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COMPUTER INTERFACE MR-5
Owners manual
36 pgs1.29 Mb0
Owners manual
34 pgs1.27 Mb0
Owners manual
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Miller COMPUTER INTERFACE MR-5 Owners manual

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Page 1
April1986
FORM:
OM-878
IMPORTANT
contents
manual
on
before
used
the
safety
installing,
equipment.
use
safe
untrained
this understand
by
only
operation
unit.
of
both
with
This
persons
persons
Contact
these
Read
manual
this
this
material
operating,
and
unit
trained
of
welding
to
your
instructions.
and
understand
and
with
unit,
throughout
or
these
and
equipment.
install,
distributor
operate,
the
the
power
special
both
maintaining
instructions
experienced
Do
or
do
If
you
entire
source
emphasis
manuals,
this
for
are
the
in
allow
not
maintain
not
fully
Effective
With
MR-5 COMPUTER
GAS/CURRENT
CON
TROL
Serial
MODEL
INTERFACE
No.
JG036750
SENSING
OWNERS
MANUAL
MILLER
718
ADDITIONAL
ELECTRIC
S.
BOUNDS
APPLETON,
NWSA
CODE
PAINTED
COPY
WI
IN
ST.
54912
PRICE
NO.
U.S.A.
P.O.
4579
MFG.
Box
USA
70
CENTS
fullER
CO.
1079
Page 2
LIMITED
WARRANTY
~
~
~
~
~
~
7
~\
~
~)
rI
LIMITED
tions
~
warrants
Equipment ship
No
warranty
accessories
engines,
warranties
the
engines
date
which
Exceptasspecified
to
components
year,
MILLERMATIC wire
not
result
Miller
ranted
within
mont
1.
2.
3.
4.
5.
6.
provided
the
of
WARRANTY
Miller
hereof,
to
furnished
and
material
trade
warrantedbytheir
are
of
original
have
a
Electric
its
Distributor/Dealer
Miller
by
of
the
as
is
made
by
items
other
or
accessories
of
their
respective
purchase,
two
year
warranty.
below,
normal
such
including
Equipment
the
to
Arc
Original
.AJ All
Replacementorrepair
Batteries
date
having
welder
as
spot
parts
nozzles
from
defect
shall
be
required
in
the
original
power
main
power
guns
Miller
of
such
periods
user:
feed
is
failure.
following
the
welders,
welr*ig
otherMillermatic
that
that and
in
workmanship
event
sources
rectifiers
notified
This
warranty
with
clusive
-
Subject
Mfg.
time
Miller
manufactured
and
is
other
free
and
with
to
Co..
that
from
place
respect
items
the
Appleton,
manufacturers,
manufacturer
Tecumseh
except
Millers
warranty
useful
lifeofless
tips,
come
nozzle
honor
to
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and
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in
contact
insulators
or
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failure
resulting
the
date
and
components
and~~srne
Feeders
exclusive
parts
in
writing
within
supersedes
other
no
terms
all
new
defect
of
delivery
to
by
are
for
and
contactor
with
where
material.
claims
of
delivery
torches...
of
labor..
thirty
EFFECTIVE:
guarantees
and
Wisconsin
and
in
workman-
by
engines,
others.
sold
subject
if
any
one
year
Onan
engines
does
not
than
one
the
welding
failure
on
from
a
of
....
3
90
60
6
months
(30)
all
previous
condi-
unused
Miller.
trade
Such
to
All
.
from
apply
(1)
points,
does
war-
defect
Equip-
1
year
years
days
1
year
days
days
JANUARY
MILLER
warranties
or
with
therefore
or,
the
Miller
price
return
optionofrepair Appleton, facility,
any
defect claim
ANY
liON
BREACH MIGHT CUSTOM
ANY
FITNESS
ANY
CLUDED
WRITING,
ULTIMATE
USERS
EXPERIENCED WELDING
CONSUMER
~O~RJ~
1986
2.
warranties
expressedorimplied.
In
the
respect
where
reasonable
(less
case
shall
authorized
service
reasonable
of
the
of
to
the
be,
cost
station
goods
Wisconsin,
therefore,
kind
willbeallowed.
or
faihzre,
procedures
ANY
EXPRESS
IMPUED
AS
TO
OF
CONTRACT
WARRANTY,
PERFORMANCE.
