Miller Electric NSPR 8989 User Manual
Millerfi
November
1990
FORM:
OM-135
582B
MODEL:
Robot
(per
Interface
NSPR
8989)
OWNERS
iMPORTANT:
and
the
the
safety
maintaining
by
persons
Do
ment.
Contact
power
material
trained
not
your
Read
source
throughout
this
equipment.
untrained
allow
distributor
understand
and
manual
and
experienced
If
you
used
both
This
unit
persons
do
the
with
manuals,
and
In
the
to
Install,
not
fully
entire
this
unit,
these
safe
understand
MANUAL
both
contents
before
Instructions
operationofwelding
operate,
of
with
special
Installing,
maintain
or
these
are
Instructions.
this
manual
emphasis
operating,
for
use
only
equip
this
unit.
on
or
MILLER
A
MIter
Group
P.O.
Box
Appleton,
Tel.
414-734-9821
ELECTRIC
Ltd..
Con~any
1079
WI
54912
Mfg.
USA
PRINTEDINU.S.A
Co.
Ui
ii
LIMITED
MIg.
MIl.LER
fects
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Years
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MILLERS
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failure
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that
date
follows:
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Parts
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MILLER.
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AMENDMENT
Amend
Section
Connections
3.
For
interface.
tk
______
WARNING:
Lockout/tagging
from
a.
Open
Locate
b.
Cut
c.
d.
Splice
Cover
e.
f.
Close
manual
appearing
SECTION
TO
3-5B.
units
used
Proceed
Do
Shut
not
touch
down
procedures.
fuse
box,
front
panel
lead
lead
72asclose
72
lead
splice
and
secure
was
later
ROBOT
with
Pulstar
as
ELECTRIC
live
unit,
procedures
or
access
72
at
to
lead
with
electrical
printed,
in
this
INSTALLATION
3
INTERFACE
450
follows:
electrical
welding
shutting
door.
of
F
pin
to
receptacle
77
at
front
panel
refinements
manual.
welding
SHOCK
parts.
source,
power
consist
off
and
REMOTE
REMOTE
or
tape
access
in
equipment
-
WELDING
source,
power
kill.
can
and
robot,
of
padlocking
red-tagging
17
receptacle
as
possible.
14
receptacle
other
insulation.
door.
it
line
circuit
RC16.
design
POWER
is
necessary
and
disconnect
disconnect
breaker
RC13
pin
or
D.
occurred.
SOURCE
to
change
input
switch
other
disconnecting
sheet
This
CONNECTIONS:
internal
power
in
employing
open
connections
position,
lists
exceptions
REMOTE
lockouVtagging
removing
device.
in
the
17
robot
fuses
a
Add
a
CAUTION:
See
Figure
CAUTION:
See
Be
sure
welding
3-7.
DVC
Figure
WELDING
welding
power
Voltage
INCORRECT
DIP
switch
3-7
power
source
Control
is
DVC
for
POWER
source
Owners
Board
DVC
factory
DIP
SOURCE
DIP
BOARD
set
for
switch
main
control
Manual
Switch
operation
setting
may
board
for
modification
Setting
DIP
SWITCH
with
when
not
Label
Delta
using
respond
has
been
POSITION
weldfi
another
with
output
modified
procedure.
can
451
welding
welding
corresponding
use
a
equipment
power
source.
0
to
cause
power
to
+
source.
to
10
volt
malfunction.
set
value.
command.
DVC
SWITCH
S2
SETTINGS
Si
Add
switch
DIP
voltage
ling
another
Section
welding
3-10.
and
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output
SETTING
S2
at
power
on
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a
welding
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DELTAWELD
DELTAWELD
DELTAWELD
MAXTRON
MAXTRON
XMT200/300
ARC
SHOPMASTER
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On
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On
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power
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300,
450
PAK35O
For
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For
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Figure
SWITCHES
board
source.
300
451
651
400
3-7.
follows:
as
400
300
Hot
ON
PCi
To
1
ON
ON
ON
Soft
Start.
Start.
DVC
VOLTAGE
allow
change
2
0
0
ON
DIP
Switch
setting
factory
Turn
1
ON ON
ON
ON
ON
Off
Setting
CONTROL
the
set
position
2
ON
ON
ON
ON ON
Si
-3.
proper
3
ON
Label
BOARD
command
DIP
of
4
ON
ON
ON
S~15o864A
5
ON
ON
ON
ON
ON
PCi
signal
switches
voltage
from
a
for
level
Deltaweldfi
control
451
to
a
1.
2.
3.
4.
Add
SOURCE
If
the
number
WARNING:
Do
Shut
not
touch
down
tagging
Lockout/tagging
from
fuse
ELECTROSTATIC
Put
on
properly
Transport
Perform
Loosen
Locate
trol.
Set
power
Close
Section
robot
screws
voltage
position
source.
and
3-11.
interface
JJ400026,
secure
ELECTRIC
live
electrical
unit,
welding
procedures
procedures
or
box,
shutting
DISCHARGE
grounded
boards
circuit
work
only
securing
control
DIP
of
VOLTAGE
control
proceed
board
switches
access
to
is
as
SHOCK
before
off
at
static-safe
a
front
PCi
door.
