Miller Electric A.B.B. Robot Interface Gas Control Hub And Spindle manual

A.B.B. Robot Interface Gas Control Hub And Spindle Processes OM-884 1 17 005G February 2000 Description Automatic Welding Interface Automatic W elding Visit our website at www.MillerWelds.com[...]

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .MillerW eld[...]

T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

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OM-884 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means W arning! Watch O[...]

OM-884 Page 2 Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.1 and Z87[...]

OM-884 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. F A[...]

OM-884 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g n e t i c F i e l d s W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However , after examining more than 500 studies spanning 1[...]

OM-884 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives. Y Identifie un message de s é curit é particulier . [...]

OM-884 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage. LES RA YONS DE L ’ ARC peuvent pro- voquer des br û lures dans le[...]

OM-884 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables. D Ne pas installer l ’ appareil à proximit é de produits inflammables D Ne pas surcharger l[...]

OM-884 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American W el- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Of fice, Washington, D.C. 20402. Recommended Safe Practice for the[...]

OM-884 Page 9 SECTION 2 – INST ALLA TION 2-1. Specifications Dimensions W eight Component Height Width Depth Net Ship Robot Interface 22-1/2 in. (572 mm) 16-1/2 in. ♦ (419 mm) 6-1/4 in.* (159 mm) 38 lbs. (17 kg) Gas/Current Sensing Control 4-1/2 in. (108 mm) 5-1/2 in. (140 mm) 10-1/2 in. (267 mm) 5 lbs. (2.3 kg) T otal 61 lbs. (27.7 kg) Spool S[...]

OM-884 Page 10 2-3. Connection Diagram Ref. S-0290 1 Robot Interface 2 1 15 V olts AC/Contactor And Output Control Cord 3 W elding Power Source 4 W eld Cables 5 Shielding Gas Supply 6 Electrode (Welding Wire) 7 W ork 8 Wire Drive Assembly 9 Motor Control Cord 10 Gas Control 1 1 Gas Control Cord 12 Arc Sensing Cord 13 Arc Failure Connection Inside R[...]

OM-884 Page 1 1 2-5. Shielding Gas Connection T o Regulator/Flowmeter ssb3.1 5/94 – ST -158 697-A Obtain gas cylinder and chain to running gear , wall, or other stationary support so cylinder cannot fall and break of f valve. 1 Cap 2 Cylinder V alve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from val[...]

OM-884 Page 12 2-7. Arc Sensing Connections ST-121 083-A Locate arc sensing cord, and connect 4-socket plug to receptacle RC12 on robot interface. T o make connection, align keyway , insert plug, and tighten threaded collar . 1 Positive Weld Output T erminal On Welding Power Source 2 Weld Cable Lug Location 3 Arc Sensing Lead Ring T erminal Locatio[...]

OM-884 Page 13 2-9. 24-Socket Receptacle RC17 Information Socket* Socket Information A Provides connection to 2T A; for customer use. B Current Detect output to robot control unit with respect to Socket D; isolated CR1 contacts rated 1A at 120 V AC. D Current Detect output to robot control unit with respect to Socket B; isolated CR1 contacts rated [...]

OM-884 Page 14 2-10. Arc Failure Light Connections S-0292 . Arc Failure light on robot inter- face front panel turns on and off by a signal from robot control unit. Obtain proper length of 18 gauge/2-conductor cord for this connection. Fo r robot control units when 24 vdc is used: 1 Route cord through strain relief on right side panel of robot inte[...]

OM-884 Page 15 2-1 1. Matching Digital V oltage Control (DVC) Board T o W elding Power Source Ref. ST-1 19 647-C / SB-152 372 / S-150 864-C 1 DVC Board PC1 2 DIP Switch T ools Needed: Non-Conductive DEL T AWELD 300 DEL T A WELD 451, 450 DEL T A WELD 651, 650 MAXTRON 300, 400 MAXTRON 450 XMT 200/300 ARC P AK 350 SHOPMASTER 300 DIMENSION 400 S2 S1 DV[...]

OM-884 Page 16 2-12. Hub Assembly Installation ST-126 870-A 1 Spool Su p p o r t 2 Hub Support Shaft 3 Retaining Ring 4 Hub Assembly 5 Brake W asher 6 Fiber W asher 7 Hex Nut Install hub assembly as shown. T ighten hex nut until a slight drag is felt while turning hub. T ools Needed: 9/16 in 1 2 3 4 5 6 7 2-13. Installing Spool-T ype Wire And Adjus[...]

OM-884 Page 17 2-14. Installing Optional Reel-T ype Wire ST-161 000-A / ST -152 463 / Ref. ST-157 999-A 1 Retaining Ring 2 Lock 3 Spanner Nut 4 Wire Retainer 5 Welding Wire 6 Wire Reel 7 Hub Remove retaining ring. Pull lock an d turn. Remove spanner nut, wire retainer , and wire reel from hub. T o install wire lay wire reel on flat surface and inst[...]

OM-884 Page 18 3-2. W ork Clamp sb4.1 2/93 1 Work Clamp Connect work clamp to a clean, paint-free location on workpiece, as close to weld area as possible. Use wire brush or sandpaper to clean metal at weld joint area. Use chipping hammer to remove slag after welding. T ools Needed: 1 3-3. Front Panel Controls Ref. ST-1 19 645-A 1 Power Switch Use [...]