ARISE
OF
TRADE
IMPUED
AND
EXCEPT
FOR
ALL
AND
WARRANTY
PARTiCULAR
DISCLAIMED
AS
MILLER
PURCHASE
AND
FOR
EQUIPMENT
USE.
and
Millers
quality
Millers
at
in
writing
of
repair
(4)
or
depreciation
at Customers
or
replacement
or
no
compensation
Miller
shall
to
followed.
be
WARRANTY
BY
IMPUCA11ON,
OR
EQUIPMENT
EXPRESSLY
PRODUCTS
OPERATION
IN
THE USE
MILLERS
is
ex
of
breach
of
payment
F.O.B.,
WHICH,
COURSE
any
option
by
or
at
Upon
instruct
NOT
GUARANTY
OF
warranty
goods,
(1)
Miller
replacement
oforcredit
based
risk
will
a
for
receipt
the
AND
BUT
OF
MERCHANTABIUTY
PURPOSE.
FURNISHED
MILLER.
BY
.
PROVIDED
BY
COMMERCIAL/INDUSTRIAL
PERSONS
BY
AND
NOT
AND
WARRANTIES
or
the
exclusive
or
repair
in
appropriate
upon
and
expense.
be
F.O.B..
MILLER
authorized
eansportation
of
notice
claimant
PROVIDED
OR
ANY
FOR
THIS
OPERA11ON
DEAUNG.
WITH
BY
BY
ARE
INTENDED
MAINTENANCE
FOR
CONSUMERS
DO
other
any
(2)
replacement
at
an
for
the
actual
Factory,
of
the
on
HEREIN
REPRESENTA
REMEDY
PROVISION,
OF
INCLUDING
RESPECT
MILLER
MILLER
TRAINED
NOT
duty
remedies
(3)
cases,
authorized
purchase
use)
upon
MILLERs
service
costs
apparent warranty
AND
FOR
LAW,
OR
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TO
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EX
IN
FOR
AND
OF
OR
EXTEND
i?
at
of
?
Page 3
TABLE
OF
CONTENTS
SECTION
SECTION
SECTION
SECTION
Section
-
1
1.
-
2.
1
-
3.
1
2-1. 2-2.
-
3.
2
3-1.
-
3
2. 3-3. 3-4. 3-5.
-
1.
4
-
2.
4
-
4
3.
No.
-
INTRODUCTION
1
General
Information
Receiving-Handling Description
-
INSTALLATION
2
Location Gas/Current
Computer
-
FUNCTION
3
Power
Overload
Voltmeter Wire
Indicator
-
SEQUENCE
4
Input
Output
Wire
Speed
Signal
Stick
Sensing
Interface
OF
Switch
Protection
Meter
Lights
From
Signals
Check
CONTROLS
OF
Welding
From
And
Safety
Control
-
Welding
OPERATION
Computer
Connections
Power
Power
Interface
Source
Source
Connections
Page
No.
2
2
2
2 2 3
4
4
4 4 4
5 5
5
SECTION
5-1. 5-2.
-
3.
5
-
4.
5
-
5.
5
5-6.
-
MAINTENANCE
5
Inspection
Overload
Display
Board
And
Protection
Board
Replacement
Troubleshooting
Use
Indicator
Of
Upkeep
Meter
Chart
Lights
TROUBLESHOOTING
&
Check
Procedures
For
Troubleshooting
6
6
7 7
8
10
Page 4
Page 5
SECTION
-
1
INTRODUCTION
Gas/Current
Model
MR-5DW
Sensing
Control
31
5
Weight
lbs.
lbs.
(14
(2.3
kg) kg)
2-7/8
(73.0
4-1/2
(108
i1n.
mm)
in.
mm)
+
16.5
~
9-7/8
(251
in.
mm)
(419
in.
mm)
case
only
1
10-1/2
(267
5/16
Diameter
in.
mm)
in.
(7.9
2
Figure
mm)
Holes
1
-
1.
Specifications
3-1/2
(89
1)
mm)
In.
TB109
TB-i
847
10
320
OM-878
Page
1
Page 6
-
GENERAL
1.
1
General
A.
Information
labels,
ment
design,
troubleshooting
followed
ment.
B.
The
presented
and
tags,
installation,
which
the
for
Safety
installation,
troubleshooting
and
safety
operated,
in
accordance
codes
of
Section
Power
Manual.
levels
procedures
of
such
of
practices
and
the
be
installed,
persons
plicable
the
end
Arc
Welding
Owners
Safety
pear
words
different
instructions
throughout
ITAT1~.th~II~CI
INFORMATION
in
this
the
on
plates
operation,
should
and
effective
safe
operation,
of
arc
welding
which
others.
and
but
as,
-
1
Source
Therefore,
maintained
with
not
Safety
in
specifically
manual
this
CAUTION
and
hazard.
