Ii [IDI liD Ii LI
LID Ii I Dli
COMPONENTS TO BE REPLACED
Ret: D-1 11 566
BY QUALIFIED PERSONNEL ONLY
Figure B Circuit Card, Meter
-
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-882 Page 4
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11
19
Figure C
-
Control Panel
OM-882 PageS
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Part
No.
Item Dia.
No. Mkgs.
Description
Quantity
Figure C
111 992 Control Panel (Fig A Pg 2 Item 1)
1
PC2
071 642 CIRCUITCARD,digitalmotorspeed(FigC2PglO)
1
2
3
4
5
6
7
083 147 GROMMET, screw8-10 push in
052 964 RELAY, enclosed 24 volts dc DPDT
038 839 BLOCK,terminal20amp5 pole
035 914 RECTIFIER, integrated 30 amp 400 volts
109 017 TRANSFORMER, control
1
1
1
1
1
4
CR2
5T
SRi
T2
605 741 CLIP, mtg-resistor
8
R3
Ri
079 497 RESISTOR, WWfixed25 watt2K ohm
030 651 RESISTOR,WWfixed25wattl0ohm
006 426 CLAMP, capacitor2 inch
1
1
1
1
1
1
2
9
10
11 Cl
12 CR1
13 iT
031 692 CAPACITOR, electrolyte 750 uf 200 volts dc
034 841 RELAY, 24 volts ac DPDT
038 832 BLOCK, terminal 20 amp9 pole
038 783 BLOCK, terminal 20 amp 12 pole
14 2T,3T
601 219 LINK,jumper
8
8
1
1
3
2
2
2
2
1
2
1
1
2
1
15
110 375 STAND-OFF,support
16
111 065 PANEL, mtg-components
110 565 CIRCUIT CARD, filter (Fig C4 Pg 12)
110 391 GUIDE, mtg-circuit card
079 844 SPRING, holddown-relay
095 521 RELAY, enclosed 24 volts dc 4PDT
027 811 CONNECTOR, 14 pin
026 202 DIODE, 1 amp 400 volts SP
048 588 BRACKET, mtg-relay
048 029 CLIP, retaining-socket relay
111 408 CIRCUITCARD,voltagecontrol(FigCl Pg8)
113 221 CIRCUITCARD,interface(FigC3Pg11)
009 335 STAND-OFF, No. 4-40 x 5/8 x 1/4
073 730 TERMINAL, header 22 pin
17 PC6
18
19
20 CR3,4
21
22 D3,4
23
24
25 PCi
26 PC3
27
28
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-882 PageS
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COMPONENT TO BE REPLACED
BY QUALIFIED PERSONNEL ONLY
Ret: D lii 410
Figure Cl
-
Circuit Card, Voltage
OM-882 Page 7
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Dia.
Part
No.
111 408 Circuit Card, Voltage (Fig C Pg 6 Item 25)
IC, linear 324
096 275
Mkgs.
Description
Quantity
Figure Cl
3
2
2
19
1
5
4
A1-3
Cl ,2
C3 ,4
039 482 CAPACITOR, electrolyte 100 uf 35 voltsdc
000 348 CAPACITOR, tantalum 0.47 uf 35 volts
CAPACITOR, ceramic0.1 uf 50 voltsdc
073 739
CS-i5,17-24
Cl 6
097 488 CAPACITOR, ceramic0.15 uf 50 volts
028 351 DIODE, signal 0.020 amp75 volts SP
095 258 CHOKE, 1000 UH28MA
D1-4,6
L1-4
Ql
Rl
TRANSISTOR, NPN200MA4OvoIts
RESISTOR, carbon film 0.25 watt 270 ohm
037 200
035 824
009 173 POTENTIOMETER, cermet 20 turn 0.5 watt 5K ohm
4
1
R2,34,35,41
R3
R4,20,26,27,30,
38,40
RESISTOR, carbon film 0.25 watt 18K ohm
039 333
039 332 RESISTOR, carbon film 0.25 watt 15K ohm
7
R5,9,10,18,25,28,
29,37,39
R6,7,12-1 5,36
R8
000 885 RESISTOR, carbon film 0.25 watt 10K ohm
044 789 RESISTOR, carbon film 0.25 watt lOOK ohm
9
7
1
2
1
3
2
1
1
RESISTOR, carbon film 0.25 watt 150K ohm
052 136
038 POTENTIOMETER, cermet 25 turn 0.5 watt 2K ohm
331 RESISTOR, carbon film 0.25 watt 4.7K ohm
R11,16
000
039
R17
RESISTOR, carbon film 0.25 watt 12K ohm
R19,21 .43
R22,42
R23
053 572
052 138 RESISTOR, carbon film 0.25 watt 20K ohm
052 139 RESISTOR, carbon film 0.25 watt 39K ohm
039 325 RESISTOR, carbon film 0.25 watt 82K ohm
R24
RESISTOR, carbon film 0.25 watt5.lKohm
