Miller Electric MR-5, Millermatic 350 User Manual

Y8y7?~i

IMPORTANT:

contents
manual
on
before
equipment. This

use

safe

untrained
this unit.
understand these

of both this

used

with

the safety

installing,

only by

operation of welding

material

persons

personstoinstall,

Contact

Read

and

manual

this unit,

throughout

operating,

unit

and

trained

your

distributorifyoudonot

instructions.

understand

and

the

with

special

or maintaining this

these

instructions

and

experienced

equipment.Donot allow

operate,

the entire

power

eutiphasis

both

manuals,

or maintain

source

are

for

in the

fully

Effe~ti.EWith

MODEL

MR-5/ARC
COMPUTER

GAS/CURRENT

CONTROL

SanEIFic...H1:33:~’

TM

PAK

350

INTERFACE

SENSING

I

OWN

ER’S

MANUAL

MILLER

ADDITIONAL

ELECTRIC

718SBOUNDS

APPLETON,WI54912

COPY

NWSA

CODE

PRINTEDINU S

ST,P0

PRICE95CENTS

NO.

A

MFG.

Box

USA

4579

+5

millER

Co.

1079

LIMITED

WARRANTY

This

warranty

4;

LIMITED

tions

warrants to

4;

Equipment

ship

and

No

warrantyismadebyMiller

accessories

engines,

4;

the

4!

4;

4;

~Ji

4~

<

~

warrantiesoftheir

engines

date of

haveatwo

Exceptasspecified

to

components

year, suchasspot

MILLERMATIC

wire

including

not

result

Miller

ranted Equipmentinthe

within

ment to

1.

Arc

2.

Load

3.

Original

Ilabor-1

4.

All

All
Replacementorrepair

7.

Batteries

provided
of

the
Asamatterofgeneral

submittedbythe

supersedes

WARRANTY

hereof,

Miller

its

furnishedbyMillerisfree

materialasof

or other

trade

accessories

are

warranted

original

year

nozzles

from defectinworkmanshipormaterial.

shallberequired

the

following

the

original

welders,

banks

main

year

welding guns,

other

Millermatic

that

Millerisnotifiedinwriting

date

of such

all

previous MILLER

Subjecttothe

Electric

Distributor/Dealer

purchase,

warranty.

having normal
parts

periods

power

power

onlyl

failure.

original

Mfg.

the

time

items

manufacturedbyothers.

and

other

respective

bytheir

manufacturer

except

below,

Miller’s warranty

welder

that

and

user:

feeder/guns

useful

tips,

comeincontact with the

nozzle

to honor warranty

eventoffailure

from

sources,

robots,

rectifiers

Feeders

parts,

policy

user

within

Co.,

that

from defectinworkman

and

placeofdeliverybyMiller.

with

respecttoengines,

items

manufacturers,ifany . All

Tecumseh

lifeofless

relay

and

insulators

resulting

the

dateofdeliveryofEquip

and

and

plasma

exclusive

within

only,

Miller

the

EFFECTIVE:

warranties

terms

and

Appleton,

all

components.1

foregoing

Wisconsin

new

and unused

are

sold

subject

for

one

year

engines

does

not

than

contactor points,

where failure

torches...90days

oflabor..60days

may

one

welding

claimsonwar

fromadefect

3

6

months

thirty

1301

honor

periods.

OCTOBER1,1986

andisexclusive

condi

­with

therefore

or,

­the

Ill

Miller
price

returnofthe

to

optionofrepairorreplacement
Appleton,

facility,
any
defectorfailure,
claim

ANY

•flONASTO
BREACHOFCONTRACT
MIGHT

­CUSTOMOFTRADEORCOURSEOFDEALING, INCLUDING

ANY

­FITNESS FOR

ANY
CLUDED

WRITING,

ULTIMATE
USERS

EXPERIENCEDINTHE USE

WELDING

CONSUMER USE. MILLER’S
TO,

MILLER’S

trade
Such

from

which

apply

does

year

1

year

years

1

year

days

claims

with no

other

guaranteesorwarranties

In

the

caseofMiller’s

respecttothe

shall

where

reasonable

(less

kind

ANY

EXCEPT

AND

be,atMiller’s

authorizedinwritingbyMillerinappropriate

service

procedures

IMPLIED

IMPLIED

AND ALL

costofrepairorreplacementatan

stationor14)

reasonable

goodsatCustomer’s

Wisconsin,orFOB.,ata

therefore,nocompensation

willbeallowed.

EXPRESS

WARRANTY,

PERFORMANCE,

ARISEBYIMPLICATION,

WARRANTYOFMERCHANTABILITYOROF

PARTICULAR

AND

DISCLAIMEDBYMILLER.

AS

MILLER

PURCHASE

AND

FOR

EQUIPMENT

NO

WARRANTIES

breachofwarrantyorany

qualityofany

depreciation

Miller

shall

to be

followed.

WARRANTY

EQUIPMENT

EXPRESSLY

PRODUCTS

OPERATIONBYPERSONS

RESELLERISAUTHORIZEDTOEXTEND

goods,

option

(11

paymentofor

based

risk

willbeFOB.,

Upon

receiptofnoticeofapparent

instruct

the

NOT

GUARANTYORREPRESENTA

WHICH,

AND NOT

AND ANY
BUT FOR

PURPOSE,

FURNISHEDBYMILLERISEX

PROVIDED BY

BY

COMMERCIAL/INDUSTRIAL

AND

WARRANTIESDONOT

TO,

ANY

expressedorimplied

the exclusive remedies

repairor121

credit for

upon

and

MILLER authorized

for

transportation

claimantonthe

PROVIDED

OPERATIONOFLAW,

WITH

ARE

MAINTENANCE

FOR

CONSUMER.

other

replacement

cases,

authorized

the purchase

actual

expense.

usel

MILLER’s

Factory,

service

costs

warranty

HEREIN

REMEDY

THIS PROVISION,

RESPECT

MILLER

INTENDED

TRAINED

CONSUMERS

EXTEND

duty

(3)

upon

at

of

AND

-

FOR

TO

-

IN

FOR

AND

OF
OR

May

~OM.882j

31,1990

ERRATA

After
to

data

AMENDMENTTOSECTION2—INSTALLATION

IMPORTANT:

in

this

Add the
SOURCE

IMPORTANT:

connectedtothe
terminal.

Amend
AC/Contactor Control

IMPORTANT:

computer

SHEET

this

manual

appearing

A25ft.

installation. Retain

foliowing

CONNECTIONS: Wire

Section

interface

was

laterinthis

(8m)

IMPORTANT

If dc

electrode

negative

2-3C.

COMPUTER

Connection

Cords

are

available.

printed,

interconnecting

cord

weld

supplied

refinementsInequipment

manual.

for

future

blocktothe

Stick Sensing

negative

output

weldingisdesired,

terminal

INTERFACE-WELDING

that

may

cord

withafive-pin

use.

end of Section

Connections

and

not

be used

the

design

Amphenoiplugissupplied

2-3A.

reverse connections so

lead

withaclampisconnectedtothe

in this

installation.

occurred.

COMPUTER

POWER

SOURCE

Match

This

INTERFACE-WELDING

cordtowelding

sheet

lists

exceptions

with

this

unit

butisnot

the

lead

with

ring

positive

CONNECTiONS:

power

weld

source

used

POWER

terminal

output

115

Volts

and

is

1.

Align

keyways,

collar

fully clockwise.

2.

Align

keyway,

threaded

3.

Place

appropriate

remote control

Amend

A

There
screwsonstrain

screwsonstrain

A.

Section 2-5.

WARNING: ELECTRIC

0

Do

0

Shut

ging

Lockout/tagging

from

fuse box,orshutting

are

several

CVICC

Connections

WARNING:

A

insert

4-socket

insert

14-pin

collar fully

not

down unit,

procedures

terminal

reliefonunit
reliefifnecessary,

clockwise.

remote control switch(es)onthe

device.

COMPUTER

touch

procedures

strips

Read

INTERFACE

live

electrical

welding

before

inside the

rear

and

follow

Amp

plug

into

matching

Amphenol

SHOCK

powersource, and

making

consistofpadlocking

off

panelifnecessary,

and reinstall

plug

into

TERMINAL

can

kill.

parts.

interconnections.

and

red-tagging

computer

safety

interface

top

informationatbeginning of Section

and

cover

receptacleoncomputer

matching

welding

robot,

circuit

locate
when

receptacleonwelding

power

sourceinthe

STRIP

line

CONNECTIONS

and

disconnect

disconnect

breakerorother

for

control
procedureisfinished.

connections. Remove

appropriate terminal

interface,

proper

input

power

switchinopen

disconnecting

strip

2-5

and rotate

power

source,

position

employing

position, removing fuses

device.

unit

top

for

connections.

before

threaded

and

rotate

for

useofa

locko

ut/tag

cover,

loosen

Tighten

proceeding.

-

1.

Locate

2.

ForCCoperation,

IMPORTANT:

terminal

The

Strip

2T.

remove

Inductance controlisdisabled

jumper

link

between

terminalEandFon

when operatingintheCC(constant

2T.

current)

mode.

B.

ARC

FAILURE

Light

Connections

(Figure 2-4)

WARNING:

A

The ARC FAILURE

Locate

supplied

1.

For

a.

Open

b.

Route

c.

Make cord connectionstoterminal

d.

Close

e.

Connect

2.

For

a.

Obtaina115or24

b.

Open

c. Route
d.

Make

e.

Close

f.

Connect

g.

Cut
contactsonisolation

h.

Connect

i.

Route cord

j.

Connect

lengthof18

robot control

robot control

cord under

robot control

cordto2TF

robot control

robot control

customer supplied18gauge/2-conductor cord under

cord connectionstoterminal

robot control

cordtoisolation

off

terminals from

one end of

cordto2TF

Read

and

light

orlthe

computerinterface front panelisturnedon

gauge/2-conductor cord

units

withnoother

unit

door,

cross member

unit

door,

and

Units

when

vac,or24

unit

door,

unit

door,

one end of

relay.

cordtoa

through strain

and

follow safety Informationatbeginning

and

for

this

connectionsatjig

and

locate

jig

below

door.

strip

common and

and

route cord

2TG.

115or24 vac,or24

Vdc

isolation

and

locate

strip

and

route

relay

coil

and

supplied18gauge/2-conductor

setofnormally-open

relief on

2TG.

rear

relay,

jig

common
cordtojig

voltage source.

panelofcomputer interface.

connection,
terminal

terminal

through strain

terminal

strip

2.

the Weld Alarm

vdcisusedatjig terminal

and install

strip

2.

and

the

Weld Alarm

interface.

contactsonisolation

and

strip

relief on

into

jig

cross member

of Section

off

by a

proceedasfollows:

2:

terminal.

rear

panelofcomputer

interface.

terminal.

cord,

and
relay.

