FORM: OM-884B

Miller April 1992

Effective With Serial No. KC188391

MODEL: ABB Robot Interface

Gas/Current Sensing Control
Hub And Spindle

OWNERS MANUAL
IMPORTANT: Read and understand the entire contents of both this manual
MILLER ELECTRIC Mfg. Co.
and the power source manual used with this unit, with special emphasis on A Miller Group Ltd.. Compeny
the safety material throughout both manuals, before Installing, operating, or P.O. Box 1079
maintaining this equipment. This unit and these instructions are for use only Appleton, WI 54912 USA
by persons trained and experienced in the safe operation of welding equip Tel. 414-734-9821

ment. Do not allow untrained persons to install, operate, or maintain this unit.
Contact your distributor if you do not fully understand these instructions.

PflINTED IN U.S.A
K!>

:1~.
MILLERS TRUE BLUETM LIMITED WARRANTY
Effective January 1, 1992
(Equipment with a serial number preface of KC or newer)

This limited warranty supersedes atl previous MILLER warranties and is eeclusive with no other guarantees or warranties eepressed or implied.

*
LIMITED WARRANTY Subject to the terms and conditions below. MILLER Electric Accessory Kits
Mfg. Co-. Appleton, Wisconsin, warrants to its original retail purchaser that new *
Replacement Parts
MILLER equipment sold aher the effective dale of this limited warranty is free of de
fects in material and workmanship at the time it is shipped by MILLER. THIS WAR
MILLERS True BIuerM Limited Warranty shall not apply to:
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES. EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FIT
NESS. Items furnished by MILLER, but manufactured by others, such as engines or

trade accessories. These items are covered by the manufacturers warranty, if

any.
Within the warranty periods listed below, MILLER will repair or replace any war
ranted parts or components that fail duets such defects in material or workmanship.
MILLER must be notilied in writing within thirty (30) days of such defect or failure, at 2. Consumable components: such as contact tips, cutting nozzles, csnt actors

which time MILLER will provide instructions on the warranty claim procedures to be and relays.
tollowed.
3 Equipment that has been modified by any party other than MILLER, or equip
MILLER shall honor warranty claims on warranted equipment listed below in the ment that has been improperly installed, improperly operated or misused

event of sucha failure within the warranty time periods. All warranty time periods
based upon industry standards, or equipment which has not had reasonable
start on the date that the w55 delivered to the original retail purchaser. and necessary maintenance, or equipment which has been used for operation
equipment
and are as follows: outside of the specifications for the equipment.

t. 5 Years Parts 3 Years Labor MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMER
CIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN
*
Original main power rectifiers THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

2. 3 Years Parts and Labor

In the event of a warranfy claim covered by this warranty, the eectusive remedies
*
Transformer/Rectifier Power Sources shall be. at MILLERS option: (1 (repair: or (2) replacement: or, where authorized in
Plasma Arc Cutting Power Sources writing by MILLER in appropriate cases. (3) the reasonable cost of rnpsiror replace
ment at an authorized MILLER service station: or (41 payment of or credit forthe pur
*
Semi-Automatic and Automatic Wire Feeders
chase price (less reasonable depreciation based upon actual usn( upon refurn of the
*
Robots
goods at customers risk and espense MILLERS option of repair or replacement
wilt be P.O.B ,Factory at Appleton, Wisconsin, orF.O.B. at a MILLER authorized ser
3. 2 Years Parts and Labor
vice facility as determined by MILLER. Therefore no compensation or reimburse
*
Engine Driven Welding Generators ment for transportation costs of any kind will be allowed. -

(NOTE: Engines are warranted separately by the engine manufacturer.)

TO THE EXTENT PERMfTTED BY LAW, THE REMEDIES PROVIDED HEREIN
4. t Year Parts and Labor
ARE THE SOLE AND EXCLUSfVE REMEDIES. IN NO EVENT SHALL MILLER BE
Motor Driven Guns LIABLE FOR DIRECT INDIRECT SPECIAL, INCtDENTAL OR CONSEQUENTIAL

Process Controllers DAMAGES (INCLUDING LOSS OP PROFIT), WHETHER BASED ON CON

TRACT, TORT OR ANY OTHER LEGAL THEORY.
Water Coolant Systems
HP Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
*
Grids RANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY
*
Spot Welders REMEDY FOR BREACH OP CONTRACT TORT OR ANY OTHER LEGAL
*
Load Banks THEORY WHICH, BUT FOR THIS PROVfSION, MIGHT ARISE BY IMPLICATION,
* OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALfNG, IN
SDX Transformers
CLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR PfTNESS
*
Running Gear/Trailers FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
*
Field Options FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MfLLER.

(NOTE: Field options are covered under True Blue~M for the remaining
installed in, tsr minimum of Some states in the U.S.A. do not allow limitations of how long an implied warranty
warranty period of the product they are or a
lasts. or the soctusion of incidental, indirect, special or consequential damages, so
one year whichever is greater)
the above limitation or eeclusion may not apply to you. This warranty provides spe

5. 6 Months Batteries cific legal rights, and ofher rights may be available, but may vary from state fo stale.

6. 90 Days Parts and Labor In Canada, legislation in some provinces provides

for certain addifional warranties
or remedies other than staled herein, and to the estnnt that they may not be
as
MIG Guns/Tb Torches
waived. the limitationS and esclusiorms ssf out above may not apply. This Limited
Plasma Cutting Torches
Warranty provides specific legal righfs, and other rights may be available, but msy
*
Remote Controls vary from province to province.

< I

RECEIVING-HANDLING

Before unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for loss or damage
with the delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
When requesting information about this equipment, always provide Model Designation and Serial or Style Number,

Use the following spaces to record Model Designation and Serial or Style Number of your unit. The information is located on the rating label
or nameplate.

Model _________

Serial or Style No.

Date of Purchase

miller 5/92
ERRATA SHEET

P After this manual

to data appearing
was printed, refinements in
later in this manual.
equipment design occurred. This sheet lists exceptions

AMENDMENT TO SECTION 3 INSTALLATION

Amend Section 3-4B. ROBOT INTERFACE WELDING POWER SOURCE CONNECTIONS: Output Control Con
nections To PULSTAR

CAUTION; WELDING POWER SOURCE will not respond with output corresponding to set value.
a Be sure welding power source main control board is modified to use a 0 to + 10 volt command.

See welding power source Owners Manual for modification procedure.

Amend Figure 3-9. Voltage Control Board DIP Switch Setting Label

DVC SWITCH SETTINGS

S2 Si

1 2 1 2 3 4 5

DELTAWELD 300 ON ON ON

DELTAWELD 451 0 ON ON

DELTAWELD 651 0 ON ON

MAXTRON 300, 400 ON ON

MAXTRON 450 ON ON ON

XMT 200/300 ON ON ON

ARC PAK35O ON ON ON

SHOPMASTER 300 ON ON ON

DIMENSION 400 ON L\ t~ ON

PULSTAR 450 ON

O On For Optional Soft Start. Turn Off Si -3.