RESISTOR, carbon film 0.25 watt6.8Kohm
RESISTOR, carbon film 0.25 watt 8.2K ohm
R3 1
052 137
035 826
091 799
1
1
1
R32
R33
035 823 RESISTOR, carbon film 0.25 watt 100 ohm
R45
092 648 RESISTOR, carbon film 0.25 watt zeroohm
26
1
TERMINAL, header 14 pin
089 347
RC25
RC26
Ul
U2,4
U3
VR 1
VR2
089 346 TERMINAL, header 12 pin
112 058 IC, interface2i2
1
1
095 268 IC, intetface2ll
2
IC,digital40ll
IC, linear3l7T
1
008 970
095 269
1
932 IC, linear 7915
1
046
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-882 Page 8
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0z~ o ,~
~“-‘-0
~
A50
~
w
—
!rr~
GATE
ANODE
D
CATHODE
ft~
G
(LARGE TERM)
LOLC)
~
O5~
C5O~
0 0 0
t
N~
C%J
—
+
0
rn~
c~4
—
0
~ft
R90
T U V W X Y Z
Ret: 0-093 449-G
COMPONENTS TO BE REPLACED
BY QUALIFIED PERSONNEL ONLY
Figure C2
-
Circuit Card, Digital Motor Speed
OM-882Page 9
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Dia.
Mkgs.
Part
No.
Description
Quantity
Figure C2
071 642 Circuit Card, Digital Motor Speed (Fig C Pg 6 Item 1)
IC, linear3S8
4
1
ASO-53
C50
009 159
039 482 CAPACITOR, electrolyte 100 uf35voltsdc
CAPACITOR, mylar0.0022 uf 200 volts dc
031 699
1
CS 1
073 739 CAPACITOR, ceramic0.1 uf50voltsdc
035 833 CAPACITOR, mylar0.033 uf 100 voltsdc
005 023 CAPACITOR, tantalum 2.2 uf 20 volts
031 643 CAPACITOR, ceramic0.01 uf 500 volts dc
073 549 CAPACITOR, mylar0.015 uf 200 volts
2
C52 ,6 1
C53,62
C54
2
1
C55,66-75,77
C56
12
1
CAPACITOR, tantalum 5.6 uf 3S voltsdc
1
C57
C60
031 677
035 561 CAPACITOR, mylar4 uf 200 volts
CAPACITOR, poly-film 0.47 uf 400 volts dc
044 602
1
2
C63,64
C65
031 721 CAPACITOR, mylar0.22 uf 200 volts dc
095 033 RELAY, enclosed 24 volts ac 4PDT
091 861 SOCKET, relay
1
1
CR50
1
079 844 SPRING, holddown-relay
026 202 DIODE, 1 amp 400 voltsSP
1
10
D50-54,56-60
D55
DIODE, zener 15 volts 5 watt
080 910
081 800 IC, interface 2907
1
1
2
1
1
1
1C50
TRANSISTOR, NPN 200MA40 volts
037 200
037 824
039 335
QSO,53
THYRISTOR, SCR 7.4 amp200 volts SP
TRANSISTOR, UJT 1 SMA40 volts
Q51
Q52
R50
030 839 RESISTOR, WWfixed 5 watt 220 ohm
R51 ,54,55,57,67,
68,74,75,82,89 035 827
RESISTOR, carbon film 0.25 watt 10K ohm
RESISTOR, carbon film 0.25 watt 20K ohm
RESISTOR, carbonfilm0.25wattl5Kohm
10
3
1
R52,56,61
052 138
039 332
R53
R58,62,65,66,71
72,76,90
R59
035 884 RESISTOR, carbon film 0.25 watt 100K ohm
030 007 POTENTIOMETER, cermet 15 turn 0.75 watt 50Kohm
039 335 RESISTOR, carbon film 0.25 watt 47Kohm
039 106 RESISTOR, carbon film 0.25 watt 1 K ohm
039 331 RESISTOR, carbon film 0.25 watt 4.7K ohm
8
1
3
2
1
1
2
1
1
1
2
1
1
15
1
1
1
1
R60,87,88
R63,79
R64
RESISTOR, carbon film 0.25 watt 10 meg ohm
RESISTOR, carbon film 0.25 watt 1 .5K ohm
R70
049 015
039 328
R73,83
R77
052 142 RESISTOR, carbon film 0.25 watt 120K ohm
039 108 RESISTOR, carbon film 0.25 watt 82K ohm
R78
RESISTOR, carbonfilm 0.25 watt 22K ohm
035 886
R80
R81,84
R85
035 825 RESISTOR, carbon film 0.25 watt 1K ohm
030 937 RESISTOR, carbon 0.5 watt 10 ohm
030 090 RESISTOR, carbon0.S watt 47 ohm
R86
RESISTOR, carbonfilm 0.2S watt zero ohm
TRANSFORMER, pulse
092 648
085 399
081 799
T50
VR5O
VR51
IC, linear78LO8
047 272 IC, linear78Ll2
HEAT SINK
037 261
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-882 Page 10
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Dia.