2-5

signalfromthe

strip

2T:

below

door.

install terminalstoconnect

before

robot control

proceeding.

unit.

interface.

to

OM-882 Page

2

Add

Figure

2-4.

Arc

Failure Light

Robot

control

Unit

Connections

Jig

Terminal

Strip

2

Common

weld

Alarm

Computer

2TF

2TG

2TL

Interface

+24VDC

Arc

Failure

Indicator

Light

To Voltage

(115VAC, 24VAC,

Robot

Control

Unit

Weld

Alarm

Figure

Source

24VDC)

Jig

2-4. Arc

Interface

Failure

Light

Connections

AMENDMENTTOSECTION5-MAINTENANCE&TROUBLESHOOTING

Add the

Amend
Amend

3.

following SteptoSection

Inspect

Figure

Figure

motor

5-3.

Circuit

5-4.

Circuit

control

Diagram

Diagram

relay,

5-1-INSPECTION

CR2,

and

cleanorreplaceasrequired.

For

Computer

For

Voltage

AND

Interface

Control

UPKEEP

(see

Board

Page4on

PCi

(see

this

Page5on

-rj 2TF ~—

Errata)

this

Errata)

Arc

Failure

Indicalor

Light

TA-il5

648

Amend
Add

Figure

Figure

5-9.

5-6.

Circuit Diagram

Wiring Diagram

For

Interface

(see

Pages7and8on

Board PC3 (see

this

Errata)

Page6on

this

Errata)

OM-882

Page

3

AMENDMENT

TO SECTION

5-MAINTENANCE&TROUBLESHOOTING

Amend

Figure

K

5-3.

Circuit

U K U

-

~

Diagram

-~

For

k~,

-,

Computer

000

0~

C0CWL.~CI~N

~

Interface

000000

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d

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OM-882 Page

Ua’AGE

4

a

I

C.’J

to

C~4

1~

6

6

z

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Cu

Cu

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to

o

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to

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z

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Cu

4

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(3

0)

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OM-882

-

Page

5

5V

,24V

4ELD

JOG

JOG

RE..

FIgure

START

F~C

WELD

CURRENT

RELA’

(RE.

RE.A’

5-6.

AR

AL

2

AL

~

AJ

A

4

CIrcuit

AC
6

Diagram

.24

C.

For

interface

Board

PC3

Effective

With

Serial

‘LO

Circuit

No.

JK588314

A

06

CR

Diagram

‘24

C ON-S

No.

REFEEC

ACTOR

6050’

CJRRE’.’

CECXC

T

CON’N-C’CR

AC

B-128

016-A

CR5

CR4

Thru KA819026

CC

~ELC

S’ART

UDO

(L(~fl(

RELO

CURRENT

RELAY A.

406

(RE6I

C07R40N,

REV. RELAX

AR
AE

—

AL

A

ALA

1<

Figure 5-6.Circuit

Diagram

For

interface

Board

PC3

Effective

With

Circuit

Serial

06

CR

6

Diagram

No. KABi

045

C66

T

OR?

CR4

No.

B-i37905

9027

C

SELFEC
AC’CR

6080’

CLPRE

N

CE

CEO

0C7,’4C’CR

AC

C

OM-882 Page

6

‘N

Add

Figure

5-9.

Wiring

Diagram

cc

r-.

I”

1~

0

6

z

E

Cu

C)

0

C)

-

cc

U,

to
to

1..

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cc

to
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6

z

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C.)

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w

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ir

OM-882

Page

7

c~J

1~

6

z

E

Cu

I-

C)

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w

0

to

U,

to
to

6

2

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0)

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Cu

C)

C

OM-e82 Page 8

0)

L..

AMENDMENTTOPARTS

LIST

Amend

Parts

2-1
2-1

2-4

2-17
2-20

2-

C2,3,6-10

2-39
2-48

3-56

3-

4-

6-2

6-5

6-12
6-15
6-16

6-25

6-26
6-26

6-28

8-

8-

8- R48,49

11—
11—

11-

11-

11—

13-

13-3

13-6

List

as follows:

Dia.

Mkgs

PC4

51

Ri-S

SR

1,2

CR1

PCi
PC3
PC3
RC5

C3
C4

REED

CR5

Ti

Part

No.

111

992

117724

070 634

049 989
604

109

028

291

090 890

iii

564

011

622

Added

044

635

083

147

035 914 035
034

841

110375
111

065

111

408

113 221
128014
073

730

073 739 073

000 885 000

Added

072

130

072

130

005023 Deleted

073

739

028

3S1

109

936
079682
010

610

Replaced

With

117

724

129

952

123

154 LABEL,

118

676

604

109

028

291

135

304

117836
011

609

110

438

048 284
079 534

079

531

604

571

iii

122.HOUSING

109 770

030

028

083

147

704

109

006

110375

121

313

131

247

128 014
128014 CIRCUITCARD,interface,

073

730
739

88S

049

015

072

130

Deleted

073739
028351

117 617
136

59S

115

104

110386 RELAY,encI24VACDPDT
117725

117 726

Description

CONTROL

JK636568)

CONTROL
CABLE,

WIRE,
CAPACITOR,
CABLE,
CIRCUITOARD,

SWITCH,

CABLE,
(consisting

HOUSING

.

TERMINAL,
CLAMP, cable
CABLE,

TERMINAL,

RESISTOR,C.5W
GROMMET,
RECTIFIER,

RELAY,
STANDOFF,

PANEL,
CIRCUIT

CIRCUIT
TERMINAL,

CAPACITOR,

(EU

w/JK655454)

RESISTOR,
(Elf

w/JK655454)

RESISTOR,CF.25W10meg ohm
(Eff

w/JK655454)
CAPACITOR,
(Elf

w/JK588314

Elf

w/KA819027

Elf

w/KA819027

CAPACITOR
(Elfw/JK5883

DIODE, (qty

CONTROL

RELAY,current

CONNECTOR
TRANSFORMER,control

CAPACITOR/RESISTOR,

PANEL,
PANEL,

warning general

volt

sensing

(qty

chg)

port

tgl

interconnecting

of)

PLUG&SOCKETS,

port

PLUG

(qty

end

24VAC

rntg-components

CARD,
CARD, interface

hdr22pin

(qty

chg

BOX,

(Elf
(Effw/JK636569)

(Eff

(qty

chg)

No.188/c

meter

SPDT

iSA

female

strain

reliefsz11

No.

184/c

&

PINS,

female1pinsz45

1.5K

chg)

(qty

chg)

integ

DPDT

(qtychg)

Voltage

(qty

chg

chg

added

(qty

chg

thru KA819026)

(qty

chg

deleted

14)
added D16)

gas/current

CLAMP, cable

w/JH290689

precautionary

w/HJ304076)

(orderbyft)

125V
25ft

(Eff

w/JK678982)

iskt

14-18w

(orderbyft)

(consisting

ohm

30A

600V

(Effw/JK636569)

(Elf

w/JJ377225)

control

added C25-30)

deleted

(Effw/JK655454)

(Effw/JK588314)

(Effw/KA819027)

R46,47)

C6,9,10)

Cli

(Elf

sensor

1/2

(consisting

thru

(consisting

16-22w

w/JK588314)

in

of)

of)

of)

Quantity

OM-582

1

1

1
1

2

6ft

7

61

t

1
1

1
1
4

1

25ft

1

14

1

2

2

1

7
1

1
1
1
1

25

ii

2

Page

9

Parts

Lists Continued

C4,S

R4

13-

13-

~First

digit represents

BE

SURETOPROVIDE MODEL

page

Added
Added

no

-

digits following

AND

000

859

601

394
136584
007501

SERIAL

•

CAPACITOR,

eIctlt

•RESISTOR,C2WlOKohm

BRACKET,
WASHER,

dash

represent

NUMBER

mtg

flat

WHEN

reed

nyl

item

no.

ORDERING REPLACEMENT

220uf 35VDC

relay

.265

ID x

.437 OD

2

1

2

PARTS.

OM-882 Page

10

TABLE

OF

CONTENTS

Section

SECTION

1-1.
1-2.

I

-

SECTION

2-1.

2-2.
2-3.
2-4.
2-5.

SECTION

3-1.
3-2.
3-3.

3-4.
3-5.
3-6.
3

-

7.

SECTION

No.

1-INTRODUCTION

General

Receiving-Handling

3.

Description

2-INSTALLATION

Location
Gas/Current

Computer Interface-Welding

Computer Interface-Welding

Computer Interface Terminal

3-FUNCTIONOFCONTROLS

PowerSwitch
Inductance
Overload

Voltmeter

WireSpeedMeter

Ammeter

Indicator

4-SEQUENCEOFOPERATION

Information

Sensing

Control

Protection

Lights

And

Safety

Control

Connections

Power

Source

Power

Source Interface

Strip

Connections

Connections

Connections.

Page

2

2
2

2
3

3
4
5

6
6
6

6

6

6

6

No.

4-1.

4-2.
4-3.

SECTION

5-1.

5-2.

5-3.

5-4.

5-5.

input

Signal

From

Welding

Output

Wire

5-MAINTENANCE8TROUBLESHOOTING

Inspection
Overload

Display
Board

Troubleshooting

Signals

Stick

Board

Replacement

From

Check

And

Upkeep

Protection

Meter

Chart

Power

Source

Computer Interface

Check

Procedures

6
7

7

7
7

8
8

10

SECTION

1-INTRODUCTION

I-

I

Gas/Current

Model

MR-5AP

Sensing

Weight

31

lbs.

Control5lbs.

(14

(2.3

kg)

kg)

+

16.5

in.

(419

2-7/8

(73.0 minI

minI

in.

case only

Figure

16

in. (7.9

Diameter2Holes

1-1.

mm)

Specifications

TB-i

In.

mm)

TB-i

14346

10320

OM-882

Page

1

1-1.

GENERAL

A.

General

Information
labels,

ment

tags,

design,

INFORMATION

presented in this

and

platesonthe

installation,

troubleshooting which

followed

for

the

safe

ment.

B.

Safety

The

installation,
troubleshooting of
practices
and

be
persons

plicable
the
Arc

Owner’s
Safety

pear
words
different

WARNING

and

carefully

or

CAUTION

and

2-1.