AND
manual
unit
and
pertains
maintenance,
be
read,
use
understood,
of
maintenance,
equipment
ensure
personal
this
equipment
only
manual
this
limited
Rules
the
welding
pertaining
to,
For
those
to
highlighted
which
SAFETY
various
on
to
equip
this
equip
requires
safety
qualified
by
all
and
listed
Operation
source
power
this
unit
the
by
signal
identify
and and
and
is
ap
ap
Of
CAUTION
and
maintenance
carefully
or
damage
A
third
tions
which need
efficient
-
1
2.
this
equipment,
the
unit
have
occurred
damage
the
by
of
to
at
lading
quest
When
ment, Number
-
1
The
if
3.
computer
speed
voltmeter
terface
statements
followed
this
to
word,
signal
operation
RECEIVING-HANDLING
clean
and
carefully
during
that
may
have
purchaser
willbefurnished
occasion
to
requesting
it
is
essential
of
the
equipment
DESCRIPTION
interface
and
weld
wire
and
with
the
robot
include
procedures
result
could
equipment.
IMPORTANT
_______________,
special
of
this
equipment.
all
packing
inspect
shipment.
occurred
with
the
by
file
claim
information
Model
that
be
control
voltage
feed
speed
control
installation,
or
practices
in
minor
highlights
to
-
Prior
material
for
carrier.
the
arises.
damage
any
claims
Any
in
transit
A
manufacturer
concerning
Description
supplied.
contains
control
meter,
unit.
circuitry,
and
operation,
which
personal
obtain
to
from
for
must
of
copy
this
and
wire
circuitry
if
not
injury
instruc
the
most
installing
around
that
may
loss
or
be
filed
the
bill
on
re
equip
Serial
feed
digital
in
to
WARNING
maintenance
and
loss
-
1.
followed
of
LOCATION
allow
for
must
carefully
or
2
should
wrappers
lengths
Mounting mounting
Normally
the should
source
tionofrobot
The when
moisture,
-
2
NECTIONS
the
robot
be
and
service
it
2.
GAS/CURRENT
control
is
statements
procedures
could
result
life.
(Figure
to
room
open
installation,
be
considered
holes
are
purposes.
computer
mounted
wire/drive
manual
life
Figure
unit.
in
and
efficiency
interface The line
assembly.
for
subjectedtohigh
corrosive
(Figures
vapors,
2-1
include
maintenance
installation,
or
practices
in
serious
1
and
when
locating
in
each
1-1
gives
is
gas/current
between
and
of
the
2-2)
information.
levels
extreme
SENSING
And
-
1)
remove
mounted
the
See
system
CONTROL
-
and
unit
operation,
which
personal
lION
The
location
covers
repair.
components.
component
dimensions.
on
top
are
dust,
heat.
control
power
reduced
CON
sensing
welding
installation
of
if
not
injury
-
2
and
Lead
for
of
sec
dirt,
The
gas/current
and
current
These
when
cess.
components
using
INSTALLATION
Lockout/tagging
disconnect
from
fuse
box,
breakerorother
1.
Insert
cord
gas/current
clockwise.
2.
Route
positive gas/current assembly.
3.
Connect
to
gas
must
regulator/flowmeter
sensing
sensing
the
Gas
procedures
switch
in
or
disconnecting
16-pin
into
corresponding
sensing
cable
weld
weld
sensing
hose
supply
regulator/flowmeter.
be
accurately
control
reed
function Metal
open
Amp
from
output
from
relay.
contains
with
the
Arc
Welding
consist
of
position,
off
and
red-tagging
device.
from
plug
receptacle
control,
and
welding
terminal,
control,
the the
gas/current
controlled
the
at
source.
the
robot
(GMAW)
padlocking
gas
system
fuses
circuit
valve
pro
line
interconnecting
the
on
wire
gas
collar
source
the
drive
control
flow
by
a
rotate
power
through
sensing
The
OM-878
WARNING
Do
not
Shut
and
down
lockout/tagging
terconnections.
Page2
ELECTRIC
touch
live
unit,
disconnect
SHOCK
electrical
we/ding
power
input
procedures
can
parts.
power
before
kill.
source,
robot
and
employing
making
in
Page 7
Deltaweld
Control
Voltage
Receptacle
Strain
Relief
Sensing
Puistar
Control
Arc
Control
Voltage
Receptacle
Voltage
Receptacle
Pak
Volta~
Recepu
Welding
Interface
Fflteri
Power
Receptacle
OE~
p.:
I
Source
:~:
1
15VAC/Contactor
Control
Figure
Receptacle
2
-
1.
:.:
_______
Gas/Current
Control
Panel
Rear
15VAC/Contactor
1
Control
Cord
Receptacle
View
Sensing
Deltawold
Power
TB-l09
Welding
Source
848
Robot
*If
ApplIcable
-
3.
COMPUTER
SOURCE
2
POWER
2-2)
touch
not
down
disconnect
ELECTRIC
tagging
WARNING
__________
Do Shut
and
lockout!
terconnections.