Part
No.
Description
Quantity
1
Mkgs.
Figure C3
113 221 Circuit Card, Interface (Fig C Pg 6 Item 26)
Al
009 159 IC,linear358
Cl
039 482 CAPACITOR, electrolyte 100 uf 35 volts dc
1
1
1
C2
000 348 CAPACITOR, tantalum 0.47 uf 35 volts
C3,6,9,10 072 130 CAPACITOR,tantaluml uf35voltsdc
C4
005 023 CAPACITOR,tantalum2.2uf20volts
073 739 CAPACITOR,ceramic0.1 uf50voltsdc
099 018 RELAY,enclosed24voltsdcSPDT
095 521 RELAY, enclosed 24 volts dc 4PDT
091 861 SOCKET, relay
1
1
1
1
1
1
6
3
3
4
C5,11
CR4-6
CR2
079 844 SPRING, holddown-relay
D3-8
D9,10,15
Qi -3
026 202 DIODE, 1 amp400 volts SP
028 351 DIODE,signalo.O2Oamp7SvoltsSP
037 200 TRANSISTOR, NPN 200MA 40 volts
035 826 RESISTOR, carbonfilm0.2Swatt6.BKohm
R1,2,8,11
R3,6,7,12,13 039 331 RESISTOR,carbonfilm0.25watt4.7Kohm
1
1
1
R4
072 561 RESISTOR,carbonfilm0.2Swatt27OKohm
039 106 RESISTOR, carbonfilm 0.25 watt 470 ohm
R5,10
R9
052 145 RESISTOR, carbonfilm 0.25 watt47OK ohm
079 759 TERMINAL, header 12 pin
079 795 TERMINAL, header 13 pin
081 832 IC,linear78MlS
1
1
1
1
RC18
RC19
VR1
c-’J
E
E~I
C2 P6
(N m~j fl
L)
03
E l
VRI ‘~‘ I~3K
DZN~
(N-i
Cl 6 ~j R7
o -
+
08
07
-
~
L....U
CR2
III
04
a~o
RCl8<cncowuoi~~J~ ~— RCl9.~-
.~
.~
.~
.~
. 4 - 4 - 4 - 4 - 4
-
0
e
e
Ret: C-lOS 275-A
COMPONENTS TO BE REPLACED
BY QUALIFIED PERSONNEL ONLY
Figure C3
-
Circuit Card, Interface
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-882 Page 11
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Part
No.
Dia.
Mkgs.
Description
Quantity
Figure C4
110 565 Circuit Card, Filter (Fig C Pg 6 Item 17)
C1-6,9-14,46,47
028 292 CAPACITOR, ceramic0.OOSuflOOOvoltsdc
14
14
7
C20-25,28-33,48,49 028 291 CAPACITOR, ceramic0.1 uf500voltsdc
L1-3,5-7,9
RC21
110190 CHOKE,1000UH
089 347 TERMINAL, header 14 pin
092 160 TERMINAL,headerl6pin
1
RC22
1
ASSEMBLY I 10565
G
QI~IDQI~ID
•
•
•
• •
a.~
Cu
-J
Cl
7 ~ IID Q ~ D ~
•
•
•
•
•
•
C46
C47
-i
-J
LU
C4
C3
C29
)
C 3 2 C 1 3
I ’
I r
I ,
m
m
m
r l
11
m
m
m
m
i i
i i
‘ I
0
0
0
Ret: C-i10 567
COMPONENTS TO BE REPLACED BY
QUALIFIED PERSONNEL ONLY
Figure C4
-
Circuit Card, Filter
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-882 Page 12
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Item Dia.
No. Mkgs.
Part
No.