The

covers
repair.

and

procedures

the

safetyofothers. Therefore, this equipmentisto

installed,

operated,

in accordance

codes

such

as,

end

of Section

Welding

Power

1-Safety

Sourceinthe

Manual.

instructions

throughout

specifically

this

WARNING

levelsofhazard.

statements

maintenance

followed could

proceduresorpractices

lossoflife.

statements

maintenance

LOCATION

location should

and
Lead

proceduresorpractices

(Figure

wrappers

lengths

components.
Mounting

mounting

holes

are

purposes.

AND

manual

unit

pertainstoequip-

operation,

shouldberead,

and

effective

operation,
arc

welding

which

and

maintained

with

but

not

maintenance,

understood,

useofthis

maintenance,

equipment

ensure

onlybyqualified

this

manual and

limited

Rules

to,
For

welding

pertainingtothis

manual

and

highlightedbythe

CAUTION

include

resultinserious

include

installation,

installation,

SECTION

1-1)

allow

roomtoopen

for

installation,

mustbeconsidered

provided in

Figure

1-1

maintenance,

each

gives

unit

SAFETY

and on

various

equip-

requires

personal

safety

all

those

listed

Operation

power

source

unitap-

which

identify

operation,

whichifnot

personal

operation,

which if not

and remove

when

locating

component

dimensions.

and
and

and

ap-

at

Of

signal

injury

2

and

for

carefully

or
A third

tions

efficient

1-2.
this
the
have
damage

by

of

followed

damage

to this

signal

which

operation of

RECEIVING-HANDLING-Before

equipment,

unit

and

occurred

that

the

purchaser

lading

willbefurnishedbythe

questifoccasiontofile
When requesting

ment,itis

essential

Numberofthe

1-3.

DESCRIPTION-The

trol

contains
amperage
and

with
tion in
rent

The
and

These
when

control

wire

feed

the

robot

the

constant

capabilities.

gas/current
current

components

using

cess.

INSTALLATION

-

Normally

the

the

robot control
shouldbemountedinline
source
of

The

and

robot

service

wire

manual

life

whenitis

moisture,

corrosive

could

result in

equipment.

word,

need

clean

carefully

during

may

special

this

all

inspect

shipment.

have

occurred in

with

•s•s,

emphasistoobtain

equipment.

packing

for

the

carrier.Acopyofthe

claim

arises.

information concerning

that

Model

equipmentbesupplied.

computer

wire

feed

speed,

circuitry,

speed

meter,

control. The

weld

digital

and

controlisshipped

voltage mode

sensing

sensing

the

Gas

computer

unit.

control contains

reed

relay.

function

Metal Arc

with

Welding (GMAW)

interfaceismountedontop

The

gas/current

between

drive

assembly.

for

specific information.

and

efficiencyofthe

subjectedtohigh

vapors,

and

minor

personal

highlights

injury

instruc

the most

installing

material

any

Any

transit

from

damage

claim

for

mustbefiled

around

that

loss

manufactureronre

this

equip-

Description

voltage,

ammeter,

and

interface

and

voltmeter,

Serial

con

weld

circuitrytointerface

for

opera

but

has

constant

the

gas

valve

the

robot

system

sensing

the

welding

See

installation section

system

are

control

power

reduced

levelsofdust,

extreme

heat.

may

or

bill

cur

pro

of

dirt,

-

-

-

-

-

-

OM-882

Page

2

Wire

Receptacle

Welding Power

Interface

Receptacle

RC17

Stick

Source

Sensing

RC12

Voltage

Receptacle

Inductance

control

control

RC13

Figure

2-1.

Strain

Relief

115

control

Rear

Gas/current

control

Volts

Ac/contactor

ReceptacleRd1

Panel

View

Sensing

Receptacle

RC9

re-114

347

2-2.

GAS/CURRENT

NECTIONS

N-.

•

Do

not

•

Shut
robot, and

“lockout/tagging

(Figures

ELECTRIC

touch

down

unit,

disconnect

SENSING

2-1

And

SHOCK

live electrical

welding

procedures”

terconnections.

Lockout/tagging

disconnect

from fuse

procedures

switchinopen

box,

or shutting

consistofpadlocking

position,

off

breakerorother disconnecting

A.

Computer

Control

1.

Align

ching

rotate threaded

2.

Align

ching
and

rotate threaded

B.

Gas/Current

Interface-Gas/Current

Connections

keyways,

insert 14-pin

receptacleoncomputer

collar

fully

keyways,

insert

16-pin

receptacleongas/current

collar

Sensing

nections

Align

keyways,

ching

receptacleongas/current

rotate threaded

C.

Weld

Route

cable
output
trol, to
weld

terminal,

the

cable

Owner’s

Cable

from

wire

terminal

Manual

insert

14-pin

collar

fully

Connections

welding

through

drive

assembly

for

location).

plug

clockwise.

power

the

gas/current

(see

CONTROL

2-2)

can kill.

parts.

power

input

source,
power
before

employing

makingin-

removing

and

red-tagging

device.

Amp

plug into

interface,

clockwise.

Amp

plug

sensing

fully

clockwise.

Control-Motor

from

motor

into

sensing

source

and

Motor/Drive

control,

positive

sensing

connect

Assembly

Computer

Interface

RC17

CON

and

line

fuses

circuit

Sensing

mat

and

into

mat-

control,

Con

mat-

and

weld

con

cable

to

115

Rd

-

D.

Gas

Connections

Connect

hose

from

supplied)atgas
sing

control.

gas

regulator/flowmeter

source

to IN finingongas/current

Connect

assemblytofittingongas/current

gas

flow

must

regulator/flowmeter

E.

Touch

-

Connect

gas/current

ing

connection.

2-3.

POWER

cord with

sensing

from

outlet cable. Polarityisnot

COMPUTER

SOURCE

be

accurately

at

the

Sensor Connections

two

friction

controltotouch

INTERFACE

CONNECTIONS

2-2)

ELECTRIC

•

Do

not

touch

live electrical

•

Shut

-

Lockout/tagging

disconnect

from

down

robot, and

“lockout/tagging

terconnections.

switchinopen

fuse box,orshutting

unit,

welding

disconnect

procedures”

procedures consistofpadlocking

breakerorother disconnecting

There

are several

ween
source.
following

the computer

Examine

connections.

cords

interface

and

select

used

-

Volts

AC/Contactor

control

Cord

Arc

Power

Pak

Welding
Source

gas

hose from

source.

connectors

SHOCK

parts.

input

position,

off

and

device.

for

interconnections

and

the

(customer

wire

sensing

control.

controlled by

coming

sensor

leads

important

-

WELDING

(Figures

2-1

can kill.

power

source,

power
before

employing

makingin-

removing

red-tagging

welding

proper

cord

sen

-

drive

The

a

from

com

-

for

this

And

and

line

fuses

circuit

bet

-

power

for

the

Arc

Connection

Robot

Control

Failure

In
UnIt

Figure

2-2.

GaslCurrent

Sensing

Motor

Control

Control-

Cord

Interconnection

Diagram

Sensor

TB-i14357

OM-882

Page

3

A. Wire

1.

2.

Stick

Align

keyway,

into

matching

and

rotate

Connect
power

3.

Connect
source negative

B.

Voltage

1.

Align

keyway,

ching
rotate threaded

2.

Align

keyway,
receptacleonwelding
threaded

C.

115

Volts

tions

Two

cords

are

supplied
Amphenol

with

plug

cond, supplied
andafour-pin

1.

Align

keyways,

matching
rotate threaded

Sensing

insert

Connections

four-socket

receptacleoncomputer

threaded

lead

source

lead

Control

collar

with

ring

positive

with

clamp

output

Connections

insert

17-socket

fully

terminal

output

to welding

terminal.

terminal.

receptacleoncomputer

collar

fully

clockwise.

insert

collar

fully

AC/Contactor

necessary

the

welding

and

two

with

the

Amp

plug.

17-pin

clockwise.

for

this

power

twistlock

robot,

insert

plug

power

source,

Control

connection.

source,

receptacles.

has

two

four-pin

receptacleoncomputer

collar

fully

clockwise.

Amphenol

interface,

clockwise.

to welding

plug

into

interface,

into

matching

and

Connec

One

hasa14-pin

These-

twistlock

Amp

plug

interface,

plug

power

mat-

and

rotate

cord,

plugs

into
and

2.

Connect

ching plugs,

3.

Align

matching

and

2-4.

COMPUTER

POWER
(Figures

2-1, 2-2,

WARNING:

•

Do

not

•

Shut
robot,

the

keyway,

receptacleonwelding

rotate threaded

SOURCE

ELECTRIC

touch live electrical

down

and
‘lockout/tagging
terconnections.

Lockout/tagging
disconnect

from fuse box, or shutting off

-

breaker

1.

or

Align
ching

procedures

switchinopen

other

disconnecting

keyway,

receptacleoncomputer

rotate threaded

2.

Align

keyways,

plugs

from

receptaclesonbottom
interface,

clockwise.

twistlock

and

insert

receptacles

rotate plugs

14-pin

to the

clockwise.

Amphenol

power

collar

fully

clockwise.

INTERFACE

-

WELDING

INTERFACE CONNECTIONS

And

2-3)

SHOCK

can kill.

parts.

unit,

welding

disconnect

procedures”

insert

power

input

consistofpadlocking
position,

and

device.

24-socket

source,

power
before

red-tagging circuit

employing

makingin-

removing

plug

into

interface,

collar

fully

clockwise.

insert

four-,

interconnecting

of welding

and

rotate threaded

six-,

cord

and

into

power

collars

matching

mat

plug

into

source,

and

line

fuses

mat-

and

ten-pin

source

fully

-

OM-882

Page

Power

Source

Welding

Current

(WCR)

Detect

Figure

4

2-3.

Welding

Power

Source

Interface

Connections

3.

Remove

welding

panel.

4.

Route

remaining

2

through
source

5.

Connect

a.
b.

c.
d.
e.

6.

Reinstall and

-5.

COMPUTER

strain

interface,

leadsasfollows:

Red

leadtoterminal 52.

Blue

leadtoterminal 50.
White
Green
Long

green

to

chassis

CONNECTIONS

IMPORTANT:

withafive-pin
butisnot

future

use.

Amphenol

usedinthis

power

cord

source

from computer

reliefinbottom

to 14-position

leadtoterminal 35.
leadtoterminal 36.

lead

with

ring

ground.

secure

A

25

side

panel.

INTERFACE

ft.

(8m) interconnecting

TERMINAL

plugissupplied

installation. Retain

interface

interface

of welding

terminal

terminal

connects

with

cable

side

power

strip.