CONTROL
be
used
follows:
parts.
power
setting
consist
and
wrist
in
proper
access
Si
and
kill.
can
source,
and
DIP
switches.
of
padlocking
red-tagging
strap
can
BEFORE
(ESD)
static-shielding
work
area.
and
door,
in
with
lower
S2
according
BOARD
an
early
left
portion
wire
feeder,
line
circuit
breaker
damage
handling
carriers
door.
open
of
component
label
to
MODIFICATION
Deltaweld
model
and
disconnect
or
circuit
boards.
circuit
or
inside
FOR
450
disconnect
switch
other
disconnecting
boards.
packages.
mounting
and
unit
EARLY
650
or
welding
input
in
open
panel
Figure
MODEL
power
position,
device.
inside
3-7
for
power
employing
removing
interface
robot
appropriate
WELDING
source
prior
lockout/
fuses
con
welding
POWER
serial
to
OM-135
5828
Page
2
a
WARNING:
Do
not
Shut
tagging
Lockout/tagging
from
fuse
ELECTRIC
touch
down
unit,
procedures
or
box,
live
procedures
ELECTROSTATIC
i
Put
on
properly
Transport
Perform
circuit
work
only
SHOCK
electrical
welding
before
shutting
off
DISCHARGE
grounded
boards
static-safe
at
a
parts.
power
making
consist
and
wrist
in
proper
kill.
can
and
can
BEFORE
wire
board
circuit
damage
handling
source,
circuit
of
padlocking
red-tagging
(ESD)
strap
static-shielding
work
area.
feede~
modifications.
line
and
disconnect
breakerorother
circuit
carriers
boards.
circuit
or
packages.
disconnect
switch
disconnecting
boards.
input
in
open
power
employing
position,
device.
Iockout/
removing
fuses
IMPORTANT:
control.
1.
Loosen
2.
Locate
trol.
3.
Mark
4.
Mark
5.
Note
6.
Place
7.
Locate
8.
Use
J6,
J4,
9.
Apply
10.
Apply
11.
Reinstall
12.
Reconnect
Receptacle
board
PCi
trol
A
customer-supplied
screws
voltage
and
and
position
circuit
jumpers
a
sharp
and
small
a
sealant
a
RC1
securing
control
disconnect
disconnect
of
board
tool
J8.
amount
circuit
marked
6
leads
follows:
as
circuit
Ji
to
coating
board
76,
cord
front
access
PCi
board
from
leads
plugs
board
on
a
stationary
thru
J8onsurfaceofboard
remove
of
solder
over
into
leads
and
and
77,
from
and
sealant
all
in
unit
plugs
78
voltage
to
jumper
must
(Miller
door,
in
lower
PCi.
remove
work
coating
bridge
its
original
to
be
#042562)isrequired
and
left
portion
control
from
surface
from
all
the
foil
locations.
door.
open
of
component
PCi.
board
unit.
that
so
(see
Figure
jumper
component
locations,
padsatjumper
position.
appropriate
changedatplug
locations.
PLG1
to
3-8).
4
connect
mounting
side
and
remove
Ji, J3,
connected
the
is
J5,
welding
facing
and
to
power
inside
panel
up.
foil
jumper
J7.
receptacle
source
robot
between
RC1
to
interface
pads
on
voltage
the
weld
con
at
con
J2,
IMPORTANT:
1.
Locate
2.
Mark
window
3.
Bend
4.
Insert
Lead
a.
Lead
b.
c.
5.
6.
Lead 78
Reconnect
Close
Figure
Add
See
and
and
remove
side
on
locking
lead
contacts
76
to
77
to
to
and
secure
3-8.
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receptacle
disconnect
leads
of
plug
tabs
on
plug
opening
opening
plug
plug
opening
PLG14
plug
access
Locations
RC1
plug
to
lead
into
to
pin
PLG14
and
77,
76,
bend
down
contacts
follows:
as
plug
10.
8.
9.
receptacle
door.
On
Voltage
designations
from
receptacle
from
78
locking
Out
RC1
50
thatthey
on
Control
plug
tab,
voltage
etchedoncircuit
RC1
on
voltage
PLG1
4
inserting
by
and
Board
pull
secure
control
contact
contacts
board
PCi
board
to
identify
control
end
of
attachedtolead
inserted
when
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board
a
small,
plug
PCi.
from
into
openings.
flat-tip
screwdriver
plug.
plug.
OM-1355828Page3
into
Ret.
SD148
322
AMENDMENT
Amend
Delete
This
Amend
Amend
Diagram
Diagram
diagramnolonger
Diagram
Diagram
TO
7-1.
7-2.
7-3.
7-4.
SECTION
Circuit
Circuit
applies
Circuit
Circuit
Figure
7
Diagram
Diagram
Diagram
Diagram
3-8.
Jumper
ELECTRICAL
For
For
effective
For
For
Locations
Robot
Voltage
with
Serial
Motor
Interface
DIAGRAMS
Interface
Board
No.