Description
Quantity
Figure D
109 936 Control Box, Gas/Current Sensor
1
1
LABEL, general precautionary
047 497
1
+079 682 WRAPPER
2
1
079 687 RELAY, current
3 REED
4
1
109 021 CASE SECTION, bottom/front/sides
049 455 CORD, No. 182/c (order byft)
010 610 CONNECTOR, clamp-cable 1/2 inch
010 494 BUSHING, snap 1-3/8 ID x 1-3/4 mtg hole
057 358 BUSHING, snap ID x 1 .37 mtg hole
2ft
1
5
6
2
7
2
8
2
FITTING, hose-brassbushing 1/4 NPTx5/8-18
FITTING, pipe-coupling 1/4 NPT
9
010 604
602 934
079 573
1
10
1
FITTING, pipe-nipple L 1/4 NPT x 6
11
2
079 574 BRACKET, mtg-component
12
1
13 RC7
047 637 HOUSING RECEPTACLE & SOCKETS (consisting of)
• TERMINAL, female
14
1
079 534
14 D2
15 4T
16 GS1
17 RC16
109 938 DIODE, 1 amp 400 volts SP
038 081 BLOCK, terminal 20 amp4 pole
109 561 VALVE, 24 volts dc 2 way 1/4 IPS port 1/8 orifice
090 246 RECEPTACLE W/PINS (consisting of)
079 535 • TERMINAL, male
9
6 7
8
2
1
TC-109 Lao
Figure D
-
Control Box, Gas/Current Sensor
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-882 Page 13
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ERRATA SHEET
Afterthismanualwas prInted,refinements Inequipment design occurred. This sheet lists exceptIons
to data appearing later in this manual.
AMENDMENT TO SECTION 2
-
INSTALLATION
IMPORTANT: A 25 ft. (8m) interconnectingcord witha five-pin Amphenoiplug issuppliedwith this unitbut isnot used
in this installation. Retain cord for future use.
Amend Section 2-5. COMPUTER INTERFACE TERMINAL STRIP CONNECTIONS
WARNING: ELECTRIC SHOCK can kill.
•
•
Do not touch live electricalparts.
A
Shutdown unit, welding powersource, and robot, anddisconnect inputpoweremployinglockout/tag-
ging procedures before making interconnections.
Lockout/taggingprocedures consist of padlocking line disconnect switchin open position, removingfuses
from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.
There are several terminal strips insidethe computerinterface forcontrol connections. Remove unit top cover, loosen
screws on strain relief on unit rear panel if necessary, and locate appropriate terminal strip for connections. Tighten
screws on strain relief if necessary, and reinstall top coverwhen procedure is finished.
A. CV/CC Connections
WARNING: Read and follow safety information at beginning of Section 2-5 before proceeding.
A
1. Locate terminal strip 2T.
2. For CC operation, remove jumper link between terminal E and F on 2T.
IMPORTANT: The Inductance control is disabled when operating in the CC (constant current) mode.
B. ARC FAILURE Light Connections (Figure 2-4)
WARNING: Read and follow safety information at beginning of Section 2-5 before proceeding.
A
The ARC FAILURE light on the computer interface front panel is turned on and off by a signal from the robot control
unit. Locate supplied length of 18 gauge/2-conductor cord for this connection, and proceed as follows:
1. For robot control units with no other connections at jig terminal strip 2:
a. Open robot control unit door, and locate jig terminal strip 2.
b. Route cord under cross member below door.
c. Make cord connections to terminal strip common and the Weld Alarm terminal.
d. Close robot control unit door, and route cord through strain relief on rear panel of computer interface.
e. Connect cord to 2TF and 2TG.
2. For robot control units when 115 or 24 vac, or 24 vdc is used at jig terminal strip 2T:
a. Obtain a 115 or 24 vac, or 24 vdc isolation relay, and install into jig interface.
b. Open robot control unit door, and locate jig terminal strip 2.
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-v
c. Route customer supplied 18 gauge/2-conductor cord under cross member below door.
d. Make cord connections to terminal strip common and the Weld Alarm terminal.
e. Close robot control unit door, and route cord to jig interface.
f. Connect cord to isolation relay coil and voltage source.
g. Cut off terminals from one end of supplied 18 gauge/2-conductor cord, and install terminals to connect to
contacts on isolation relay.
h. Connect one end of cord to a set of normally-open contacts on isolation relay.
i. Route cord through strain relief on rear panel of computer interface.
j. Connect cord to 2TF and 2TG.