STRIP

cable

this

unit

for

There

are

several

terface

loosen

for

control

screwsonstrain
necessary, and
nection.

and

The

Tighten

reinstall

A.

ARC FAILURE

ARC

FAILURE

top

panelisturned

control

dctothe

unit.

The

computer

failure occurs.

conductor

cord

follows:

1.

Open

robot control

minal

strip

2.

Route cord under

3.

Make

cord

mon

and

4.

Close

robot control unit door,

through
terface.

5.

Connect

terminal

connections.

locate

screwsonstrain

strips

inside

the

Remove

unit

reliefonunit

appropriate terminal

reliefifnecessary,

computerin-

top

rear

panel

strip

cover when procedureisfinished.

Light

Connections

lightonthe

on and

robot control

interface

Locate

for

supplied

this

computer

offbya

signal

unit

arc

failure

lengthof18

connection,

unit

door,

interface

from

must

supply24volts

circuit

and

and

locate

the

when

gauge/2

proceed

2.
cross member

connectionstoterminal

the

Weld

Alarm

strain

reliefonrear

cord

commonto2TL

below

door.

strip

terminal.

and

route

panelofcomputerin-

and

positive to

cover,

for

con

front

robot

jig

com

cord

arc

as

ter

if

-

-

-

WARNING:

•

Do

•

Shut
and

“lockout/tagging

ELECTRIC

not

touch

down

disconnect

live electrical

unit,

welding

input

procedures”

SHOCK

parts.

power

can kill.

power

before

terconnections.

Lockout/tagging

disconnect
from

fuse box,orshutting off

procedures

switchinopen

consistofpadlocking
position,

and

red-tagging

breakerorother disconnecting device.

SECTION

2TG.

source,

and

robot

B.

CV/CC

employing

makingin-

removing

line

fuses

1.

Locate

2.

ForCCoperation,

terminalsEand F on

circuit

IMPORTANT:

when

operatingintheCC(constant

3-FUNCTIONOFCONTROLS

Connections

terminal

strip

remove

The

Inductance controlisdisabled

2T.

jumper link between

2T.

current)

mode.

Figure

3-1.

Arc

Failure

indicator

Light

Front Panel

View

Ta-i14436

OM-882

Page

5

3-1.

Placing
input

for

OFF
3
The

trol
As

of
The
fluid

The0(zero)
stiff,

characteristics,
ter

3-3.

The

opens,

POWER

the

SWITCH

POWER

powertothe interface.

the

robottoweld.

position

-2.

shuts down

INDUCTANCE

INDUCTANCE

which

canbeset

the

levelofinductance

the

weld

outputorspeedofresponse

slower

welding

response

puddle,

setting gives

fast-responding

puddle.

The7setting

i.e.,asoft,

arc, and

Selectasetting

high

weld

best

OVERLOAD

A.

Fuse

Protection

interfaceisprotected

nal

shortorexcessive

the

interface

replacement

B.

Wire

procedures.

Drive

(Figure

3-1)

switchintheONposition

The

interface

Placing

the

POWER

switchinthe

the interface.

CONTROL

controlisa

for

inductance

increases,

(Figure

digital

pushbutton

levels1through

the

rate of

slows

time

producesasofter

and

flatter,

arc, andasmall,

gives

smoother

minimum

inductance,

maximum inductance

fast-freezing

slow-responding,

puddle

suited

PROTECTION

overload by fuse

shuts

Motor

for

from

down.

Circuit

fluidity.

the

application.

(Figure

damage

See

Breaker

duetoan

Fl.Iffuse

Section

applies

mustbeon

2-1)

con

7.

change

down.

arc,

more

bead.

i.e.,

low

spat-

3-1)

inter

Fl

5-2

for

3-4.

The

voltmeter

ofavolt while
3

-5.

The

wire

the

nearest

Actual

­the

wire

3-6.
The

ammeter

amp

while

a

3-7.

There
are

visual

The

GAS

to indicate
The

CONTACTOR

power

weld

outputisavailable.

-

The

WIRE

motorisenergized
The

CURRENT

relayisenergized

VOLTMETER

displays

(Figure

weld

welding

WIRE

SPEED

speed

meter

inch

and preset

feed

speed

AMMETER

METER

displays

per

minute while

wire

feed speed

feedback

(Figure

displays

welding

INDICATOR

are

five

and preset

LIGHTS

indicator

indicationsofvarious

light

turnsonwhen

shielding

gas

light

source

contactorisenergized

FEED

light

to indicate that

light

turnsonwhen

to indicate thatanarcisestablished.

3-1)

voltagetothe

and preset

(Figure

preset

are

voltage

3-1)

wire

welding

the

nearest tenth

while

feed

and

same

circuit.

3-1)

weld

amperagetothe

amperage

(Figure

while

3-1)

lightsonthe interface.

process

the

gas

functions.

valveisenergized

flow.

turns

on

when

the

to indicate that

turnsonwhen

the

wire

wireisfeeding.

the

current

idling.

speed

to

idling.

due

to

nearest

idling.

These

welding

drive

detect

The

wire

drive

motorisprotected

overloadbycircuit

face

shuts

down.

reset

the

circuit

4

-1.

INPUT

SOURCE

and

wire

face.

These

parameters.

to

preset

to

keep

weld

SIGNAL

(Figure

drive

motor
signals

During

welding

parametersatpreset

breaker

Manually

CB1. If

depress

breaker.

SECTION

FROM

4-1)-The welding

send

signalstothe

are

used

welding

values

these

and

compensations

from

damage

CB1

opens,

the

reset

4-SEQUENCEOFOPERATION

WELDING

power

computer

to

determine

signals

are

levels.

due to

the

inter-

button

to

POWER

source

inter-

weld

compared

are

made

The

ARC

FAILURE

outage while

Welding

Current

No-Load

WeldingT~

Voltage

WeldAbnormal

D~LY

Start

light

welding.

Arc

0

to 50V

—F

Open when

turnsonwhen thereisan

Initiation

H-

abnormality

occurs.

arc

Crater

—

Time

TA-i14379

OM-882

Page6

Figure

4-1.

Input

Signal

Timing

Chart

4-2.

OUTPUT

TERFACE

input

signals
motor,
of
source

Wire

the

computer

and

Start

robot,

Relay

(Figure

from

and

interface

wire

feed

SIGNALS

4-2)-The

the

welding

wire

stick

regulates the

functions

Open

I I

FROM

power

check

Arc

Close

COMPUTERIN-

interface

interprets

source,

circuit.

welding

while

welding.

Initiation

wire

The

the

drive

output

power

Voltage1.25VDC

Command

2.5VDC

1OVDC

5VDC

I

I I

Close

~~chlng~

I

I I I

Output To

Motor

Start

Figure

4-3.

weldiscompleted,

determineifthe
the

weld

WIRE

puddle.

4-2.

STICK

Output

the

welding

Signal

CHECK

wire

stick

wire

Feedbackisusedtodetermineifthe

weld.Ifthe

weld,

the

feedback

robot

can

indicates

cycletoits

SECTION

•~j~j~~j5

this

unit

for

maintainedina

when

necessary.

precautionary

5

-

1.

INSPECTION

Every

legibility.

clearly

See

labels.

six

months

All

precautionary

readable

the

Parts List

AND

UPKEEP

Open

TA-i14378

Timing Chart

(Figure

4-3)-After

checkisperformed

has

burned

back

wireisfree of

the

wireisfree of

next

sequence.

out

the

to

of

the

the

Figure

If

the

feedback
power
provide

sourceissenta1

minimum welding

contactorispulsed
voltage

shouldbeenough to free
usedtodetermineifthe
the

feedback

cletoits

If

the

voltage
free

more

welding

If

the

Weld

gram
from

next

feedback

command

the

welding

voltage

wire

wire
Abnormal error
module,

the

weld.

4-3.

indicates

indicates

sequence.

indicates

is given,

wire.

increases

(see

Figure

remains

and

Wire

on.Ifthe

wireisnow

the

The

stuck,

willbedisplayedonthe

the

wire

5-MAINTENANCE&TROUBLESHOOTING

inspect

state

labels

and

forpart

the

labels

must

replaced

number

on

be

of

1.

Repairorreplace, as
and

cables; give

and

cracked insulation

equipment.

2.

Remove grease

moisture

from

particular

and

electrical

Stick

Check

the

wireisstuck,

.25

VDC

command

power

wire

source

was stuck,

the wire.

free of

wire

the

wireisstill

and

is free,

the

contactor

the

stuck,ahigher

check is performed

are

usedtotry

4-3).

the

robot

will

shut down,

mustbephysically

required,

all

hoses,

attentiontofrayed

and

areas

whereitenters

grime

from

components;

parts

and

cables.

TA~114379

the

welding

signal

output.

the

pulsed

Feedback

the

weld.

robot

cancy-

pulsed

and

and

free

robot

removed

cords,

to

The

is

to

two

the

pro

If

a

-

WARNING:

•

Do

not

•

Shut

down

and

‘lockout/tagging

ELECTRIC

touch live electrical

unit,

disconnect

SHOCK

welding

input

procedures”

inspectingorservicing.

Lockout/tagging
disconnect

from

fuse box,orshutting off

procedures

switchinopen

consistofpadlocking
position,

breakerorother disconnecting
Usage

and

shop

conditions

and

typeofmaintenance.

will

Inspect

can kill.

parts.

power

source,

power

before

and

employing

internally

removing

and

red-tagging

device.

determine

the

frequency

equipmentasfollows:

robot

line

fuses

circuit

5-2. OVERLOAD PROTECTION

WARNING:

•

Do

•

Shut

and

“lockout/tagging

ELECTRIC

not

touch

down

disconnect

live electrical

unit,

welding

input

procedures”

SHOCK

parts.

power

power

(Figure

can kill.

source,

inspectingorservicing.

Lockout/tagging
disconnect

from

fuse box,orshutting off

procedures consistofpadlocking

switchinopen

position,

and

red-tagging

breakerorother disconnecting device.

employing

before

removing

3-1)

and

robot

internally

line

fuses

circuit

OM-882

Page

7

Figure

5-1.

Display Board

Meter

Checks

CAUTION:

IMPROPER

unit.

If

replacement

of

the

proper

becomes

size,

List).

To

replace

1.

the fuse,

Depress

proceedasfollows:

and

rotate

counterclockwise.

2. Pull

3.

4.

5.

5-3.
5-1)-Check

for

checking

out

fuse

is

free.

Insert

new fuse

Install

fuse

Depress
until

and

coverissecure.