Control
Board
On
(see
PCi
KC231
Board
PC3
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page
859
PC2
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8
on
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Errata
this
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6
and
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PCi
Sheet)
7
on
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this
Errata
Sheet)
OM-135
582B
Page
4
AMENDMENT
TO
SECTION
8
PARTS
LIST
Amend
.
.
.
.
.
.
.
.
20-
.
20-
.
20-
.
20-
.
20-
.
20-
.
20-
.
20-
.
20-
.
21-
.
21-
.
21-
.
19-
19-
19-
19-
19-
19-
19-
19-
Parts
.
..
.
..
PLG25
.
.
.
.
List
Dia.
Mkqs.
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RC13
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as
028
.
. .
049
079 844
048 029
026 202
137695
.
.
.
.
..
109
.
.
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Part
No.
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700
Description
CAPACITOR,
..
RELAY,
. .
BRACKET,
..
SPRING,
..
SOCKET,
..
CLIP,
..
..
..
..
..
..
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MODEL
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27
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not
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ORDERING
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OM-135
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5
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No.
OM-135
SD-083
5828
388-B
Page
7
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FOR
CHIPS
Diagram
7-4.
Circuit
Diagram
For
Interface
Board
Circuit
PC3
Diagram
No.
SB-141
311-A
OM-135
5828
Page
9
RECEIVING-HANDLING
OM-135
5829-11/90
Before
age
claims
unpacking
that
may
for
loss
Assistance
from
the
distributor
ers
Transportation
When
requesting
provide
ways
Number.
Section
SECTION
SECTION
equipment,
occurred
have
or
damage
for
filingorsettling
and/or
Department.
information
the
Model
Description
No.
-
1
SAFETy
1-1.
1-2.
General
Safety
2
SPECIFICATIONS
check
during
with
claims
the
equipment
about
Information
Alert
carton
shipment.
the
delivering
may
this
and
PRECAUTIONS
Symbol
for
any
dam-
File
carrier.
be
obtained
manutactur-
equipment,
Serial
or
Style
TABLE
AND
And
Safety
And
Signal
any
al
OF
Use
tion
mation
Model
Senal
Date
CONTENTS
SIGNAL
Words
the
following
Serial
and
located
is
_______________________________
or
Style
of
Purchase
WORDS
or
No.
spaces
Style
the
on
____________________
_____________________
to
record
Number
data
the
of
your
cardorthe
Page
Model
unit.
Designa~
The
nameplate.
No.
1
1
infor
SECTION
SECTION
2-1.
3INSTALLATION
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
4-
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
Amps/lnductanc~
Description
Site
Selection
Equipment
Gas/Current
Voltage
Robot
Robot
Arc
Welding
Burnback
OPERATOR
Power
Jog
Purge
Voltmeter
Wire
Indicator
Sensing
Interface
Interface
Failure
Wire
Switch
Push
Push
Speed
Lights
Control
Buttons
Installation
Sensing
Control
Connections
Welding
Robot
Terminal
Light
Installation
CONTROLS
Button
Meter
Meter
Interconnections
Power
Control
Strip
Source
Unit
Connections
Connections
Connections
1
2
2
3
3
4
4
5
6
6
7
7
7
7
7
7
7
SECTION
5-1.
5-2.
5
SEQUENCE
Input
Signals
Output
OF
From
Signals
OPERATION
Robot
From
Robot
Control
Interface
Unit
8
8
Section
SECTION
No.
MAINTENANCE
6
&
TROUBLESHOOTING
Page
No.
SECTION
SECTION
6-1.
6-2.
6-3.
6-4.
6-5.
6-6.
6-7.
7-
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
-
8
Figure
Figure
Figure
Figure
Figure
Figure
Routine
Overload
Reinstallation
Display
Circuit
Maintenance
Protection
Of
Board
Board
PC4
Handling
Troubleshooting
Use
Of
Indicator
ELECTRICAL
7-1.
PARTS
8-1.
8-2.
8-3.
8-4.
8-5.
8-6.
7-2.
7-3.
7-4.
7-5.
7-6.
7-7.
Circuit
Circuit
Circuit
Circuit
Circuit
Circuit
Circuit
Circuit
Circuit
Circuit
Circuit
Circuit
Circuit
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
Diagram
LIST
Card,
Card,
Card,
Card,
Card,
Card,
Hub
Meter
Lights
DIAGRAMS
Voltage
Motor
Interface
Meter
Interface
Wire
Assembly
Check
Precautions
For
Troubleshooting
For
Robot
For
Voltage
Motor
Control
For
Interface
For
Display
For
Arc
Failure
For
Touch
Control
Speed
PC4
Touch
Digital
PC3
PC5
PC6
Interface
Board
PCi
Board
Board
Board
PC4
Board
Sense/Wire
PCi
PC2
PC2
PC3
PC5
Stick
Board
PC6
. . . .
8
9
9
9
10
11
13
14
15
16
17
17
18
18
22
24
26
27
28
29
Table
Table
2-1.
Specifications
6-1.
Troubleshooting
LIST
OF
CHARTS
AND
TABLES
1
12
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