Lockout/tagging
disconnect
from breaker
There tions
fuse
or
are
between
switch
box,
other
three
Arc
Failure
Connection
Control
In
Unit
INTERFACE
CONNECTIONS
SHOCK
five
electrical
unit,
we/ding
input
procedures
open
consist
position,
off
procedures
in
or
shutting
disconnecting
separate
the
cords
computer
parts.
power
power
and
device.
used
interface
Figure
can
2-2.
-
WELDING
(Figures
kill.
source,
2-1
and
employing
before
of
making
padlocking
red-tagging
for
interconnec
and
welding
Motor
Interconnection
And
robot
in
line
fuses
circuit
Control
Cord
power
the
following
A.
1.
2.
B.
1.
Diagram
source.
connections.
Voltage
Connect
assembly
source
Connect
is
Voltage
Insert
5-pin
into
cord
power
source,
Examine
Sensing
lead
where,
connected.
lead
Control
and
with
weld
with
Connections
Connections
ring
clamp
Amphenol
corresponding
and
rotate
select
terminal
from
cable
work
to
on
plug
receptacle
collar
Touch
the
proper
to
welding
table.
remaining
clockwise.
TB-log
cord
wire
on
Sensor
851
for
drive
power
of
end
welding
OM-878
Page
3
Page 8
2.
Place
welding
control
C.
115VAC/Contactor
1.
Insert
contactor
source,
Power
Switch.
Circuit
Breaker
power
switch
two-pole
control
and
rotate
source
in
the
twistlock
receptacle
plug
ON
position.
Control
plug
clockwise.
SECTION
REMOTE
Connections
from
on
welding
VOLTAGE
cord
power
-
3
into
2.
3.
OF
Place
welding
TOR
control
Insert
three-pole
11
5VAC
source,
CONTROLS
power
switch
receptacle
and
rotate
source
in
the
twistlock
on
clockwise.
REMOTE
ON
position.
plug
the
CONTAC
from
welding
cord
into
power
-
3.
POWER
the
to
weld.
to
shuts
3-2.
A.
The
nal
short
should
tiOn
B.
POWER
1.
switch
interface.
Placing
the
interface
OVERLOAD
Fuse
interface
or
open,
for
5-2
Wire
SWITCH
in
the
ON
The
interface
the
POWER
down.
PROTECTION
Protection
is
protected
excessive
the
overload
interface
replacement
Drive
Motor
Indicator
Gas
Light
Contactor
Indicator
(Figure
must
switchinthe
from
damage
by
would
procedures.
Circuit
Light
3-1)
applies
beonfor
(Figure
fuse
shut
Breaker
Figure
-
due
Fl.
down.
Placing
input
the
OFF
position
3-1)
to
an
If
fuse
See
3
power
robot
inter
-
the
Sec
Indicator
Front
1.
Fl
Current
Light
Panel
-
3
speed
nearest
and feed
3-5.
five
indication
The
energized
The
power
weld
View
WIRE
4.
meter
inch
preset
speed
INDICATOR
indicator
GAS
light
and
CONTACTOR
source
output
SPEED
displays
per
wire
feedback
lights
of
various
turns
shielding
contactor
is
available.
minute
feed
METER
preset
while
speed
circuit.
LIGHTS
the
on
process
to
on
light
Wire
Speed
1PM
Meter
welding
are
interface.
functions.
indicate
should
gas
turns
is
energized
(Figure
feed
wire
the
same
(Figure
that
flow.
when
on
3-1)
and
3-1)
These
the
to
TB109
-
speed
idling.
due
to
-
are
gas
the
indicate
847
The
to
Actual
the
There
visual
a
valve
welding
wire
the
wire
are
is
that
The overload should button
the
3
displays welding
OM-878
circuit
-
3.
Page
drive
by
open,
would
VOLTMETER
weld and
4
motor
circuit
the
have
breaker.
voltage
preset
is
protected
breaker
interface
be
to
(Figure
to
the
voltage
from
CB1.
If
would
shut
manually
3-1)
nearest
while
idling.
damage
circuit
breaker
down.
depressed
-
The
tenth
of
due
The
to
voltmeter
volt
a
CB1
reset reset
while
when
an
when
feed
the
arc
the
is
current
is
established.
there
to
The
motor
The
WIRE
CURRENT
relay
ARC
The
outage
FEED
energizes
is
energized
FAILURE
while
light
indicate
to
turns
light
indicate
to
light
welding.
turns
turns
that
on
on
wire
when
that
on
feed
wire
started.
detect
is
an
arc
Page 9
-
INPUT
1.
4
SOURCE
wire
and
These
face. paramters.
to
preset
keep
weld
to
(Figure
drive
motor
signals
During
welding
parameters
SIGNAL
welding
values
4-1)
send
Arc
SECTION
FROM
-
The
signals
used
are
these
and
compensations
at
preset
Initiation
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welding
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to
to
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-
4
power
computer
determine
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weld
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OF
-
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3.
weld
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determine
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completed,
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indicates
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wire
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its
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check
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4-1)
is
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of
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to
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4
-2.