DISPLAY

points

power

with

into

with

fuse

rotate

BOARD

are

providedonthe

supply

meters.

~

•

Do

•

Be
cedures
ty

practices.

•

Shut
or

ELECTROSTATIC

ELECTRIC

not

touch

sure

that

are

familiar

down

unit

test

equipment lead

live

electrical

personnel

before

DISCHARGE

electronic components.

•

Put

on a

handling

•

Transport

per

•

Perform

1.

Remove

2.

Locate display

properly

circuit

all

static-shielding

work

computer

grounded

boards.

static-sensitive

onlyata

board

FUSES

type,

cover when

fuse
holder

fuse

METER

can

necessary,

and

rating

fuse

holder

fuse

holder

cover.

cover

holder

cover

CHECK

damage

use

only

(see

holder

back

into

clockwise

display

and

input

command

SHOCK

can

kill.

parts.

with

and

performing

follow

testing

standard

makingorchanging meter

connections.

(ESD)

wrist

can

strap

damage

componentsinpro

carriers

interface

and

packages.

static-safe

top

work

cover.

area.

PC4.

this

fuses

Parts

cover

cover

unit.

(Figure

board

for

the

pro

-

safe-

BEFORE

-

3.

Check

voltage according to

4.Ifa

5.Ifthe

meter

power

supply

correct

meter

and

(see

the

meter is

Section

5-4).

power supplyorcommand

rect,

replace

display

and

board

5-4).

5-4.
(Figure

Lockout/tagging

disconnect
from

BOARD REPLACEMENT

5-2)

WARNING:

•

Do

not

•

Shut
robot, and

“lockout/tagging

or

servicing.

switchinthe

fuse

box,

ELECTRIC

touch

live electrical

down

unit,

disconnect

SHOCK

welding

input

procedures”

procedures consistofpadlocking

open

position,

or shutting

off

breakerorother disconnecting

ELECTROSTATIC
circuit

•

board

Putonproperly
handling

•

Transport

per

static-shielding

•

Perform

DISCHARGE

components.

grounded

circuit

boards.

all

static-sensitive

carriersorpackages.

work

onlyata

static-safe

INCORRECTLY INSTALLED
circuit

•

with
Retain

boards.

Be

sure

that

ed

onto

connectors

IMPORTANT:

respect to

all

hardware

plugs

are

before resuming

All

directions,

the

operator facing

removed during

properly

reinstallation.

A.

Display Board

1.

Remove

unit

PC4 And

top

cover.

Figure

5-1.

command

not

working,

voltage

replace

voltage is

PC4

(see

Section

PROCEDURES

can kill.

parts.

power

power

before

source,

employing
inspecting

removing

and

red-tagging

device.

(ESD)

can

damage

wrist

strap

BEFORE

componentsinpro

work

area.

PLUGS

can

damage

aligned and

operation.

suchasleftorright,

the

unit

front

this

procedure

Meter

Replacement

is

the

incor

and

line

fuses

circuit

install

are

panel.

for

-

-

-

OM-882

PageS

2.

Remove

not

3.

Disconnect
ching

4.

Gently

Do

and

screws securing

remove

stand-offs.

plugs

receptacles

pull board

not

pullupor

LED’s

maybedamaged.

PLG2O
on PC4.

straight

down;

boardtostand-offs.

and

PLG24

away

otherwise,

from

from

front

the

mat

panel.

meters

Do

5.

To

replace

a.

Remove

­b.

support.

Gently

tain

meter(s) proceedasfollows:

nuts

and

lock

washers

pull

meter

straight

outofsocket.

spacers.

from

meter

Re-

Digital

Motor

Speed

Receptacle

Interface

Receptacle

Receptacle

RCS

RC1

9

Voltage

Circuit

R(

Board

PCi

Receptacles

RF Filter

Receptacles

RC2O

Board

Ret

TO-i14344

Circuit

And

Circuit

PCS

R021

RC24

And

RC22

Figure

5-2.

Circuit

Board

Replacement

OM-882

Page

9

c.

Slide

spacers

d.

Push

meter

protruding

e.

Reinstall

metertoboard.Donot

meter

6.

To

install

line

boardupwith

meters

7.

Reinstall

8.

Reconnect

and

securing

receptaclesonnew

9.

Reinstall

B.

Motor

1.

Remove

2.

Remove

3.

Gently

4.

Insert

5.

Reinstall

6.

Reinstall

C.

Replacement

unit

Board

unit

securing

pull

new

securing
unit

Boards

1.

Remove

unit

2. Disconnect

3.

Unlatch
ing

standoffs

rail.

onto new

into

socket

meter

with

throughtorearofPC4.

lock

washers

and

overtighten

maybedamaged.

replacement

display

front

panel

LED’s.

screws.

PLG2O

and

PLG24

PC4.

top

cover.

PC2

Replacement

top

cover.

screw

and

board

from

receptacle

board

into

RC5.

screw

and

top

cover.

Procedure

top

cover

and

locate

plug(s)

from

and

board.

slide

board

support.

meter

supports

nutstosecure

board,

carefully

openings

to matching

unlatch

standoff.

RC5.

latch

standoff.

For

Remaining

board.

out

of

nuts

retain-

or

for

4.

Slide

new

board

into

retaining

doffs.

5.

Connect

new

6.

Reinstall

5

-5.

TROUBLESHOOTING

WARNING:

•

Do

not

•

Shut

and

‘lockout/tagging

plug(s)

board.

unit

ELECTRIC

touch

live electrical

down

unit,

disconnect

to matching

top

cover.

SHOCK

welding

,nput

procedures”

inspectingorservicing.

Lockout/tagging
disconnect
from

fuse box,

procedures

switchinopen

or shutting

consistofpadlocking

position,

off

breakerorother disconnecting

MOVING

•

HOT

•

Troubleshootingtobe

PARTS can

Keep

clearofmoving

SURFACES

Allow

cooling

cause

can

cause

period

performed

parts.

before

sons.

Itisassumed

installed

operatorisfamiliar

unit

was

relatedtothe

designedtodiagnose
the troubles

Use

this chart in
while performing
troubleisnot

cedures,

tion

shouldbecontacted.Inall

malfunction,

shouldbestrictly

that

the

computer

accordingtoSection2of

with

the

functionofcontrols,

working

properly,

welding

that

may
conjunction

and

process.

and

provide

develop

with

troubleshooting

remedied

the

nearest Factory

the

after

manufacturer’s

followed.

rail

and

latch

receptacle(s)

CHART

can kill.

parts.

power

source,

power

and

employing

before

removing

and

red-tagging

device.

serious injury.

severe

burns.

servicing.

onlybyqualified

interface

that
The

remedies

in this

the

was

this

manual,

the

troubleisnot

following

for

unit.

circuit

procedures.Ifthe

performing these

Authorized

Service

casesofequipment

recommendations

stan-

on

robot

internally

line

fuses

circuit

per

properly

the
the

chart

is

some

of

diagrams

pro
Sta-

-

-

OM-882

Unit

No

Page

TROUBLE PROBABLE CAUSE REMEDY

does

not

operate.

FuseFlopen.

Check

Fl,

and replaceifnecessary
5-2). Correct overload
operation.

Circuit

meter

display.

Meter

breaker

not working.

CB1

tripped.

Check
overload

Use

check

CBl,

and resetifnecessary.

problem

before

pointsondisplay

mineifpowerisavailabletometer

10

Display board

working.

PC4

not

Use
(see

okay,

5-3).Ifcheck
Section

check pointstodetermineifpowerisavailable

Section

replace

points

5-4).

5-3).Ifcheck pointsdonot
PC4

(see

problem before

continuing

board

are

okay,

replace

Section

5-4).

(see

Section

continuing

Correct

operation.

PC4todeter

(see

Section

meter

(see

test

TROUBLE PROBABLE CAUSE REMEDY

No

wire

feed.

Wire

feedsatmaximum. Tach

No

arc

voltage control.

Robot

signal.

Relay

CR1

Motor

board

ing.

board

drive

motor

Voltage
tions.

Wire

stick sensing

tions.

not

working.

PC2

not

PC5atwire

not

working.

control

work-

connec-

connec-

Check

PC2.

and
Replace

Replace

input

Signal

B (common)

CR1.

PC2

Replace PC5.

Check and

Check

and

secure

secure

signal

from

robottomotor

shouldbe0-10

on RC5.

(see

Section

5-4).

connections

connections

vdc

-

(see

(see

between

Section

Section

board

pins

2-3).

2-3).

K

Robot

shuts down

Touch

Robot

Sensor

moves

wireisstuck.

Wire

speed

goestozero.

No

wire

retract.

error.

when

(1PM)

due

to

welding

meter

Voltage

board

PCi

not

working.

Incorrect robot command

voltage.

Touch

Wire

Wire stick

Sensor

stick

connection.

sensing

connections.

connec-

tions.
Incorrect

robot command

voltage.

Motor

board

PC2

not

work-

ing.
Control

relay

CR2

not

work-

ing.

Replace

Check
PCi.

PCi

(see

Section

robot command

Command

voltage

5-4).

voltage at voltage

shouldbe0-10

vdc

ween pinsBBandCC(common)atRC25.
Check

continuityofleads

gas/current
Secure

Be
and

welding
minal

Check

Check

PC2.

all

connections.

sure

that

blue

leadisconnectedtoterminal

power

strip.

and

robot command

Signal

sensing

red leadisconnectedtoterminal

source

secure

connections

shouldbe0-10

between

control.

gun/torch

Repairorreplace.

interface14position

(see

Section

voltage at motor

vdc between

andB(common)atRC5.

Replace

Replace

PC2 (see

CR2.

Section

5-4).

board

bet

and

52

50 on

ter

2-3).

board

pins

K

Robot

shuts

down.

Interface

board

working.

Incorrect

robot command

voltage.

Loose

weld

output

tions.

Interconnecting

Interface

board

working.

PC3

connec-

cords.

PC3

not

Replace

Check

PC2.

PC3

robot command

Signal

andB(common)atRC5.

Clean

and

tighten

Check

all

interconnecting

or

not

replace.

Replace

Check

PC3

(see

Section

5-4).

voltage at motor

shouldbe0-10

connections.

cords for

and

secure

(see

Section

5-4).

vdc between

breaks;

all

connections.

board

pins

repair

OM-882

K

Page

11

5-6.

USEOFINDICATOR

On

LIGHTS

FOR

TROUBLESHOOTING

Ga~

Indicator

Light

Off

Gas

flows:

System

Contactor
System

normal

On

closed:

normal

On

Gas

(on).