A On For Optional Hot Start. S-150 864.0

Figure 3-8. Voltage Control Board DIP Switch Setting Label

AMENDMENT TO SECTION 7- ELECTRICAL DIAGRAMS

Amend Diagram 7-1. Circuit Diagram For Robot Interface (See Page 2 on this Errata Sheet)
 242-B
SC-15

1
Interfac
.1

IC
Rob t
For

U 0 /07
Diagr m
CD L

K
0

0
52
69
2

WITH Circuit
J ~p
POSITU liVE
H

C
Q~J~JT 70

7/
IN
FTP?
I

30 .
7-1.
F

D
0

0
Ca4~TE0 PCLSTAP. POSIT1~ MAXTPA
ro

FACT~Y WITH J.PER I.

Diagr m
C 0 ~
6

A
0

0
~ USE
AiPE FcAC I-CVE F~LTAWED.
21

U 0

6/271J8450
L

K 0

J 0

CI 0

C 0

E
0
Z
0 0
C0
V
C 0

PS .~ B 0 4

A 0 /

IT

C P 0 H F S C
AMENDMENT TO SECTION 8 PARTS LIST

Amend Parts List as follows:

Dia. Part Replaced

Mkgs. No. With Description Quantity
23-19 121 594 . .
121 594 . .
CABLE, interconnecting (consisting of) 1
152 370 . . .
HOUSING PLUG & SOCKETS, (consisting of) 1
079 534 CONNECTOR, circ skt push-in 14-l8ga 14
079 739 CONNECTOR, circ clamp str rif 1
110 015 . . .
CABLE, port No. 187/c (order by ft) lOft
141 162 . . .
HOUSING PLUG & PINS, (consisting of) 1
134 731 CONNECTOR, circ pin push-in 14-l8ga 14
079 739 CONNECTOR, circ clamp str rlf 1
25-21 ..
PCi ..
148320 ..
152371 ..
CIRCUIT CARD, voltage control (Effw/KC330157) 1
26-8 072 292 ..
154 098 ..
SHAFT, support spool 1
26- Added .
+605 941 ..
WASHER, flat stl .640 ID x 1.000 OD x 1 4ga thk 1
26- Added .
+141 700 . .
RING, retaining ext .625 shaft x .OSOthk 1

*~Firstdigit represents page no digits following dash represent item no.

+Part of 072 094 Hub & Spindle Assembly.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-884B Page 3
 OM.8849 -
4 92

TABLE OF CONTENTS

Section No. Page No.

SECTION 1 SAFETY. PRECAUTIONS AND SIGNAL WORDS

1-1. General Information And Safety 1

1-2. Safety Alert Symbol And Signal Words 1

SECTION 2 SPECIFICATIONS

2-1. Description 1

SECTION 3 INSTALLATION

3-1. Site Selection 3

3-2. Equipment Installation .3
3-3. Gas/Current Sensing Control Interconnections 4

3-4. Robot Interface Welding Power Source Connections 4

3-5. Robot Interface Robot Control Unit Connections 5

3-6. Pulstar Or Deltaweld And Arc Failure Light Terminal Strip
Connections 7

3-7. Welding Wire Installation 8

3-8. Setting DIP Switches On Voltage Control Board PCi 8
3-9. Voltage Control Board Modification For Early Model Welding
Power Sources 9

SECTION 4 OPERATOR CONTROLS

4-1. Power Switch 10

4-2. Selector Switch 10
4-3. Jog Push Button 10
4-4. Purge Push Button 10
4-5. Voltmeter 10
4-6. Wire Speed Meter 10
4-7. Ammeter 10
4-8. IndicatorLights 11
4-9. Burnback Control ii

SECTION 5 SEQUENCE OF OPERATION

5-1. Input Signals From Robot Control Unit 11

5-2. Output Signals From Robot Interface 11

SECTION 6- MAINTENANCE & TROUBLESHOOTING

6-i. Routine Maintenance 12

6-2. Overload Protection 12
6-3. Reinstallation Of Hub Assembly 13
6-4. Display Board PC4 Meter Check 14
6-5. Circuit Board Handling Precautions 15
6-6. Troubleshooting 15
6-7. Use Of Indicator Lights For Troubleshooting 17
 Section No. Page No.

SECTION 7- ELECTRICAL DIAGRAMS

Diagram 7-1. Circuit Diagram For Robot Interface 19

Diagram 7-2. Wiring Diagram For Robot Interface 20

SECTION 8 PARTS LIST

Figure 8-1. Control Box 22

Figure 8-2. Control Panel, w/Components 24

Figure 8-3. Hub & Spindle Assembly 26
Figure 8-4. Control Box, Gas/Current Sensor 27

LIST OF CHARTS AND TABLES

Table 2-1. Specifications 1

Table 6-1. Troubleshooting 16
 SECTION 1 SAFETY PRECAUTIONS AND SIGNAL WORDS

1-1. GENERAL INFORMATION AND SAFETY 1-2. SAFETY ALERT SYMBOL AND SIGNAL
WORDS
A. General
The following safety alert symbol and signal words are
Information presented in this manual and on various Ia- used throughout this manual to call attention to and den
bels, tags, and plates on the unit pertains to equipment tify different levels of hazard and special instructions.

design, installation, operation, maintenance, and /%~ This safety alert symbol is used with the signal
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equipment.
4~ words WARNING and CAUTION to call atten
tion to the safety statements.

B. Safety
The installation, operation, maintenance, and trouble-
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in-
stalled, operated, and maintained only by qualified per-
sons in accordance with this manual and all applicable
codes such as, but not limited to, those listed at the end
of Section 1 Safety Rules For Operation Of Arc Weld-
ing Power Source in the welding power source Owners
Manual.
WARNING statements identify procedures or
practices which must be followed to avoid seri
ous personal injury or loss of life.
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip
ment.

SECTION 2 SPECIFICATIONS

Table 2-1. Specifications

Dimensions Weight
Component Height Width Depth Net Ship
22-1/2in. 16-1/2in. 6~l/4in.* 38lbs.
Robot Interface
(572 mm) (419 mm) (159 mm) (17 kg)
Gas/Current 4-1/2 in. 5-1/2 in. 10-1/2 in. 5 lbs. Total 61 lbs.
Sensing Control (108 mm) (140 mm) (267 mm) (2.3 kg) (27.7 kg)
SpoolSupport 13-3/4in. 8-3/4in. 8-1/2in. 6Ibs.
Assembly+ (349 mm) (222 mm) (216 mm) (2.7 kg)
Add 2-1/4 in. (57 mm) for brake resistor. +Spool Support without optional wire reel.

*Add 7/8 in. (22 mm) for front panel knob.

2-1. DESCRIPTION PULSTAR 450 welding power source can be used in

The robot interface control to interface with

standard or pulsed mode.
is.designed
an ABB robot and a DELTAWELD series or PULSTAR The gas/current sensing control contains the gas valve
450 welding power source. This unit provides preselec- and current sensing reed relay.
tion and digital display of weld volts and wire feed speed
(using DELTAWELD or PULSTAR models), and peak These components function with the robot system when
amperage (using PULSTAR models only). The using the Gas Metal Arc Welding (GMAW) process.