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Figure
Current
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signals
robot,
computer
and
wire
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from
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r
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-
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-
1.
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4-2)
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oto~
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remains
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indicates
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stuck,
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.25
6.25
of
was
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is
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the
be
displayed
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stuck,
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stuck,
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the
wire.
determine
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on
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sequence.
a
higher
pulsed
and
free
down,
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removed
to
is
wire
the
to
two
the
a
pro
OM-878
Page
5
Page 10
SECTION
-
MAINTENANCE
5
&
TROUBLESHOOTING
IMPORTANT
______________
this
maintained
when
precautionary
5-1.
WARNING
__________
for
unit
necessary.
INSPECTION
Do
not
Shut
and
lockout!
legibility.
in
a
labels.
ELECTRIC
touch
down
disconnect
tagging
inspecting
Lockout/tagging
fuse
or
and
of
Repair
and
and
switch
box,
other
shop
maintenance.
or
cables;
cracked
disconnect from breaker
Usage
and
type
1.
equipment.
2.
Remove
moisture
months
six
Every
All
precautionary
the
AND
readable
Parts
UPKEEP
c/early
See
SHOCK
live
electrical
unit,
welding
input
procedures
or
servicing.
procedures
in
open
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off
disconnecting
conditions
will
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as
replace,
give
insulation
grease
electrical
from
required,
particular
and
grime
inspect
state
for
List
can
parts.
power
source,
power
consist
of
position,
and
red-tagging
device.
determine
equipment
attention
and
areas
from
and
parts
the
labels
labels
and
replaced
number
part
kill.
and
employing
before
internally
padlocking
the
frequency
as
all
hoses,
to
where
components;
cables.
on
be
must
robot
line
fuses
circuit
follows:
cords,
frayed
it
enters
of
5-2.
_________
WARNING
OVERLOAD
Do
not
down
Shut
and
lockout!
ELECTRIC
touch
disconnect
inspecting
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disconnect from
breaker
CAUTION
__________
unit.
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1.
2.
3.
4.
switch
fuse
box,
other
or
IMPROPER
If
replacement
of
the
proper
List).
the
fuse,
Depress
counterclockwise.
Pull
is
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out
free.
fuse
new
fuse
PROTECTION
SHOCK
electrical
live
unit,
welding
input
tagging
or
procedures
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procedures
in
open
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size,
type,
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and
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fuse
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with
fuse
parts.
power
power
consist
position,
off
and
device.
FUSES
necessary,
and
follows:
as
fuse
when
holder
fuse
holder
(Figure
kill.
can
source,
employing
before
of
padlocking
red-tagging
can
damage
use
rating
holder
fuse
holder
cover.
back
cover
3-1)
and
robot
internally
line
fuses
circuit
this
fuses
only
Parts
(see
cover
cover
into
unit.
Rear
Display
View Board
-
1PM
For
5Vdc
cover
For
and
is
~
5.
Depress
until
Of
PC4
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Wire
Meter0.5Vdc
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Voltmeter
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0
rotate
secure.
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V1
yin2
V2~
V2
~
+
>
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holder
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cover
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-
0
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.5
-
.8
clockwise
For
For
1PM
Vdc
OM-878
Page
0-50
source
wire
to
output.
to
drive
Corresponds
power
Corresponds
of
the
-
1.
Figure
6
5
Display
Board
Meter
Checks
0-800
motor.
volt
welding
1pm
output
Page 11
-
3.
-
DISPLAY
Check
meter
Do
not
Be
sure
5
5-1)
for
VOLT
Ii~Il~e~
cedures
Shut
or
down
test
practices.
ty
ELECTROSTATIC
electronic
Do
not
properly
on
ding
Transport
static-shielding
per
Perform
BOARD
are
points
power
and
supply
WIRE
ELECTRIC
touch
ilve
that
personnel
familiar
are
unit
equipment
DISCHARGE
components.
touch
any
a
grounded,
all
static-sensitive
work
only
METER
and
on
input
1PM
parts.
meter.
can
provided
SPEED
SHOCK
electrical
performing
and
with
before
lead
follow
making
connections.
or
(ESD)
electronic
wrist
components
strap
is
static-dissipating
carriers
at
a
components
and
static-safe
CHECK
the
display
command
kill.
testing
standard
changing
can
while
worn
mat.
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work
area.
(Figure
board
for
the
pro
safe
meter
damge
unless
stan
in
pro
3.
4.
Gently
Do
not
and
To
replace
Remove
a)
LEDs
pull
pull
board
or
up
be
may
meter(s)
nuts
down;
damaged.
proceed
lock
and
from
away
otherwise,
follows:
as
washers
front
the
from
panel.
meters
meter
support.
b.