(on).

I

does

not

flow:

Check

gas

I,

Contactor open:
Check

interconnecting
cords.
Check

interface board

valve

-Contactor

operation.

PC3.

Wire

Feed

IF

Gas

flows:

Check
and

gas line

Check

Indicator

IF

Contactor

Check

Indicator

gas

valve

for

interface

Light

closed:

display

L.~,

1

operation

leaks.

board

board

PC3.

PC4.

Gas

dodes

System

Contactor
System

normal

normal

IF

not

Off

IF

Open:

,~.1

IF

flow:

(off).

(off).

Wire feeds:

System

Arc

System

No
Check

normal

started:

normal

arc:

weld

(on).

I

—

On

(on).

On

parameters.

Wire

does not

Check

circuit

Check

relay

Check

interface

No

arc:

Replace

Arc

started:

Check

signal

Signal

shouldbe24vdc
between
2TG.

feed:

breaker

CR1.

board

Current

reed

relay.

Arc

Failure

from

robot.

terminals 2TL

CB1.

PC3.

Indicator

Indicator

and

Wire

feeds:

Check

input

signal

robot

to motor

Signal

shouldbe0-10
between
(common)atRC5.

Check

wire

Light

Arc

started:

Replace

No
Normal

reed

Ligl~

arc:

during

board

pinsKand

feed board

relay.

II

idling.

from

B

PC2.

vdc

PC2.

Wire

does not

System

No

arc:

System

Arc

started:

Normal

normal

•

Off

V

normal

-Off

while

feed:

(off).

(off).

welding.

OM-882

Page

12

Check

display

board

PC4.

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Page

13

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OM-882

Page

15

WELD

START

•15

V.

•24

V.

G

AS
AS

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V.

07

0

F

A

REV.

,.~

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(FAD)

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c~

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J

N

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Figure

5-6.

Circuit

Diagram

For

Interface

Board

~CGAS B

Circuit

~F~-*~

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Diagram

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R~UOT

cGJTACT~

B-113

431

OM-882

Page

16

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5-7.

Circuit

Diagram

For

Display Board

V.

IN

(ST

IN

ROW
RFH

RFL
DOW

LOW

HI

Circuit

PC4

Diagram

No.

B-ill

341

OM-882

Page

17

AP

AE

A.A

As

AG

N-,

AF

AD AC

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Diagram

PC6

CAR

H-

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No.

~—9

~

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B-ill

C20

C21

H

-

•

A

117

OM-882

Page

18

Yay

-

K

Effe~tiv

With

Serial

Nc.

~H1

3

?.~i1

PARTS

LIST

Fig

C

1

OM-882

Page

TC-1 14

345

Figure

1

A-Control Box

Item

No.

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

27
28
29
30
31
32

33

34
3S
36
37
38
39
40

41

42
43
44
4S

46

47
48

49
50

A

R2

PLG9

PLG16

PLG12

RC11

PLG17

ICN4
ICN2

ICN3

RC1

3

C2,3

RC17

RC12

PC4

PLG21,25

111

010 855

010

070 634

+

109

079
030

010
010

030 949
056

109

047 636

079 535
079 739
096 813

048 598

079 534
049 989

073 686
039 328

604
600 848

600

601

601

111

097
039 734

090

097
010 916
070
057

047 838

039

039 685

049 455
048

079

111

109330

091 100
604 910
604
090

109
109

604 825

109

113

097 867

028

094

076 624

057 084

111
073 756
081

Control

992

CONTROL
RETAINER,

853

FASTENER,
LABEL,

026

COVER,

683

HEAT
RESISTOR,

941

193

TUBING,3/BODxl8gawallxl/4

199

TUBING,

HEAT
SHIELD, resistor

170

041

CABLE,

HOUSING

•

CLAMP,
CABLE,
HOUSING

CABLE,

PLUG,4socketMS-3106A-145-25

•

CLAMP,

•

WIRE,

109

•

WIRE,

750

TERMINAL,

226

•

INSULATOR

228

CLAMP,

951

CABLE,

PLUG,

868

CLAMP,

263

CABLE,

866

PLUG,17pin

CONNECTOR,

731

BLANK,

360

BLANK,
BLANK,

PLUG,

273

CLAMP,
CABLE,

283

RECEPTACLE

535

TERMINAL,

199

CABLE,

PLUG,24socket
CLAMP,
CABLE,

CABLE,

571

CABLE,

890

159

CONNECTOR

157

CONNECTOR
CABLE,

158

CONNECTOR

736

CABINET, control
RECEPTACLE,17pin

291

CAPACITOR,

RECEPTACLE,24pin

591

RECEPTACLE, 4
BUSHING, snap

564

CIRCUIT
STAND-OFF,

380

HOUSING, terminal

Box

PANEL (FigCPg

screw

No.

2

screw-hd

warning

top

SINK

WW

.275IDx

SINK

interconnecting-motor/gas

PLUG&PINS

TERMINAL,

TERMINAL,

stranded
stranded12ga

Spin MS-3106A-165-8P

male

cable

l8ga

PLUG&SOCKETS

female

volt-sensing

cable

ring

universal25amp

control-interconnecting

l7socketMS-3106A-20-295

cableAN-3057-12

No.

18/c

MS-3106A-20-29P

clamp-cable
snap-in
snap-in

snap-in1inch

cable

AN-3057-8

No.

182/c

W/P

male

interconnecting

cable

20 ga

l8ga

No.208/c

183/c

ceramic

CARD,

No.

No.

electric

fixed

100

.048

15/c

(order

(consisting

AN-3057-6

16 ga

tongue

(orderbyft)

1-3/32x1-1/8
1-3/8

mtg

(order

INS

MS-3106A-24-285

AN-3057-16

5/c

(orderbyft)

4/c

(order

(order

(orderbyft)

MS-3102A-20-29P

0.1uf500

MS-3102A-14S-2P

pin

MS-3102A-145-2P

1/4IDx

meter

6-32xS/8x1/4

header14pin

6)

2

shock

can

wattS

wallx1

(consisting

byft)

(consisting
of)

(orderbyft)
(orderbyft)

1/2

stud

(consisting

3/4

inch

mtg

hole

mtg

hole

byft)

(consisting

(consisting

byft)

byft)

3/8

mtg

(FigBPg

kill

etc

ohm

(consisting

of)

hole

of)

of)

volts dc

hole

4)
hex

of)

of)

of)

1

4
4

1
1
1
1

4

2

1
1

1

1

14

2

1

8ft

1

16

1
1
1

1

9ft

35ft

1
1
1
1

1

2

20ft

1
1
1
1

2

1
1

25ft

1

4

1
1

1
6ft
6ft
6ft

1

1

6ft

1

1

1

2

1

1

1

1

7

2

OM-882

Page

2

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure

4.Recommended Spare

+

BE

A

51

52
53
54
55
56
57
58
59

When

SURETOPROVIDE

Fl

51

CB1

S2

RC9

Dl

PLG18
PLG19

PLG20,26

PLG22
PLG24

PLG27

orderingacomponent

*012

112

089 032
046 432

073 487
011

011 991

112392

047 637

079
026 202
079 760
079 798
081
092
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111

254

655
622

534

379

159
198

500

Parts

MODEL

Control

LABEL,

LENS,
HOLDER,

FUSE,
NUT,
SWITCH,
CIRCUIT
SWITCH,

HOUSING

TERMINAL,
DIODE,1amp
HOUSING, terminal
HOUSING,

HOUSING,
HOUSING,
HOUSING,

CONNECTOR,

originally displayingaprecautionary

AND

Box

(Cont’d)

Miller robot

led

4341

fuse

miniature

speed

No.

toggle

BREAKER,1pole1.5

code

RECEPTACLE&SOCKETS

terminal

terminal

terminal

terminal

SERIAL

computer

glass10amp

2

3PDT15amp

female

400

volts

SP
header12pin
header13pin

header12pin
header16pin
header6pin

plug5position

NUMBER

WHEN

interface

250

volts

125
amp

ORDERING

volts

250

volts

(consisting

label,

of)

the

label

should

REPLACEMENT PARTS.

alsobeordered.

1

5

1

1

4

1
1
1
1

14

1

1

1

2

1

1

1

OM-882

Page

3

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure

Cl

B

,2

C3-5

Dl

,2 028

LCDl-3

LEDl,2,4,5

LED3

Ri-S

R6,8,l

1

R7,9,l0

RC2O

RC21

-23

RC24

VR1,2

ASSE~ABLY

1Y564

2C2

111

000 348

073 739

108

089 028

097 763
044 635
030 140

003 272
081

109

084 194
071

070 026

cc

I

J~

564

Circuit

CAPACITOR,
CAPACITOR,

351

DIODE,

453

METER,

Card,

Meter

tantalum

ceramic 0.1 uf50volts

signal

0.020

amp75volts

DCO-200MV
LED,5330A1040MCD
LED,

5330A19200MCD
RESISTOR,
POTENTIOMETER,

RESISTOR,

382

TERMINAL,

161

TERMINAL,
TERMINAL, header6

248

IC,

linear

STAND-OFF,

~ C02

carbon film

cermet15turn

carbon film

header12pin
header13socket

pin

78M05

No.6-32

(FIgAPg2Item

0.47uf35

volts

dc

SP

0.25

watt

680

ohm

0.75

0.25

watt1meg ohm

x7/16xl/4

2C22

hex

122

48)

watt

220K

ohm

210

2223

LCD3

2
3

3
3
3

3
3

3
3

1

2
2

±

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LED 4

BE

SURETOPROVIDE

21

LED ~~UT)~4~

~
02

COMPONENTSTOBE

BY

QUALIFIED

MODEL

AND

SERIAL NUMBER

~1i

Figure

LED

2

23

LIDIi[IDIIliDIiLI

REPLACED

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B-Circuit

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D-111566

OM-882

Page

4

11

OM-882

PageS

Figure

19

C-Control

Panel

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure

1

PC2

2
3

CR2
4
5

SRi
6

7
8

9

10
11
12

CR1

13
14

2T,3T

15
16
17

PC6

18

19

20

CR3,4

21

22

D3,4
23
24
25

PCi

26

PC3

27
28

C

5T
T2
R3

Ri
Cl

iT

111

992

071

642

083
052 964

038 839
035 914

109 017

605

741

079 497
030

651
006 426
031

692
034

841
038 832

038 783

601

219

110

375

111

065

110 565
110

391
079 844
095

521
027

811
026 202

048

588
048

029

111

408

113

221
009 335

073 730

Control Panel

(FigAPg2Item

1)

CIRCUITCARD,digitalmotorspeed(FigC2PglO)

147

GROMMET,
RELAY,

BLOCK,terminal20amp5
RECTIFIER,
TRANSFORMER,

CLIP,
RESISTOR,

screw8-10

enclosed24volts dc

integrated30amp

control

mtg-resistor

WWfixed25

push

pole

watt2K

in

DPDT

400

volts

ohm

RESISTOR,WWfixed25wattl0ohm
CLAMP,
CAPACITOR,

capacitor2inch

electrolyte

750 uf 200

volts dc

RELAY,24voltsacDPDT

BLOCK,

BLOCK,

terminal20amp9pole
terminal20amp12pole

LINK,jumper
STAND-OFF,support

PANEL,
CIRCUIT
GUIDE,
SPRING,
RELAY,

mtg-components

CARD,

mtg-circuit

filter

card

(FigC4Pg

holddown-relay

enclosed24volts dc

12)

4PDT

CONNECTOR,14pin
DIODE,1amp

BRACKET,
CLIP,

retaining-socket

CIRCUITCARD,voltagecontrol(FigCl

400

volts

mtg-relay

SP

relay

Pg8)

CIRCUITCARD,interface(FigC3Pg11)
STAND-OFF,

TERMINAL,

No.