OM-884 Page 1
 5-1/2 in.
(140 mm)
7-3/4 in.
(197 mm)

in.
(89 mm)

1/2 in. (13 mm)

Dia. 4 Holes

19-1/8 in.
(486 mm)

K 16-1/2 in.
(419 mm)
4-1/2 in.
(108 mm)

II
Side View

9-7/8 in.
(251 mm)
~~.2Hol~s
10-1/2 in.
(267 mm)

ST-hg 644-B ST-ito 320-A

Robot Interface Gas/Current Sensing Control

Overall Dimensions And

Mounting Hole Locations

Inches Millimeters

A 21-7/8 556

B 13-3/4 349

C 3 76

D 2-1/2 63.5

E 3-1/2 88.9

F 4-1/2 114

G 10-11/16 275

ST-080 486-C

Figure 2-1. Dimensional Views

OM-884 Page 2
 SECTION 3 INSTALLATION

3-1. SITE SELECTION (Figure 2-1) 3. The interconnecting cords must be routed so that
they are not caught, pinched, or strained during
Select an installation site which provides the following: welding operations.
1. Correct input power supply (see unit nameplate) 4. One weld output cable must be routed to the Gas/
CurrentSensing control.
2. Shielding gas supply (if applicable)
5. Welding wire must be routed so that it does not
3. Water supply (if applicable)
contact the weld control or any other grounded
4. Adequate ventilation and fresh air supply equipment.
5. No flammables C. Equipment Installation
6. A clean and dry area Obtain appropriate mounting brackets or adapter plates
as necessary and mounting hardware. Prepare struc
7. Proper temperature that avoids extremes of heat ture for equipment installation. Secure weld control,
or cold Gas/Current Sensing control, and all other equipment
onto structures in the welding area.
8. Proper airflow around unit
D. Hub Installation (Figure 3-1)
9. Adequate space to open and remove cover and

wrapper for installation, maintenance, and repair The hub assembly is supplied with the robot interface.
functions. Remove the hub assembly from the shipping carton, and
install it as follows:
Mounting holes provide the capability to install and se
cure the system components in a permanent location. 1. Remove hex nut from end ofhub support shaft.
Figure 2-1 gives overall dimensions and mounting hole
2. Align keyway and insert hub support shaft
layout.
through selected hole in hub support. Hole selec
tion in hub support depends on wire spool size. Be
3-2. EQUIPMENT INSTALLATION
sure the brake washers are properly seated in the

A.
hub.
Supplied Equipment
3. Reinstall hex nut onto support shaft. Tighten hex
The following equipment is supplied as standard and re
nut until a slight drag is felt while turning hub.
quires installation or assembly:
4. Install welding wire according to Section 3-7.
1. Weld Control with Gas/Current Sensing Control
Cord, Motor Cord, and Voltage Sensing Cord
2. Gas/Current Sensing Control

3. Hub and Spindle Assembly

~etainIng Ring
4. Spindle Support
5. 25ft. (8 m) WeldControlWelding Power Source
Interconnecting Cord
srake Washer
6. lOft. (3m) Gas Hose

B. Equipment Location
Hub Assembly
When deciding on equipment location, consider the fol Hex Nut

lowing:
1. The equipment must be mounted to a structure
capable of supporting the weight of the equip
ment.
Hub Support
2. The lead lengths of the cords supplied with the
equipment will limit the area in which the equip
ment can be located. Some cords can be ex ST.126 870

tended by using optional extension cords (check

with welding equipment distributor). Figure 3-1. Hub Assembly Installation

OM-884 Page 3
3-3. GAS/CURRENT SENSING CONTROL INTER 2. Align keyways, insert 16-pin Amp plug into
CONNECTIONS (Figures 3-2, 3-3 And 3-4) matching receptacle RC16 on gas/current sens
ing control, and rotate threaded collar fully clock
A WARNING: ELECTRIC SHOCK can kill. wise.
______
Do not touch live electrical parts.
B. Gas/Current Sensing Control Motor Connec
Shut down unit, welding power source, and tions
robot, and disconnect input power employing
lockout/tagging procedures before making in Align keyways, insert 14-pin plug from motor cord into
terconnections.
matching receptacle RC7 on gas/current sensing con
Lockout/tagging procedures consist of padlock trol, and rotate threaded collar fully clockwise.
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and C. Weld Cable Connections
red-tagging circuit breaker or other disconnect
ing device. For Electrode Positive/Reverse Polarity, route cable
from welding power source POSITIVE weld output ter
There are several cords supplied for gas/current sens
minal, through the gas/current sensing control, to the
wire drive assembly, and connect cable to weld cable
ing control interconnections. Examine and select the
terminal (see Motor/Drive Assembly Owners Manual for
proper cord for the following connections.
location).

D. Gas Connections

Connect hose from gas regulator/flowmeter. (customer

00000
supplied) at gas source to IN fitting on gas/current sens
)0000( ing control. Connect gas hose from wire drive assembly
00000
)0000( to fitting on gas/current sensing control. The gas flow
00000
)0000(
must be accurately controlled by a regulator/flowmeter
00000
at the source.
)0000(
00000
)0000(
00000
)0000( 3-4. ROBOT INTERFACE WELDING POWER-

0 0~0 0
0 ~ 0 SOURCE CONNECTIONS (Figures 3-3, 3-4,
Gas/Current Sensing
00000
Control Receptacle RC9. And 3-5)

WARNING: ELECTRIC SHOCK kill.

115 Volts AC/Contactor
Control Receptacle RC13
Including Output Control
For DELTAWELD Models
a Do not touch live electrical parts.
can

Shut down unit, welding power source, and

robot, and disconnect input power employing
lockout/ta gging procedures before making in
terconnections.

Strain Relief Lockout/tagging procedures consist of padlock

ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
Arc Sensing
Receptacle RC12 There are several cords used for interconnections be
tween the robot interface and
welding power source. Ex
amine and select the proper cord for the following con
nections.
Welding Power Source
InterfaceReceptacle RCI7 A. Arc Sensing Connections
1. Align keyway, insert four-socket Amphenol plug
into matching receptacle RC12 on robot inter
Figure 3-2. Right Side View face, and rotate threaded collar fully clockwise.

A. Robot Interface Gas/Current Sensing Control 2. Connect lead with ring terminal to welding power
Connections source POSITIVE weld output terminal as shown
on Figure 3-4.
1. Align keyways, insert 14-pin Amp plug into
matching receptacle RC9 on robot interface, and 3. Connect lead with clamp to welding power source
rotate threaded collar fully clockwise. NEGATIVE weld Output terminal.

OM-884 Page 4
 Weld Cables

Arc Failure Connection Electrode

In Robot Control Unit (Welding Wire)
cord

Wire Drive
Assembly S 0290

Figure 3-3. Interconnection Diagram For PULSTAR Welding Power Source

Positive Weld Output C. 115 Volts AC/Contactor Control Connection

Terminal On Power Sour
And DELTAWELD Output Control Connection
I. Align keyway, insert 14-socket plug into matching
receptacle RC13 on robot interface, and rotate

threaded collar fully clockwise.