OM-884 Page 19 3-4. Indicator Lights Ref. ST-1 19 645-A 1 Gas Indicator Light Gas sight turns on when the gas valve is energized to indicate shielding gas flow . 2 Contactor Indicator Light Contactor light turns on when the welding power source contactor is energized to indicate that weld output is available. 3 Wire Feed Indicator Light WIRE FEED l[...]

OM-884 Page 20 3-5. Burnback Control Ref. ST -1 19 647-C / SB-191 630 Burnback circuitry keeps welding wire from sticking to workpiece after arc is extinguished. This circuitry keeps weld output on welding wire from 0 to 0.25 seconds after wire has stopped feeding. This delay action permits welding wire to burn back to a point where it neither stic[...]

OM-884 Page 21 SECTION 4 – SEQUENCE OF OPERA TION 4-1. Input/Output Signals ST-094 382-B Robot interface receives input signals for contactor control, gas control, jo g , w elding volts, and wire speed. It also receives a signal to initiate a check to see if wire is stuck to workpiece at end of a weld. Robot interface sends output sig- nals t o r[...]

OM-884 Page 22 SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Clean and tighten weld terminals. Repair or replace cracked weld cable. Check 14-pin cord. Check gas hose and fittings. Check gun cable. Replace cracked parts. 6 Months Blow out or vacuum[...]

OM-884 Page 23 5-3. Overload Protection Ref. ST-800 185-A / ST -1 19 644-B If fuse F1 opens, the robot interface shuts down. T o check or change F1, proceed as follows: 1 Fuse Holder Cover 2 Fuse F1 (See Parts List For Rating) 3 Circuit Breaker CB1 CB1 protects the wire feed motor from overload. If CB1 opens, the wire feed motor stops. Check for ja[...]

OM-884 Page 24 REAR VIEW OF DISPLA Y BOARD PC4 Input Command For Wire Speed IPM Meter 0.8V = 800 IPM Input Command For V olts Meter – 0.5V = 50V Power Supply For Wire Speed IPM Meter 5VDC Power Supply For V olts Meter And Ammeter 5VDC 5-4. Display Board PC4 Meter Check Ref. ST-1 17 838-B / Ref. ST-1 19 647-C Check points are provided on display b[...]

OM-884 Page 25 5-5. T roubleshooting Y Disconnect power before troubleshooting T rouble Remedy No arc voltage control. Check and secure output control connections (see Section 2-4). Check and secure arc sensing connections (see Section 2-7). Check robot command voltage at Isolation Board PC5. Command voltage should be 0-10 vdc between sockets Y (co[...]

OM-884 Page 26 5-6. Use Of Indicator Lights For T roubleshooting Gas Indicator Light On Off Gas flows: Gas does not flow: Gas flows: Gas does not flow: System normal (on.) Check gas valve operation. Check gas valve operation and gas line for leaks. System normal (off). Check interface board PC3. Contactor Indicator Light On Off Contactor closed: Co[...]

OM-884 Page 27 SECTION 6 – ELECTRICAL DIAGRAMS 151 242-E Figure 6-1. Circuit Diagram For Robot Interface[...]

OM-884 Page 28 SECTION 7 – P ARTS LIST SC-119 647-A 1 2 3 4 5 67 8 9 10 1 1 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Fig 7-2 5 30 31 32 33 34 35 36 . Hardware is common and not available unless listed. Figure 7-1. Control Box Description Part No. Dia. Mkgs. Item No. Figure 7-1. Control Box Quantity 1 PLG24 167 361 CONNECTOR & SOC[...]

OM-884 Page 29 Description Part No. Dia. Mkgs. Item No. Figure 7-1. Control Box Quantity (Continued) 19 175 1 15 CABLE, interconnecting (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 370 HOUSING PLUG & SOCKETS, (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-884 Page 30 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 12 . Hardware is common and not available unless listed. 1 19 648-C Figure 7-2. Control Panel, w/Components[...]

OM-884 Page 31 Description Part No. Dia. Mkgs. Item No. Figure 7-2. Control Panel, w/Components (Fig 7-1 Item 23) Quantity 1 PC2 071 642 CIRCUIT CARD, motor speed dig 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 RC5 1 17 374 CONNECTOR, edge mod-fork 22 skt 1 . . . . . . . . . . . . . . . . . . . . [...]

OM-884 Page 32 Description Part No. Dia. Mkgs. Item No. Figure 7-3. Hub & Spindle Assembly Quantity 1 072 094 HUB & SPINDLE, (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 058 427 RING, retaining spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-884 Page 33 Description Part No. Dia. Mkgs. Item No. Figure 7-4. Control Box, Gas Quantity 1 134 327 LABEL, warning general precautionary 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 +079 682 WRAPPER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-884 Page 34 Notes[...]

Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 7/00 Y ou r distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise [...]

PRINTED IN USA  2000 Miller Electric Mfg. Co. 6/00 Miller Elect ric Mfg. Co. An I l li noi s T ool Works Company 1635 W est S pencer St reet Applet on, WI 54914 USA International He adquarters – USA USA Phone: 920-735-4505 Auto-A t t ended USA & Canada F A X : 920-735-4134 Int ernati onal FAX: 920-735-4125 European Headqua rters – United[...]