4-40x5/8x1/4

header22pin

1
1

1
1
1
1

4

1
1

1
1
1

1
2

8
8

1
1

3

2

2

2

2

1

2

1
1

2
1

BE

SURETOPROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-882

PageS

COMPONENT

BY

QUALIFIED

TO

BE

REPLACED

PERSONNEL

ONLY

Ret:

Dlii

410

OM-882

Page

Figure

7

Cl-Circuit

Card,

Voltage

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure

Cl

A1-3

Cl

,2

C3

,4

CS-i

5,17-24

Cl

6

D1-4,6

L1-4

Ql

Rl

R2,34,35,41

R3

R4,20,26,27,30,

38,40

R5,9,10,18,25,28,

29,37,39

R6,7,12-1

R19,21

R8

R11,16

R17

.43

R22,42

R23
R24

R3

1

R32
R33
R45

RC25

R

C26

Ul

U2,4

U3

VR

1

VR2

5,36

111

408

096 275
039 482
000 348
073 739

097 488
028

351
095 258
037 200
035 824

009

173

039

333
039

332
000

885
044

789
052

136

038

000

331

039
053

572
052

138

052

139

039

325
052

137

035

826
091

799
035

823

092

648
089

347
089

346

112

058
095

268
008

970
095

269

932

046

Circuit

IC,
CAPACITOR,

CAPACITOR,

linear

Card,

324

Voltage

electrolyte

tantalum

CAPACITOR, ceramic
CAPACITOR, ceramic
DIODE,
CHOKE, 1000

TRANSISTOR,
RESISTOR,
POTENTIOMETER,
RESISTOR,

RESISTOR,
RESISTOR,

RESISTOR,
RESISTOR,

POTENTIOMETER,
RESISTOR,
RESISTOR,
RESISTOR,
RESISTOR,
RESISTOR,

RESISTOR,
RESISTOR,

RESISTOR,
RESISTOR,
RESISTOR,

TERMINAL,
TERMINAL,

IC,
IC,

signal

0.020
UH28MA

carbon film
carbon film
carbon film
carbon film

carbon film
carbon film

carbon film
carbon film

carbon film

carbon film

carbon film
carbon film

carbon film
carbon film
carbon film
carbon film

header14pin

header12pin
interface2i2
intetface2ll

amp75volts

NPN200MA4OvoIts

cermet20turn

cermet25turn

IC,digital40ll

IC,

linear3l7T

IC,

linear

7915

(FigCPg6Item

100uf35

0.47uf35

0.1uf50

0.15uf50

volts dc

volts

voltsdc

volts

SP

0.25 watt

270

0.5

0.25

watt

18K

0.25 watt

0.25

0.25

0.25

watt
watt

watt

15K
10K

lOOK
150K

0.5

0.25

watt

4.7K

0.25

watt

12K

0.25

watt

20K

0.25

watt

39K

0.25

watt

82K

0.25

watt5.lKohm

0.25

watt6.8K

0.25

watt

8.2K

0.25

watt

100

0.25

watt

zero ohm

25)

ohm

watt5Kohm
ohm

ohm
ohm

ohm
ohm

watt2Kohm

ohm
ohm
ohm
ohm
ohm

ohm

ohm

ohm

3
2
2

19

1

5

4

4

1

7

9

7

1

2

1

3

2

1

1

1
1
1

26

1
1
1

2

1
1
1

BE

SURETOPROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-882

Page

8

0z~

o,~

~ ~“-‘-0

ft~

LOLC)

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—

0-093 449-G

—

OM-882

Page

COMPONENTS

BY

QUALIFIED

Figure

9

C2-Circuit

TO

BE

REPLACED

PERSONNEL

Card,

Digital

Motor

ONLY

Speed

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure

C2

ASO-53

C50
CS

1
C52,61
C53,62

C54

C55,66-75,77

C56
C57
C60

C63,64

C65

CR50

D50-54,56-60

D55

1C50

QSO

,53

Q5

1

Q52
R50

R51

,54,55,57,67,

68,74,75,82,89

R52,56,61

R53

R58,62,65,66,71

72,76,90

R59

R60,87,88

R63,79

R64
R70

R73,83

R77
R78

R80

R81,84

R85
R86

T50
VR5O
VR51

071

642

009

159
039 482
031

699

073

739
035 833
005

023
031

643
073

549
031

677
035

561
044 602

031 721
095 033
091 861
079 844
026 202
080 910
081

800
037

200
037 824
039 335

030 839
035 827

052

138

039 332
035 884

030 007
039 335
039

106

039

331
049 015
039 328

052

142

039

108

035 886
035 825

030

937
030 090
092 648
085

399
081

799

047

272
037

261

Circuit
IC,

CAPACITOR,
CAPACITOR,

linear

Card,

3S8

Digital

electrolyte
mylar

0.0022
CAPACITOR, ceramic
CAPACITOR,
CAPACITOR,

mylar

0.033 uf

tantalum
CAPACITOR, ceramic
CAPACITOR,

CAPACITOR,
CAPACITOR,
CAPACITOR,
CAPACITOR,
RELAY,
SOCKET,
SPRING,
DIODE,1amp

DIODE,
IC,

interface 2907

TRANSISTOR,
THYRISTOR,
TRANSISTOR,
RESISTOR,

RESISTOR, carbon
RESISTOR, carbon
RESISTOR,

RESISTOR, carbon
POTENTIOMETER,

RESISTOR,

RESISTOR,
RESISTOR,

RESISTOR,
RESISTOR,
RESISTOR,
RESISTOR,
RESISTOR,
RESISTOR,
RESISTOR,
RESISTOR,

RESISTOR,
TRANSFORMER,
IC,

linear78LO8

IC,

linear78Ll2

HEAT

SINK

mylar

0.015 uf 200

tantalum

mylar4uf 200

poly-film 0.47uf400

mylar

0.22

enclosed24voltsac4PDT

relay

holddown-relay

400

volts

zener15volts5watt

NPN

200MA40volts

SCR

7.4

UJT1SMA40volts

WW

fixed5watt

film
film

carbonfilm0.25wattl5Kohm

film

cermet15turn

carbon

film

carbon film
carbon

carbon
carbon

film
film

film
carbon film
carbon film

carbon film
carbon film
carbon

0.5

carbon 0.S

carbon film

pulse

Motor

Speed

100

uf35voltsdc

uf 200

0.1

uf50voltsdc

100

2.2uf20

0.01

uf 500

5.6uf3S
volts

uf 200

volts dc

SP

amp

200

volts

220

0.25

watt

0.25

watt

0.25

watt

0.25 watt

0.25

watt1K

0.25

watt

0.25

watt10meg

0.25

watt1.5K

0.25

watt

0.25

watt

0.25

watt

0.25

watt1Kohm
watt10ohm
watt47ohm

0.2S

watt

(FigCPg6Item

volts dc

voltsdc

volts

volts dc

volts

volts dc

volts dc

SP

ohm

10K

ohm

20K

ohm

100K

ohm

0.75

watt

47K

ohm

ohm

4.7K

ohm

ohm

ohm

120K

ohm

82K

ohm

22K

ohm

zero ohm

50K

ohm

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
1

2

1
1
1

2

1
1

15

1
1
1
1

BE

SURETOPROVIDE

MODEL

AND

SERIAL

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

OM-882

Page

10

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure

R3,6,7,12,13

C3

Al

Cl
C2

C3,6,9,10

C4

C5,11

CR4-6

CR2

D3-8

D9,10,15

Qi

-3

R1,2,8,11

R4

R5,10

R9

RC18
RC19

VR1

E

113

221

Circuit

009

159

IC,linear358

039 482
000 348

072
005 023

073 739
099 018
095

091 861

079 844
026 202

028
037 200 TRANSISTOR,

035 826
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072
039

052
079 759

079 795
081

C2

(N

CAPACITOR,
CAPACITOR,

130

CAPACITOR,tantaluml
CAPACITOR,tantalum2.2uf20volts

CAPACITOR,ceramic0.1
RELAY,enclosed24voltsdcSPDT

521

RELAY,

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SPRING,

DIODE,1amp

351

DIODE,signalo.O2Oamp7SvoltsSP
RESISTOR,

331

RESISTOR,carbonfilm0.25watt4.7Kohm

561

RESISTOR,carbonfilm0.2Swatt27OKohm

106

RESISTOR,

145

RESISTOR,
TERMINAL,

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832

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m~j

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enclosed24voltsdc4PDT

relay

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carbonfilm0.2Swatt6.BKohm

carbon film
carbon film

header12pin
header13pin

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Interface

electrolyte
tantalum

400

NPN

c-’J

0.47uf35

volts

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0.25

0.25

fl

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uf35voltsdc

uf50voltsdc

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volts

watt

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1
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PERSONNEL

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.~ .~ .~

REPLACED

ONLY

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(N-i

o

-

-

~

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.4-4-4-4-4-

e

Ret:

C-lOS 275-A

BE

OM-882

SURETOPROVIDE

Page

11

MODEL

AND

SERIAL NUMBER

WHEN

ORDERING

REPLACEMENT PARTS.

Dia.

Mkgs.

Part
No.