Lock 2. Align keyway, insert 14-pin plug into matching re

ceptacle on welding power source, and rotate
Nut
thread collar fully clockwise.

3. Place welding power source OUTPUT (CON

TACTOR) switch in the REMOTE 14 position.
4. For DELTAWELD units, place welding power

Arc Sensing Lead source VOLTAGE switch in the REMOTE 14 posi

Ring Terminal Location STI21 083.A
tion.

3-4. Arc Lead And Weld Cable 35. ROBOT INTERFACE ROBOT CONTROL
Figure Sensing
Locations UNIT CONNECTIONS (Figures 3-2, 3-3, And
3-4)
WARNING: ELECTRIC SHOCK kill.
B. Output Control Connections To PULSTAR

Align keyway, insert 1 0-socket plug into matching

a can

Do not touch live electrical parts.

Shut down unit, welding power source, and

receptacle RC15 on robot interface, and rotate
robot, and disconnect input power employing
threaded collar fully clockwise.
lockout/tagging procedures before making in
terconnections.
2. Align keyway, insert 10-pin plug into matching re
ceptacle on welding power source, and rotate Lockout/tagging procedures Consist of padlock
threaded collar fully clockwise. ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
3. Place welding power source VOLTAGE switch in red-tagging circuit breaker or other disconnect
the REMOTE 10 position. ing device.
OM-884 Page 5
 Robot
Robot Interface Connections Interface
To Robot Control Unit

Weld cables

Shielding Gas
Supply

Arc Failure Connection Electrode

In Robot Control Unit Motor
(Welding Wire)
Control
Cord

Wire Drive
Assembly Ref. S-0290

Figure 3-5. Interconnection Diagram For DELTAWELD Welding Power Source

1. Obtain a proper Cord and 24-socket Amphenol Socket G: Gas Control; +24 volts dc input from robot
plug (not supplied). control unit with respect to Socket J (Circuit
Common).
2. Connect conductors at one end of cord to appro
Socket H: Wire Stick Check; +24 volts dc input from
priate sockets in plug.
robot control unit with respect to Socket J
3. Align keyway, insert 24-socket plug into matching (Circuit Common).
receptacle on robot interface, and rotate threaded Socket J: Circuit Common for Sockets E, F, G, and H;
collar fully clockwise. all circuit voltages referenced to this point.

4. Route and connect conductors at remaining end Socket K: Jog Forward; momentary contact output to
of cord to the robot control unit. robot control unit with respect to Socket 0
(Digital Common).
The input and output signals at the sockets of receptacle
Socket L: Set-Up and Weave Set-Up output to robot
AC 17 by means of the robot interface control circuitry
control unit with respect to Socket 0 (Digital
are as follows:
Common).
Socket A: Provides connection to 2TA; for customer Socket M: Weave Set-Up output to robot control unit
use.
with respect to Socket Q (Digital Common).
Socket B: Current Detect output to robot control unit Socket N: Wire Stick Signal output to robot control unit
withrespect to~Socket D; isolated CR1 con with respect to Socket Q (Digital Common);
tacts rated 1A at 120 VAC. indicates wire is stuck to work; isolated CR2
contacts rated 1A at 120 VAC.
Socket D: Current Detect output to robot control unit
with respect to Socket B; isolated CR1 con Socket P: Weld Standby output to robot control unit
with respect to Socket 0 (Digital Common);
tacts rated at 1A at 120 VAC.
indicates robot interface is in standby; iso
Socket E: Contactor Control; +24 volts dc input from lated CR5 contacts rated 3A at 120 VAC.
robot control unit with respect to Socket J Socket 0: Digital Common for Sockets K, L, M, N, and
(Circuit Common). P.

Socket F: Jog Forward; +24 volts dc input from robot Socket R: + Peak Amps; 0-10 volts dc input from robot

control unit with respect to Socket J (Circuit control unit with respect to Socket S (analog
Common). common) equals 0-500 amperes dc output.

OM-884 Page 6
Socket S: Peak Amps; analog common for Socket A If operation with a DELTAWELD welding power source is
(+ Peak Amps). desired, reconnect jumper link between 2TG and 2TH
on terminal strip 2T.
Socket W: Wire Feed Speed; analog common for
Socket X (+ Wire Feed Speed). B. Arc Failure Light Connections (Figure 3-7)
Socket X: Wire Feed Speed; 0-10 volts dc input from WARNING: Read and follow safety informa
+

robot control unit with respect to Socket W a tion at beginning of Section 3-6 before pro
ceeding.
(analog common) equals 0-1 000 1PM.
Socket Y: Arc Volts; analog common for Socket Z (+ The ARC FAILURE light on the robot interface front pan
Arc Volts). el is turned on and off by a signal from the robot control
unit. Obtain proper length of 18 gauge/2-conductor cord
Socket Z: + Arc Volts; 0-10 volts dc input from robot for this connection, and proceed as follows:
control unit with respect to Socket Y (analog
common) equals 0-50 volts dc output. 1. For robot control units when 24 vdc is used (Fig
ure3-7):
IMPORTANT: The remaining sockets in the receptacle
are not used. a. Route cord through strain relief on right side
panel of robot interface, and make proper con
nections to 1TL and 1TM.

b. Route and connect remaining end of cord to

weld alarm terminal and ground connection at
the robot control unit.

c. Connect +24 vdc to common relay contact ter

minal.

Robot Control Unit Robot Interface

S.0291
Common Terminal Weld Alarm Terminal
Figure 3-6. Front View Of 24-Socket Amphenol If So Equipped So Equipped

Receptacle With Socket Designations

3-6. PULSTAR OR DELTAWELD AND ARC FAIL +24VDC

URE LIGHT TERMINAL STRIP CONNEC

TIONS

4~ WARNING: ELECTRIC SHOCK can kill.

Do not touch live electrical parts.
1 TM
Shut down unit, welding power source, and
robot, and disconnect input power employing
lockout/tagging procedures before making in
Robot Control Unit
terconnections.

Lockout/tagging procedures consist of padlock Common Terminal Weld Alarm Terminal

If So Equipped If So Equipped
ing line disconnect switch in open position, re
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
ing device.
To Voltage Source

There terminal 115VAC, 24VAC, 24VDC)

are two strips inside the robot interlace
for control connections. Loosen screws on strain relief
Isolation Relay CR1
on unit side panel if applicable, open front panel ac
right
cess door, and locate appropriate terminal strip for con
nections. Tighten screws on strain relief if necessary,
and close and secure front panel access door when pro Robot Control Robot Interface
cedure is finished.
CR1 ITL

A. Jumper Link Reconnection For DELTAWELD #24VDC ~O--j ~O

Welding Power Source
WARNING: Read and follow safety informa
a tion at
beginning of Section 3-6 before pro
ceeding.
Arc Failure
1TM Indicator Light
The jumper link connected between 2TH and 2TJ on ter
minal strip 2T is shipped from the factory for operation S~O292

with a PULSTAR 450 welding power source. Figure 3-7. Arc Failure Light Connections
OM-884 Page 7
 2. For robot control units when 115 or 24 vac, or 24
vdc is used (Figure 3-7):

a. Route cord through strain relief on right side

panel of robot interface, and make proper con

nections to 1TL and 1TM.

b. Obtain a 115 or 24 vac, or 24 vdc isolation relay

CR1, and instalLinto robot control.

c. Route and connect remaining end of cord to one

side of the normally-open robot control relay
contact and ground.
d. Connect +24 vdc to remaining side of normally-
open robot control relay contact.
e. Connect a lead from one side of robot control ST.127 308

coil to weld alarm terminal.