Gently
tain
spacers.
Slide
c.
a
d.
Push
protruding
Reinstall
e.
meter
meter
pull
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meter
lock
to
board.
may
meter
onto
into
socket
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damaged.
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new
with
to
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and
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meter
of
nuts
of
socket.
supports.
board.
to
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supports
secure
nuts
or
1.
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2.
Locate
3.
Check
4.
If
correct meter
5.Ifthe
rect,
a
meter
computer
display
voltage
and
(see
power
replace
5-4).
5
-4.
BOARD
WARNING
__________
Do
Shut and
lockout/
or
servicing.
touch
not
down
disconnect
ELECTRIC
tag9ing
Lockout/tagging
disconnect
from breaker
ELECTROSTATIC
electronic
A.
switch
fuse
box,
other
or
components.
Do
properly
ding
Transport
per
Perform
touch
not
on
a
grounded,
all
static-shielding
work
Display
ment
interface
board
PC4.
accordingtoFigure
supply
power
the
Section
supply
display
meter
is
5-4).
command
or
board
REPLACEMENT
SHOCK
live
electrical
unit,
welding
input
procedures
open
consist
position,
off
procedures
in
or
shutting
disconnecting
DISCHARGE
electronic
any
wrist
static-dissipating
static-sensitive
carriers
static-safe
at
only
Board
a
(PC4)
and
command
not
PROCEDURES
parts.
power
power
and
device.
(ESD)
components
strap
components
or
And
top
cover.
5-1.
voltage
replace
voltage
PC4
(see
kill.
can
source,
and
employing
before
of
inspecting
padlocking
red-tagging
can
damage
unless
worn
while
mat.
is
packages.
work
area.
Meter
Replace
the
is
incor
Section
robot
line
fuses
circuit
stan
in
pro
is
5.
To
install
a
board
and
top
Interface
top
Voltage
Disconnect
6.
7.
B.
1.
2.
meters
Reinstall
Reinstall
Voltage
and
Remove
For
a.
38 from
b.
Disconnect
RC14
Remove
c.
d.
Install
Connect
e.
f.
Connect
For
a.
b.
c.
terminal
Motor
Remove
Gently
Install
a
3.
with
up
LEDs.
cover
Board
(PCi).
Board
cover
Board
lead
terminal
plug
board.
on
board.
replacement
PLG14
4
lead
T.
Board
PC2:
securing
board
pull
board.
new
line
replacement
screws.
on
from
PCi:
4
1.
to
to
from
display
front
unit.
(PC3)
unit.
from
PLGI4
board.
RC14.
terminal
screws.
board,
panel
Motor
Board
Replacement
terminal
from
U
and
receptacle
carefully
openings
(PC2).
U
and
receptacle
lead
38
RC5.
for
lead
to
2.
1.
Remove
Remove
not
remove
cover
top
screws
stand-offs.
from
unit.
board
to
stand-offs.
Do
d.
Reinstall
screws.
OM-878
Page
7
Page 12
4.
Interface
For
Disconnect
a.
receptacles
b.
Remove
Board
plugs
RC18
board.
PC3:
and
PLG18
RC19.
and
PLG19
from
MOVING
HOT
PARTS
clear
Keep
SURFACES
Allow
of
cooling
Troubleshooting
sons.
can
moving
can
period
be
to
cause
serious
parts.
cause
severe
before
performed
injury.
burns.
servicing.
onlybyqualified
per
Install
c.
d.
replacement
Connect
RC19.
Reinstall
5.
-
5
WARNING
_________
5.
TROUBLESHOOTING
Do
not
Shut and
top
ELECTRIC
touch
down
unit,
disconnect
lockout/tagging
inspectingorservicing.
Lockout/tagging
disconnect from
fuse
breaker
or
TROUBLE
procedures
switch
or
box,
other
disconnecting
PLG18
on
cover
live
electrical
welding
input
procedures
in
open
shutting
board.
RC18
to
unit.
CHART
SHOCK
power
consist
position,
off
and
device.
and
kill.
can
parts.
source,
power
before
of
padlocking
removing
red-tagging
PROBABLE
PLG19
and
robot
employing
internally
line
fuses
circuit
CAUSE
is
It
assumed
installed
to
operator
unit related
was
to
according
is
working
the
designedtodiagnose
troubles
the
this
Use
while
trouble
cedures,
tion
chart
performing
is
not
the
should
malfunction,
should
be
that
familiar
welding
that
may
in
conjunction
remedied
nearest
be
contacted.
the
followed.
the
computer
Section
to
with
the
properly,
process.
and
develop
troubleshooting
Factory
manufacturers
2
function
and
that The
provide
in
with
after
performing
Authorized
all
In
interface
this
of
of
the
following
remedies
this
unit.
circuit
the
procedures.
of
cases
recommendations
was
properly
manual,
controls,
for
is
chart
some
trouble
If
these
Service
equipment
the
the
not
is
of
the
pro
Sta
REMEDY
Unit
No
No
Wire
does
meter
wire
feeds
not
operate.
display.
feed.
maximum.
at
Fuse
Fl
open.