Add Figure 2-4. Arc Failure Light Connections
JIg TermInal
StrIp 2
Common
Computer Interface
2W
Robot
Control
unit
2TG
Weld Alarm
Arc FaIlure
Indicator
Ught
To Voltage Source
(115VAC, 24VAC, 24VDC)
0 2TF
~—
I
Robot
Control
Unit
Arc Failure
IndIcator
Light
JIg Interface
Alarm
computer
Interface
TA-i 15 648
Figure 2-4. Arc Failure LIght Connections
OM-882 Page 2
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AMENDMENT TO SECTION 5 - MAINTENANCE & TROUBLESHOOTING
r-.
Amend Figure 5-3. Circuit Diagram For Computer interface
C..’
I
C S O O
< 0 0 0 W
0 0 0
0 ~
0 0 0 0 0 0
a O O O O
-V.-
a
K
~
8
—
0 0 0 .0 0 0 .0 0 .0
0 0 0 0 0 0 0 0 0 0
6
z
~ 0j-~
;
E
(U
-N-
~
.0 ,
I
(U
0
NL&N-O
0
I _
U
L .
— ~
_
9
Z
~
L
. ~
j
C.)
0,
j
(0
0
0,
c’J
=
N-s
e
~
7
A
~
-
A
A
<
~
A
N-N-
S
0
z
I!:
N-N-N-
N-N-N-
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OM-882 Page 3
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Amend Figure 5-6. Circuit Diagram For Interface Board PC3
‘IS V
*24
V
N-24
~.C2
C i t
L .44 .).R
WELD START As
7
AS
JOG (FN-dD) ,~
CR
6
R
C GAS
WIREFEED
MOTOR
CR5
WELD
AL
CURRENT
RELAY A.J
JOG (R E V ) P4
CR6
GAS
WOBOT
CR2
CURRENT
AN
COl.*40N
AM
L.............>
REV. RELAY
~
CR4
CONTACTOR
L ~ A C
CIrcuit Diagram No. 5-128 016
FIgure 5-6. CIrcuit Diagram For Interface Board PC3 Effective With Serial No. JK588314
OM-882Page4
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Add Figure 5-9. Wiring Diagram
C.,’
1—
r-.
1 ~
6
z
E
(U
a-
0)
0
0)
0)
0)
C..’
=
6
z
aa)-
U)
•6 ~
a)
4 -
C.)
a)
E
(U
a0-)
(U
0
0)
a)
a -
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U..
uu
OM-882 Page 5
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AMENDMENT TO PARTS LIST
Amend Parts List as follows:
Dia.
Part
Replaced
With
Mk~s
No.
Description
Quantity
2-1
2-4
2-17
2-20
2-
2-48
3-56
4-
111 992
070 634
049 989
604 109
028 291
111 564
011 622
044 635
083 147
035 914
110 375
111 065
113 221
073 730
072 130
073 739
028 351
109 936
010 610
117 724 CONTROL PANEL
1
1
1
26ft
7
1
1
1
2
2
7
1
1
1
1
1
4
1
1
1
1
1
2
1
123 154 LABEL, warning general precautionary
118 676 CABLE, volt sensing (Eff w/HJ304076)
604 109 WIRE, (qty chg)
C2,3,6-1 0
PC4
028 291 CAPACITOR, (qty chg)
117836
011 609
CIRCUIT CARD, meter
51
Ri-5
SWITCH, toggle SPDT 15 amp 125 volts
030 028 RESISTOR, carbon 0.5 watt 1.5K ohm
6-2
6-5
083 147 GROMMET, (qty chg)
SRl,2
RECTIFIER, (qty chg)
110 375 STAND OFF, (qty chg)
035 914
6-15
6-16
6-26
6-28
11—
11—
121 313 PANEL, mtg-components (Eff w/JJ377225)
128 014 CIRCUIT CARD, interface (Effw/JK588314)
073 730 TERMINAL, header 22 pin
PC3
RCS
C3
072 130 CAPACITOR, (qty chg) (Eff w/JK588314)
073 739 CAPACITOR, (qty chg) (Eff w/JK588314)
028 351 DIODE, (qty chg) (Eff w/JK588314)
CS
11— D9, 10,15,16
13-
13-6
CR5
Ti
117 617
CONTROL BOX, gas/current sensor
115 104 CONNECTOR CLAMP, cable 1/2 inch
110 386 RELAY, enclosed 24 volts ac DPDT
117 725 TRANSFORMER, control
117 726 CAPACITOR/RESISTOR, (consisting of)
C4,5
R4
000 859
601 394
CAPACITOR, electrolytic 220 uf 35 volts dc
RESISTOR, carbon 2 watt 10K ohm
**First digit represents page no digits following dash represent item no.
-
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-882 Page 6
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