Figure 3-8. Optional Wire Reel And Reel-Type Wire
f. Connect proper voltage source (115 vac, 24 Installation
vac, or 24 vdc) between common terminal and
3-8. SETTING DIP SWITCHES ON VOLTAGE CON
remaining side of robot control relay coil.
TROL BOARD PCi (Figure 3-9)
3-7. WELDING WIRE INSTALLATION CAUTION: INCORRECT DVC BOARD DIP

A. Installation Of Spool-Type Wire (Figure 3-8)

a SWITCH POSITION can cause equipment
malfunction.
DVC DIP switch is factory set for operation
1. Remove retaining ring.
with Deltaweldfi 451 welding power source.
2. Slide spool of wire onto hub so that wire feeds off
See Figure 3-9 for DVC DIP switch setting
bottom of spool. when using another welding power source.

3. Rotate spool until hole in spool aligns with pin in DIP switch Si and S2 on voltage control board PCi al
hub. Slide spool onto hub until it seats against low setting the proper command signal voltage level for
back flange of the hub. controlling voltage output at a welding power source. To
4. Reinstall
change factory set position of DIP switches from a Delta-
retaining ring onto hub.
weldfi 451 to another welding power source, proceed as
B. Installation Of Optional Wire Reel And Reel- follows:
Type Wire (Figure 3-8) WARNING: ELECTRIC SHOCK kill.
1. Remove retaining ring and, if applicable, wire reel a Do not touch live electrical parts.
can

assembly from hub.

Shut down unit, welding power source, and
wire feeder, and disconnect in put power em
2. Lay wire reel assembly flat on a table or floor.
ploying lockout/tagging procedures before
3. Remove spanner nut from wire reel assembly. setting DIP switches.
Lockout/tagging procedures consist of padlock
4. Remove wire retainer, and install wire onto wire
ing line disconnect switch in open position, re
reel. Be sure that wire feeds off bottom of reel. moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect
5. Reinstall wire retainer and spanner nut onto wire
ing device.
reel.
ELECTROSTATIC DISCHARGE (ESD) can
6. Slide wire reel assembly onto hub, and rotate as damagecircuit boards.
sembly until hub guide pin is seated in reel. Put on properly grounded wrist strap BE
FORE handling circuit boards.
7. Reinstall retaining ring onto hub.
Transport circuit boards in proper static
C. Adjustment Of Hub Tension (Figure 3-1) shielding carriers or packages.
Check the hub tension Perform work only at a static-safe work area.
by slowly rotating the wire spool
or reel. The wire should unwind freely, but hub tension
1. Loosen screw securing front access door on weld
should be sufficient to keep wire taut and prevent back
lash when the wire feed stops. If adjustment is required,
control, and open door.
loosen or tighten the hex nut on the end of the hub sup 2. Locatevoltage control board PCi in left portion of
port shaft accordingly. component mounting panel inside weld control.
OM-884 Page 8
 DVC SWITCH SETTINGS

S2 Si

1 2 1 2 3 4 5

DELTAWELD 300 ON ON ON

DELTAWELD 451 0 ON ON

DELTAWELD 651 0 ON ON

MAXTRON 300, 400 ON ON

MAXTRON 450 ON ON ON

XMT 200/300 ON ON ON

ARC PAK 350 ON ON ON

SHOPMASTER 300 ON ON ON

DIMENSION 400 ON A A ON

O On For Optional Soft Start. Turn Off Si -3.

A On For Optional Hot Start. S-150 864-A

Figure 3-9. Voltage Control Board DIP Switch Setting Label

3. Set position of DIP switches Si and S2 according 1. Loosen screw securing front access door on weld
to label inside unit and Figure 3-9 for appropriate control, and open door.
welding power source.
2. Locate voltage control board PCi in left portion of
4. Close and secure front access door.
component mounting panel inside weld control.

3-9. VOLTAGE CONTROL BOARD MODIFICA 3. Mark and disconnect leads from voltage control
TION FOR EARLY MODEL WELDING POWER board PCi.
SOURCES (Figure 3-10)
4. Mark and disconnect plugs from PCi.
If the weld control unit is to be used with
early model
an
Deltaweld 450 or 650 welding power source prior to seri 5. Note position of circuit board and remove from
al number JJ400026, proceed as follows: unit.

6. Place circuit board on a stationary work surface

WARNING: ELECTRIC SHOCK kill.
a Do not touch live electrical parts.
can

7.
so

Locate
that component side is

jumpers Ji thru J8
facing up.

on surface of board
Shut down unit, welding power source, and
(see Figure 3-10).
wire feeder; and disconnect input power em
ploying lockout/tagging procedures before 8. Use a sharp tool to remove sealant coating from
making circuit board modifications. all
jumper locations, and remove foil jumper be
Lockout/tagging procedures Consist of pad tween pads at J2, J4, J6, and J8.
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off 9. Apply a small amount of solder to bridge the foil
and red-tagging circuit breaker or other discon
pads at jumper Ji, J3, J5, and J7.
necting device.
ELECTROSTATIC DISCHARGE (ESD) can
10. Apply a sealant coating over all jumper locations.
damage circuit boards.
ii. Reinstall circuit board into unit in its original posi
Put on properly grounded wrist strap BE
tion.
FORE handling circuit boards.

Transport circuit boards in proper static- 12. Reconnect marked leads and plugs to appropri
shieldingcarriers or packages. ate locations.

Perform work only at a static-safe work area.

13. Close and secure front access door.

OM-884 Page9
 Jumper Jumper Jumper
J2 JI 13

Jumper Jumper Jumper Jumper

R&. SD-i 49 322
J8 J7 J6 J5

Figure 3-10. Jumper Locations On Voltage Control Board PCi

SECTION 4 OPERATOR CONTROLS

4-1. POWER SWITCH (Figure 4-1) purges the shielding gas line of the gun. The PURGE
POWER switch in the ON push button allows the flow meter to be adjusted without
Placing the position energizes
the robot interface. The interface must be on for the ro
energizing the welding circuit.
bot to weld. Placing the POWER switch in the OFF posi
tion shuts down the interface. 4-5. VOLTMETER (Figure 4-1)

4-2. SELECTOR SWITCH (Figure 4-1)

The voltmeter displays weld voltage to the nearest tenth
of a volt while welding and preset voltage while idling.
The SELECTOR switch has three positions: RUN, SET
UP, and SET-UP WEAVE. Consult robot Owners Manu
4-6. WIRE SPEED METER (Figure 4-1)
al or robot manufacturer for SELECTOR switch func
tions.
The wire speed meter displays preset wire feed speed to
the nearest inch per minute while welding and idling. Ac
4-3. JOG PUSH BUTTON (Figure 4.1) tual and preset wire feed speed are the same due to the
The JOG push button is a momentary-contact switch. wire feed speed feedback circuit.
Consult robot Owners Manual or robot manufacturer for
JOG push button function.
4-7. AMMETER (Figure 4-1)
4-4. PURGE PUSH BUTTON (Figure 4.1)
The ammeter displays weld peak amperage to the near
The PURGE push button is a momentary-contact est ampere while welding and preset peak amperage
switch. This switch energizes the gas solenoid and while idling.