Check
5-2).
Fl,
Correct
and
overload
replace
if
necessary
problem
before
Section
(see
continuing
operation.
Circuit
breaker
~
Meter
not
Display
Robot
signal.
CR1
Relay
board
Motor
CB1
board
not
PC2
tripped.
PC4
work-
not
not
Check
overload
Use
check
mine
if
If
5-3).
Section
Use
check
Section
(see
okay,
replace
Check PC2.
Signal
and
B
Replace
Replace
CB1,
problem
points
power
check
5-4).
points
input
should
(common)
CR1.
PC2
and
before
on
available
is
points
to
5-3).
PC4
(see
signal
on
Section
(see
determine
reset
continuing
display
are
okay,
If
check
Section
from
be
0-10
RC5.
if
necessary.
board
to
meter
if
points
robot
Vdc
5-4).
operation.
PC4
(see
replace
power
do
5-4).
motor
to
between
Correct
deter
to
Section
meter
is
available
not
board
pins
(see
test
K
ing.
Tach
drive
board
motor
PC5
not
wire
at
Replace
PC5.
OM-878
Page8
Page 13
TROUBLE
PROBABLE
CAUSE
REMEDY
No
Robot
Touch
Robot
wire
arc
is
voltage
shuts
Sensor
moves
stuck.
control.
down
error.
when
due
to
welding
Voltage
tions.
Voltage
tions.
REMOTE
switch
trol
Voltage
working.
Incorrect
Touch
Wire tion.
Interface
Sensor
stick
working.
control
sensing
VOLTAGE
position.
board
robot
connections.
check
board
connec-
connec-
PCi
command
connec-
PC3
con-
not
not
Check
and
secure
Check
REMOTE
power
Replace
Check
ween
Check
PCi.
and
secure
VOLTAGE
source
PCi
robot
Command
C
pins
continuity
gas/current
Secure
Be
sure
and
welding
minal
Replace
all
that
blue
power
strip.
PC3
connections.
lead
connections
connections
must
Section
(see
command
voltage
and
E
of
sensing
red
lead
is
connected
source
Section
(see
(see
(see
control
be
in
switch
ON
position.
5-4).
voltageatvoltage
should
(common)
leads
control.
is
connected
interface
be
at
between
Repair
to
5-4).
Section
Section
on
0-10
Vdc
RC14.
gun/torch
or
terminal
to
terminal
14
position
2-3).
2-3).
welding
board
bet
and
replace.
52
50
on
ter
Wire
goes
No
Robot
to
wire
speed
zero.
retract.
shuts
(1PM)
.
down.
meter
Incorrect
robot
voltage.
board
PC2
Motor
ing.
Control
relay
CR2
ing.
Interface
board
working.
Incorrect
robot
weld
Loose
output
tions.
Interconnecting
Interface
cords.
board
working.
command
work-
not
work-
not
PC3
command
connec-
PC3
not
not
Check
PC2.
Signal
and
B
Replace
Replace
Replace
Check
PC2.
Signal
B
and
Clean
and
Check
or
replace.
Replace
robot
command
should
(see
at
Section
(common)
PC2
CR2.
(see
command
should
(see
Section
at
connections.
and
Section
PC3
robot
(common)
tighten
all
interconnecting
Check
PC3
be
RC5.
be
RC5.
voltage
0-10
5-4).
5-4).
voltage
0-10
cords
secure
5-4).
at
Vdc
between
~
at
Vdc
between
for
all
connections.
motor
motor
breaks;
board
pins
board
pins
repair
K
K
OM-878
Page
9
Page 14
-
USE
6.
5
OF
INDICATOR
LIGHTS
FOR
TROUBLESHOOTING
4,
flows:
Gas
System
Contactor
System
.
On.
normal
On
closed:
normal
on
(on).
(on).
does
Gas
Check
4,
Contactor
Check cords.
Check
Gas
flow:
not
valve
gas
operation.
Contactor
open:
interconnecting
interface
board
Wire
Indicator
PC3.
Feed
Light
4,
Gas
Check
and
Check
Indicator
Contactor
Check
Indicator
flows:
gas
line
gas
interface
Light
display
Light
valve
for
closed:
board
operation
leaks.
board
PC3.
PC4.
Gas
does
System
Contactor
System
Off
4,
not
normal
s-Off
~Ir
Open:
normal
flow:
(off).
(off).