Description

Quantity

Figure

C20-25,28-33,48,49

C4

C1-6,9-14,46,47

L1-3,5-7,9

RC21
RC22

110

565

028 292
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TERMINAL,headerl6pin

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ceramic0.OOSuflOOOvoltsdc

0.1

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m

m m

LU

ii ii ‘I

14

14

7
1

1

G

Cl

C46
C47

C4
C3

0

BE

SURETOPROVIDE

MODEL

COMPONENTS

QUALIFIED

Figure

AND

SERIAL NUMBER

C4-Circuit

TO

BE

REPLACED

PERSONNEL

Card,

Filter

WHEN

ORDERING

ONLY

BY

REPLACEMENT

PARTS.

Ret:

C-i10567

OM-882

Page

12

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure

1

2

3
4

5
6

7
8

9
10
11
12

13
14

15
16
17

D

REED

RC7

D2

4T

GS1

RC16

109

936

047

+079

079

109
049 455
010
010 494
057 358
010 604
602 934
079

079
047

079

109 938
038

109
090 246

079 535

Control

LABEL,

497
682

WRAPPER

687

RELAY,

021

CASE
CORD,

610

CONNECTOR,
BUSHING,
BUSHING,

FITTING,
FITTING,
FITTING,

573
574

BRACKET,

637

HOUSING

•

TERMINAL,

534

Box,

general

current

SECTION,

No.

182/c

snap
snapIDx1.37

hose-brassbushing
pipe-coupling
pipe-nippleL1/4

mtg-component

RECEPTACLE&SOCKETS

DIODE,1amp

081

BLOCK,

561

VALVE,24volts dc2way

terminal20amp4pole

RECEPTACLE

•

TERMINAL,

Gas/Current

precautionary

bottom/front/sides

(orderbyft)

clamp-cable

1-3/8IDx

1/2

1-3/4

mtg

1/4

NPT

NPTx6

female

400

volts

SP

1/4

W/PINS

(consisting

male

67

Sensor

inch

mtg

hole

1/4

NPTx5/8-18

IPS

port

of)

hole

(consisting

1/8

orifice

8

of)

1
1
1
1

2ft

1

2

2

2

1
1

2

1

14

1

9

+

BE

OM-882

1

When

orderingacomponent

SURETOPROVIDE

Page

13

2

MODEL

Figure

D-Control

Box,

Gas/Current

originally displayingaprecautionary

AND

SERIAL

NUMBER

WHEN

ORDERING

label,

Sensor

the

label

should

REPLACEMENT

alsobeordered.

PARTS.

TC-109

Lao

ERRATA

After

this

to

data

appearing

SHEET

manual

was

prInted,

laterinthis

refinementsInequipment

manual.

design

occurred.

This

sheet

lists

exceptIons

AMENDMENTTOSECTION

IMPORTANT:A25

in this

installation.

Amend

A

There
screwsonstrain

screwsonstrain

A.

Section

WARNING: ELECTRIC

•

•

Lockout/tagging

from

are

several

CV/CC Connections

WARNING:

ft.

(8m)

interconnecting

Retain

2-5.

Do

not

Shut

ging

fuse

terminal

reliefonunit
reliefifnecessary,

cord

COMPUTER

touch

live

down

unit,

procedures

procedures consistofpadlocking

box,orshutting

strips

Read

A

1.

2.

Locate
For

terminal

CC

operation, remove

strip

2T.

2-INSTALLATION

cord

withafive-pin

for

future

use.

INTERFACE

SHOCK

electrical

welding

rear

and

power

before

making

off

and

inside the computer

panelifnecessary, and

and

reinstall

follow

jumper

TERMINAL STRIP CONNECTIONS

can

kill.

parts.

source,

interconnections.

red-tagging

top

safety

link

informationatbeginning of

between terminalEand

and

robot,

line

circuit

interface

locate

cover

when procedureisfinished.

Amphenoiplugissupplied

and

disconnect

disconnect

breaker

for

control

appropriate

or
connections.

input

power

switchinopen

other

disconnecting

Remove

terminal strip

Section

F on

2T.

with

this

employing

position,

device.

unit

for

connections.

2-5

before

unit

butisnot

locko

removing

top

cover,

proceeding.

used

ut/tag

-

fuses

loosen

Tighten

IMPORTANT:

B.

ARC

FAILURE

WARNING:

A

The ARC

unit.

1.

2.

FAILURE

Locate

a.

b.
c.

d.
e.

a.

b.

supplied

For

robot

Open robot

Route
Make

Close
Connect

For

robot

Obtaina115or24

Open

The

Inductance

Light Connections

Read

light on

length

control units

control

cord

under

cord

connectionstoterminal strip common

robot

control

cordto2TF

control units

robot

control

control

is

disabled

(Figure

and

follow

the

computer

of

18

gauge/2-conductor

withnoother

unit door, and locate

cross

member

unit door,

and

2TG.

when

vac,or24

unit

door,

safety

interface

connectionsatjig

below

and

route

115or24

vdc

isolation

and

locate

vac,or24

when

operatingintheCC(constant

2-4)
informationatbeginning of

front

panelisturnedonand

cord

for

this

connection,

terminal strip

jig

terminal strip

door.

cord

through

relay,

jig

terminal

and

vdcisusedatjig

and install

the

strain

strip

2.

Weld

Alarm

reliefonrear

terminal strip

into

jig

2.

Section

off

by a

and

proceedasfollows:

2:

terminal.

panelofcomputer

interface.

current)

2-5

before

signal

from

2T:

mode.

proceeding.

the

robot

interface.

control

-v

c.
d.

e. Close
f.

g.

h.
i.

j.

Add

Figure

Route

customer

Make

cord

robot

Connect
Cut

contacts

Connect

cordtoisolation

off

terminals

on
one end of

Route cord
Connect

2-4.

cord

Arc

Robot

Control

supplied18gauge/2-conductor

connectionstoterminal

control

isolation

through strain

Failure Light

to

2TF

unit door,

from

one endofsupplied18gauge/2-conductor

relay

and

coil

route

relay.

cordtoa

and

setofnormally-open

relief

on

2TG.

Connections

JIg

TermInal

StrIp

2

Common

unit

Weld

Alarm

cord

strip common

cordtojig interface.

and

voltage

rear

panelofcomputer

source.

Computer

under

cross

member

and

the

Weld

Alarm

cord,

contactsonisolation

interface.

Interface

2W

2TG

below

terminal.

and install

relay.

Arc

door.

terminalstoconnect

FaIlure

Indicator

Ught

to

Robot

Control

Unit

Alarm

To

(11

5VAC,

Figure

Voltage

24VAC,

2-4.

Source

24VDC)

JIg

Interface

Arc Failure

0

2TF

~—

I

Arc

Failure

IndIcator

Light

computer

LIght

Connections

Interface

TA-i15648

OM-882

Page 2

AMENDMENTTOSECTION5-MAINTENANCE&TROUBLESHOOTING

Amend

.0,

j

I!:

N-N-N-

Figure

R3

5-3.

Circuit

N-s

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a K

~

e~7

0j-~

For

<

~

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I

8

;

I

N-N-N-

i~N-- ~

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0

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N-N-

N-LTAIN-E

A,

C04W~

OM-882

Page

3

Amend

Figure

5-6.

Circuit Diagram

For

Interface Board

PC3

WELD

JOG

JOG

REV.

‘ISV

N-24 ~.C2

START

As

AS

(FN-dD)

,~ CR R

WELD

AL

CURRENT

RELAY

A.J

(REV)

P4

COl.*40N

AM

RELAY

~

*24

Cit

7

6

V

L...

44..................).R

C

GAS

CR5

CR6

CR2

L.............>

CR4

WIREFEED

MOTOR

GAS

WOBOT

CURRENT

AN

CONTACTOR

L~AC

FIgure

5-6.

CIrcuit

Diagram

For Interface

Board

PC3

Effective

CIrcuit

With

Serial

Diagram

No.

JK588314

No.

5-128

016

OM-882Page4

Add

Figure

5-9.

Wiring Diagram

C.,’

1—

r-.

1~

6

z

E

(U

a-

0)

0

0)

0)

0)

C..’

=

z

U)

•6~

6

a-

a)

a)

4-

C.)

a)

E

(U

a-

0)

(U

0

0)

a)

a

0)

U..

-

uu

OM-882 Page 5

AMENDMENTTOPARTS

LIST

Amend

2-1
2-4

2-17

2-20

2-

2-48

3-56

4-

6-2

6-5
6-15
6-16
6-26
6-28

11—

11—

11—

13-

13-6

Parts

Listasfollows:

Dia.

Mk~s

C2,3,6-1

PC4

51

Ri

SRl,2

PC3
RCS

C3
CS

D9,

10,15,16

CR5

Ti

C4,5

R4

-5

Part

No.

111

992

070 634

049 989

604 109

0

028
111
011

291
564
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

Replaced

With

117 724

123

154

118

676

604

109

028

291

117836
011 609

030 028
083 147

035 914
110

375

121

313

128

014
073 730
072

130
073 739
028

351

117

617

115 104
110 386
117

725

117

726

000 859
601

394

Description

CONTROL
LABEL,

CABLE,

WIRE,

CAPACITOR,
CIRCUIT

SWITCH,

RESISTOR,

GROMMET,
RECTIFIER, (qty
STAND
PANEL,
CIRCUIT

PANEL

warning general precautionary

volt

sensing

(qty

chg)

CARD,

toggle SPDT

carbon

(qty

(qty

(Eff

chg)

meter

0.5

chg)

w/HJ304076)

15

watt

chg)

OFF,

(qty

chg)

mtg-components

CARD,

interface
TERMINAL, header22pin
CAPACITOR,
CAPACITOR,

DIODE, (qty

CONTROL
CONNECTOR

RELAY,

TRANSFORMER,

(qty

chg)

(Eff

(qty

chg)

(Eff

chg)

(Eff

w/JK588314)

BOX,

gas/current sensor

CLAMP,

cable

enclosed24volts ac

control

CAPACITOR/RESISTOR,

CAPACITOR,

RESISTOR,

electrolytic

carbon2watt

amp 125

1.5K

(Eff

volts

ohm

w/JJ377225)

(Effw/JK588314)

w/JK588314)
w/JK588314)

1/2

inch

DPDT

(consisting

of)

220 uf35volts dc

10K

ohm

Quantity

1
1
1

26ft

7
1
1
1
2
2
7
1

1
1
1
1

4

1
1
1
1
1
2
1

**First

digit

represents page

BE

SURETOPROVIDE MODEL

OM-882

Page6

no-digits

AND

following

SERIAL

dash

represent

NUMBER

item

WHEN

no.

ORDERING

REPLACEMENT

PARTS.