OM-884 Page 10
 Fuse (See Section 6-2)

Gas Indicator
Light

Contactor Indicator
Light

Wire Feed Current Indicator Arc Failure Jog Push

Indicator Light Light Indicator Light Button Switch Ref. ST.119 645-A

Figure 4-1. Front Panel Controls

4-8. INDICATOR LIGHTS (Figure 4-1) burn back to a point where it neither sticks to the work-
piece or the contact tube. To adjust burnback time pro
There are five indicator lights on the interface. These are
ceed as follows:
visual indications of various process functions.
WARNING: ELECTRIC SHOCK kill.
The GAS
to
light turns on when the gas
indicate shielding gas flow.
valve is energized a Do not touch live electrical parts.
can

Shut down unit, welding power source, and

The CONTACTOR light turns on when the welding pow robot, and disconnect input power employing
er source contactor is energized to indicate that weld lockout/tagging procedures before ins pect
output is available. ing or installing.
The WIRE FEED light turns on when the wire drive motor Lockout/tagging procedures consist of pad

is indicate that wire is feeding.

locking line disconnect switch in open position,
energized to
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon
The CURRENT light turns on when the current detect
relay is energized to indicate that an arc is established. necting device.
ELECTROSTATIC DISCHARGE (ESD) can
The ARC FAILURE light turns on only when properly
damage circuit boards.
connected according to instructions in Section 3-6, and
Put on properly grounded wrist strap BE
there is an arc outage while welding.
FORE handling circuit boards.

4-9. BURNBACK CONTROL Perform work only at a static-safe work area.

Burnback is provided by potentiometer R32 on Interface 1. Open front access door on weld control and lo
Circuit Board PC3 inside the unit. cate PC3.

The burnback circuitry in this unit keeps the welding wire 2. Locate potentiometer R32 in upper left corner of
from sticking to the workpiece after the arc is extin PC3.
guished. This circuitry keeps weld output on the welding
3. Rotate R32 clockwise to increase burnback time.
wire from 0 to 0.25 seconds after the wire has stopped
feeding. This delay action permits the welding wire to 4. Close and secure front access door.

SECTION 5 SEQUENCE OF OPERATION

5-1. INPUT SIGNALS FROM ROBOT CONTROL to initiate a check to see if the wire is stuck to the work-
UNIT (Figure 5-1) piece at the end of the weld.

5-2. OUTPUT SIGNALS FROM ROBOT INTER

The robot interface receives input signals for contactor FACE (Figure 5-1)
control, gas control, jog, welding volts, wire speed (using The robot interface sends output signals to the robot
DELTAWELD or PULSTAR models), and peak current control unit for current sense, wire stuck, and weld
(using PULSTAR models only). It also receives a signal standby.
OM-884 Page 11
 Wire Feed Speed 0-IOV = 0-1000 1PM

Output Volts 0-1OV = 0-50V

Peak Amps 0-1OV = 0.500 Amps Output

Robot Control
Unit To Gas Control
Computer
Intertace Contactor Control

Jog Fwd.

Wire Stuck Check

~o~
Computer
Interface ] Power On, Standby
To Robot
Current Detect
Control Unit
~Wire Stuck

Output Voltage
Shielding Gas

Wire Feed

Normal
Abnormal ST-094 382-e

Figure 5-1. Input And Output Signal Timing Chart

SECTION 6 MAINTENANCE & TROUBLESHOOTING

6-1. ROUTINE MAINTENANCE 1. Repair or replace, as required, all hose and cable;
give particular attention to frayed and cracked insu
IMPORTANT: Every six months inspect the labels on lation and areas where it enters equipment.
legibility. All precautionary labels must be
this unit for
maintained in a clearly readable state and replaced 2. Remove grease and grime from components; mois

when necessary. See Parts List for part number of ture from electrical parts and cable.

precautionary labels.
6-2. OVERLOAD PROTECTION
WARNING: ELECTRIC SHOCK kill.
Usage shop conditions determine the frequency
and
and type of maintenance. At minimum, inspect equip
a Do not touch live electrical parts.
can

ment every three months as follows: Shut down unit, welding power source, and
robot, and disconnect input power employing
WARNING: ELECTRIC SHOCK kill. lockout/tagging procedures before inspect
a Do not touch live electrical parts.
can

ing, maintaining, or servicing.

Lockout/tagging procedures consist of pad
Shut down unit, welding power source, and
robot, and disconnect input power employing locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
lockout/tagging procedures before inspect
servicing.
red-tagging circuit breaker or other disconnect
ing, maintaining, or
ing device.
Lockout/tagging procedures consist of pad
INCORRECT FUSE can damage unit.
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and Use only replacement fuse of same size, type,
red-tagging circuit breaker or other disconnect and rating (see Parts List).
ing device.
A. Wire Drive Motor Circuit Breaker CB1 (Figure
MOVING PARTS can cause serious injury.
4-1)
Keep away from moving parts.
WARNING: Read and follow safety informa-~
HOT SURFACES
Allow
can cause severe burns. a tion at beginning of Section 6-2 before pro
ceeding.
cooling period before servicing.
Maintenance to be performed only by qualified Circuit breaker CB1 protects the wire drive motor from
persons. overload If CB1 opens, the wire feed motor would stop.
.

OM-884 Page 12
Should a motor overload occur and CB1 open, proceed 4. Install fuse with fuse holder cover back into unit.
as follows:
5. Depress and rotate fuse holder cover clockwise
1. Check for jammed wire or clogged gun liner, and until cover is secure.

correct problem. If wire jams often, replace gun

liner. 6-3. REINSTALLATION OF HUB ASSEMBLY (Fig

2. If motor overload occurs often, repair or replace

ure 6-1)
wire drive motor. If it becomes necessary to replace part or all of the hub
assembly, reinstall the new hub assembly as follows:
3. Check for binding drive gear or misaligned drive
rolls, and correct problem. 1. Remove hub assembly from hub support, and
Reset circuit breaker the button. A disassemble discarding worn or broken parts.
4. by depressing
cooling period may be necessary before the cir- Slide the
2. following items onto the hub support
cuit breaker can be reset. shaft in order given.
5. Resume operation. a. Spring
B. Main Fuse Fl (Figure 4-1) b. Keyed Washer
WARNING: Read and follow safety informa
a tion at beginning of Section 6-2 before pro
ceeding.
c.

d.
Fiber Washer

Brake Washer

Fuse Fl protects the robot interlace from an internal e. Hub

short or excessive overload. If fuse Fl opens, the robot
f ~
Brake Washer
interface shuts down. If the fuse opens, correct the prob-
lem and replace Fl as follows: g. Fiber Washer

1. Depress and rotate fuse holder cover counter- 3. Align keyway, and insert hub support shaft
clockwise, through selected hole in hub support.
2. Pull out fuse with cover when fuse holder cover is 4. Install hex nut onto hub support shaft. Tighten hex
free. nut until a slight drag is felt while turning hub.
3. Insert new fuse into fuse holder cover. 5. Install welding wire according to Section 3-7.