Wire
System
Arc
started:
System
I!
No
arc:
feeds:
normal
normal
On
On
I
(on).
(on).
~
Wire does
Check
Check
Check
No
circuit
relay
interface
arc:
Replace
1
Arc
started:
reed
not
CR1.
feed:
breaker
board
Current
relay.
Arc
CB1.
PC3.
Failure
Wire
Check
robot
Signal
between
(common)
Check
Indicator
Arc
Replace
Indicator
No
feeds:
input
to
should
wire feed
Light
started:
reed
Light
arc:
motor
pins
at
signal
board
0-10
be
K
RC5.
board
relay.
and
from
PC2.
Vdc
PC2.
B
Wire
System
No
arc:
System
Arc
started:
does
-a--Off
not
normal
~
Off
4,
normal
feed:
(off).
(off).
OM-878
Check
Page
weld
10
parameters.
Check
Signal
between
3TB.
Check
signal
should
terminals
display
from
be
board
2TA
robot.
24Vdc
and
PC4.
Normal
during
idling.
Normal
while
welding.
Page 15
ICIOR
DRIVE
00
oc
41
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April
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PARTS
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Page 22
3
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Page 23
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Dia.
Mkgs.
Part
No.
Description
Quantity
Figure
1
2
3 4 5 6 7
8
9 10 11
12
13
14
15 16
17
18
19
20
21
22 23 24 25
26
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OM-878
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Part
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Figure
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OM-878
Page
6
Page 28
COMPONENTS
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449-C
OM-878
Page
7
Page 29
Dia.
Mkgs.
Part
No.
Description
Figure
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2.2uf20
0.01uf500
5.6uf35
uf
0.47uf400
5
amp
5
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
0.25
watt watt
100
uf
uf
uf50volts
uf
100
200
volts
SP
watt
200
220
watt
watt watt
watt
watt
15
watt watt watt watt
watt
0.25
watt
0.25
watt
0.25
watt
0.25
watt
10
47
0.25
watt
Speed
200
volts
turn
volts
35
volts
voltsdc
volts
volts
volts
volts
volts
voltsdc
volts volts
ohm
10K
20K
15K
lOOK
0.75
47K
1
K
4.7K 10
1
.5K
120K
82K
22K
1
K
ohm
ohm
zero
(FigBPg
dc
dc
dc
dc
dc
dc
SP
ohm ohm
ohm
ohm
watt
ohm
ohm
ohm
ohm
meg
ohm
ohm
ohm
ohm
ohm
ohm
50K
3
ohm
Item
1)
.4
1
1
2
2
1
12
1
1 1
2
1
1
1 1
10
1 1
2
1 1 1
10
3
1
8
1
3 2
1
2
1 1 1
2
1 1
13
1
1
1
1
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-878
Page
8
Page 30
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure
Cl
C3,4
Dl
LCD1,2
LED1
LED3
R1-5
R6,8
R7,9
RC2O
RC21,22
VR1,2
0
C
,2
,2
,2,4,5
571
109
000
348
073
739
028
351
108
453
089 028
097
763
044
635
030
140
272
003 092 648
081
382
109
161
071
248
070 026
Circuit
CAPACITOR, CAPACITOR,
DIODE, METER, LED,
Card,
signal
DCO-200MV
5330A10
Display
tantalum ceramicO.1
0.020
4OMCD
LED,5330A19200MCD
RESISTOR,
carbonfilm0.25watt6800hm
POTENTIOMETER,
RESISTOR,
RESISTOR,
TERMINAL,
TERMINAL,
linear
IC,
STAND-OFF,
ASSEMBLY
carbon
carbon
header
header
78M05
No.
109571
cermet
film
film
14
13
6-32
(FigAPg
0.47
75
amp
0.25
0.25
pin
socket
7/16
x
2
uf
35
volts
uf50voltsdc
SP
volts
turn watt watt
0.75
1
zero
1/4
x
15
meg
hex
Item
ohm
watt
ohm
21)
220K
ohm
2
2 2
2
4
1
5
2
2
1 1
2
2 2
1i~3
+
I
RC22
I
>
0
LCDI
I
RC2I
I
-
LCD2
0
r2
VRI
LED4
-~
U~
LEDI
~
0
.
COMPONENTS
BY
Elc~
QUALIFIED
Figure
LED5
I~I
TO
PERSONNEL
C-Circuit
DI
D2
ABCD~FGHJKLMNP
BE
REPLACED
Card,
~
ONLY
Display
LED2
ri
RI
I________
R9
LED3
Ref.
C1095?2
p7
0
OM-878
BE
SURE
Page
SERIAL
TO
PROVIDE
9
MODEL
AND
NUMBER
WHEN
ORDERING
REPLACEMENT
PARTS.
Page 31
Page 32
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