Retaining Ring Retainer*

Spanner Nut*

Spring

Keyed Washer

Brake Washer

Hub Support
Shaft

Fiber Washer
/
Hub
~ Fiber Washer

Hex Nut

Brake Washer

Hub Support
*Optlonal

ST.127 328

Figure 6-1. Hub And Reel Assemblies

OM-884 Page 13
 Input Command For In put Command For
Wire Speed 1PM Meter Volts Meter 0.5V 50V
=

0.8V = 800 1PM

Input Command For

Ammeter -0.IV = bOA
Power Supply For
Volts Meter And
Ammeter 5VDC

Ref. SO-117 838.8

Figure 6-2. Display Board Meter Checks

6-4. DISPLAY BOARD PC4 METER CHECK (Fig Transport all static-sensitive components in
ure 6-2) proper static-shielding carriers and pack
Check pointsare provided on the display board PC4 for ages.
checking power supply and input command for the me Perform work only at a static-safe work area.

ters.

1. Open robot interface access door.

4~ WARNING: ELECTRIC SHOCK can kill.

_____ Do not touch live electrical parts. 2. Locate display board PC4.
Be sure that personnel performing testing
procedures are familiar with and follow stan 3. Check voltage according to Figure 6-2.
dard safety practices.
4. If a meter power supply and command voltage is
Shut down unit before making or changing
correct and the meter is not working, replace the
meter or test equipment lead connections.
meter (see Section 6-5).
ELECTROSTATIC DISCHARGE (ESD) can
damage electronic components. 5. If the power supply or command voltage is incor
Put properly grounded wrist strap
on a BE rect, replace display board PC4 (see Section
FORE handling circuit boards. 6-5).

Board PC4

Receptacle

Ref. ST-119647C

FIgure 6-3. LocatIon Of Display Board And Components

OM-884 Page 14
 Receptacle RCt

RC28

Receptacle RC29
Voltage Board PCi
(DELTAWELD) Receptacle RC3O ST-119 648.C

Figure 6-4. Location Of Circuit Boards And Components

6-5. CIRCUIT BOARD HANDLING PRECAUTIONS EXCESSIVE PRESSURE can break circuIt
board.
4~ WARNING: ELECTRIC SHOCK can kill.
Use only minimal pressure and gentle move
_____ Do not touch live electrical parts.
ment when disconnecting or connecting
Shut down unit, welding power source, and board plugs and removing or installing board.
robot, and disconnect input power employing
lockout/tagging procedures before inspect 6-6. TROUBLESHOOTING
ing, maintaining, or servicing.
WARNING: ELECTRIC SHOCK kill.
Lockout/tagging procedures consist of padlock
ing line disconnect switch in open position, re
a can

Do not touch live electrical parts.

moving fuses from fuse box, or shutting off and Shut down unit, welding power source, and
red-tagging circuit breaker or other disconnect robot, and disconnect input power employing
ing device. lockout/tagging procedures before inspecting
or servicing.
CAUTION: ELECTROSTATIC DISCHARGE
a (ESD) damage circuit boards.
can

Put on properly grounded wrist strap BE

Lockout/tagging procedures consist of pad
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off and
FORE handling circuit boards.
red-tagging circuit breaker or other disconnect
Transport circuit boards in proper static- ing device.
shielding carriers or packages. MOVING PARTS can cause serIous Injury.
Perform work only at a static-safe work area. Keep away from moving parts.
INCORRECT INSTALLATION or misaligned HOT SURFACES can cause severe burns.
plugs can damage circuit board. Allow cooling period before servicing.
Be sure that plugs are properly installed and Troubleshooting to be performed only by
aligned. qualified persons.

OM-884 Page 15
It is assumed that the unit was properly installed accord- this robot interface. Use this table in
conjunction with the
ing to Section 3 of this manual, the operator is familiar circuit diagram while
performing troubleshooting proce
with the function of controls, the robot interface was dures. If the trouble is not remedied after performing
working properly, and that the trouble is not related to the these procedures, contact the nearest Factory Author-
welding process. ized Service Station. In all cases of equipment malfunc
The following table is designed to diagnose and provide tion, strictly follow the manufacturers procedures and
remedies for some of the troubles that may develop in instructions.

Table 6-1. Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

No arc voltage control. Output control connections. Check and secure connections (see Section
3-4).
Arc sensing connections. Check and secure connections (see Section
3-4).
Voltage Board PCi not working if Replace PCi (see Section 6-5).
using Deltaweld power source.
Voltage Board PC8 not working if Replace PC8 (see Section 6-5).
using Puistar power source.

Incorrect robot command voltage. Check robot command voltage at Isolation Board
PC5. Command voltage should be 0-10 vdc be
tween sockets Y (common) and Z at RC17.

Incorrect robot peak command cur- Check robot peak command current at Isolation
rent. Board PC5. Peak command current should be
0-10 vdc between sockets R and S (Common) at
RC17.

Robotmoveswhenwelding Wire stick connection. Be sure that leads from robot are connected to
wire is stuck. sockets H and N at RC17.

Wire speed (1PM) meter Incorrect robot command voltage. Check robot command voltage at Motor Board
goes to zero. PC2. Signal should be 0-10 vdc between pins K
~
and B (common) at RC5.

Motor Board PC2 not working. Replace PC2 (see Section 6-5).
Unit does not operate. Fuse Fl Open. Check Fl, and replace if necessary (see Section
6-2). Correct overload problem before continu
ing operation.
Circuit breaker CB1 tripped. Check Fl, and replace if necessary (see Section
6-2). Correct overload problem before continu
ing operation.
No meter display. Meter not working. Use check points on Display Board PC4 to deter
mine if power is available to meter (see Section
6-4). If check points are okay, replace meter (see
Section 6-5).

Display Board PC4 not working. Use check points to determine if power is avail
able (see Section 6-4). If check points do not test
okay, replace PC4 (see Section 6-5).
No wire feed. Robot signal. Check input signal from robot to Motor Board
PC2. Signal should be 0-10 vdc between pins K
and B (common) on RC5.

Relay CR1 not working. Replace CR1.

Motor Board PC2 not working. Replace PC2 (see Section 6-5).
Wire feeds at maximum Tach board PC7 at wire drive motor Replace PC7 (see motor/drive assembly Own
only. not working. ers Manual).

OM-884 Page 16
6-7. USE OF INDICATOR LIGHTS FOR TROUBLESHOOTING

On -
Gas Indicator Light Off

1~
Gas flows: Gas does not flow: Gas flows: Gas does not flow:

System normal (on.) Check gas valve operation. Check gas valve operation System normal (off).
and gas line for leaks.
Check interface board PC3.

On ~
Contactor Indicator Light ~
Off

I!
Contactor closed: Contactor open: Contactor closed: Contactor open:

System normal (on). Check interconnecting cords. Check display board PC4. System normal (off).
Check interface board PC3.

On Wire Feed Indicator Light Off

Wire feeds: Wire does not feed: Wire feeds: Wire does not feed:

System normal (on). Check circuit breaker CB1. Check input signal from System normal (off).
robot to motor board PC2.
Check relay CR1.
Signal should be 0-10 vdc
Check interface board P03. betwe~n pins K and B
(common) at RC5.
Check motor board P02.

On Current Indicator Light Off

Arc started: No arc: Arc started: No arc:

System normal (on). Replace reed relay. Replace reed relay. System normal (off).

~
On Arc Failure Indicator Light ~
Off

1~
No arc: Arc started: No arc: Arc started:
Check weld Check signal from robot. Normal during idling. Normal while welding.
parameters. Signal should be 24 vdc
between terminals 1 TL
and 1 TM.
Check display board P04.

OM-884 Page 17
 NOTES

OM-884 Page 18
 U) m C-) -l 0 z 7J m r m C) -I C-) r a C) I, U)

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242-A
P
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51
S

H ~~P SC-i
F No.
C -.4C P2~
0

6
P1~ ~ Diagr m
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Circuit

Interfac
Robot
For

H
Diagr m
0 Circuit
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1.
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K WITH
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H
2 P0SIT&1 list
Fl? 7-1.
IN
I

S
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0 COEIK P15*6. POSITl? HAXTIDA

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Diagram
27/1 FACT0V WITH .DQR
0
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A
L~
/5J7 &WEP Fl? ICVE OELTA~ID.
2T0
H 0

L 0 /0 /
K 0 /2
.2 0 26

WA H 0

0
6
JI
V
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S

F 27
E ~ 22

VT 01 III
0 0 62
0
C
6/

PS P 0 1

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IT

S .2 P 0 H F C C

0 00 00 a ~0 0) To ID To
 I 181 C 0 El F
I NI 0 NI I I
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~ _i~~
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PC3

P~G~e
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~ U.
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piOO
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-
9 7 9 9 5 ~ 9 ~ 9~7~ wIT flNJ7{~D C 1
____________
~ ~I~i lpINI4ILINIJl~IclNIEI0
_________________
C BIN
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~
~~~~ ~
-i~: ~1
r~
j r
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: 9 ~

ONe) T-J) T
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olol 0! J_~J_?1 ~L
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__________

I4ABCOEFG ~999559 ~

~
B

iT 99~9W5~ ~
C

~~ ~ ~~
I20II~-N]

Diagram 7.2. Wiring Diagram For Robot Interface

OM-884 Page 20
PC 3

Wiring Diagram No. SD-i 51 243-A

OM-884 Page 21
 SECTION 8 PARTS LIST

6
1

7,

17

35
29

28

27
tiA. I 21
34
26
33

32
31
25
30

SC.119 047.A

Figure 8-1. Control Box

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 8-1. Control Box

1 ..
PLG24... 084 198 HOUSING, term header 6 pin 1
081 378 TERMINAL, female lskt 22-18 wire 6
2.. PLG2O... 081 379 HOUSING, term header 12 pin
081 378 TERMINAL, female lskt 22-18 wire 12
..3...PC4.... 149 339 CIRCUIT CARD, meter (consisting of)
073 756 STAND-OFF, No. 6-32 x .625 Ig 7
5 ... PB1,2 021 105 SWITCH, PB 2
..6...CB1.... 011 991 CIRCUIT BREAKER, man reset 1 P 1 .5A 250V
011 609 SWITCH, tgl SPDT 15A 125V
086 895 SWITCH, rotary
073 487 NUT, speed No. 2 2
10 132 481 CABINET, control 1
11 057 084 BUSHING, snap-in .250 ID x .375mtg hole 1
12 079 683 HEAT SINK, resistor 1
13 030 949 HEAT SINK 1
030941 RESISTOR, WW fxd 100W 5 ohm 1
15 056 170 SHIELD, resistor 1
16 010 193 TUBING, .375 00 x l8ga wall x .250 4
17 010 199 TUBING, .275 IDx.O48walIxl 2

OM-884 Page 22
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 8-1. Control Box (Continued)

109041 CABLE, interconnecting (consisting of) 1
PLG9 ...
047636 HOUSING PLUG & PINS, (consisting of)
079 535 TERMINAL, male 1 pin 18-14 wire 14
079 739 CLAMP, cable strain relief sz 17 .703 OD 2
096813 CABLE, 1 8ga 15/c (order by ft) 18ft
PLG16 ...
048598 HOUSING PLUG & SOCKETS, (consisting of)
079 534 TERMINAL, female lskt 18-14 wire 16
19 121594 CABLE, interconnecting (consisting of)
116964 CLAMP, cable 97-3057-1012 2
110015 CABLE, port No. 18 7/c (order by ft) lOft
111 123 HOUSING PLUG & SOCKETS
20 089 870 CABLE, interconnecting (consisting of)
039716 PLUG, 10 pin MS-3106A-18-1P
073 332 CLAMP, cable 97-3057-10 2
073140 CABLE, No.18 10/c (order by ft) lOft
PLG15. 089 647 PLUG, i0skt MS-3106A-18-1S
21 010916 CONNECTOR, clamp .750
22 049 989 CABLE, volt-sensing (consisting of) 1
PLG12. 073 686 PLUG, 4skt97-3106A-14S-2S
039 828 CLAMP, cable AN-3057-6
600 848 WIRE, strd i2ga (order by ft) 35ft
604109 WIRE, strd l6ga (order by ft) l9ft
601 226 INSULATOR, vinyl clamp
601 228 CLAMP, universal 25A
600 750 TERMINAL, ring tongue 1/2 stud I
23. Fig 8-2 CONTROL PANEL
24. RC17 094592 RECEPTACLE, 24skt MS-3102A-24-28S
25. RC12 076624 RECEPTACLE, 4 pin MS-3102A-14S-2P
26. C2-5. 028291 CAPACITOR, cer disc .1 uf 500VDC 4
27. RC15 089646 RECEPTACLE, lOpinMS-3102A-18-1P
28. RC13 094480 RECEPTACLE, 14 pin MS-3102A-20-27P
.29. RC9. 047637 HOUSING RECEPTACLE & SOCKETS, (consisting of) 1
079534 TERMINAL, female lskt 18-14 wire 14
30. +116 969 DOOR, access cabinet 1
045852 CLIP, component .687dia mtg adh back 2
134327 LABEL, warning general precautionary 1
31 NAMEPLATE, (order by model and serial number)
32. 097922 KNOB, pointer 1
33. 046432 HOLDER, fuse
34. 010855 RETAINER, screw No. 2
010853 FASTENER, screw No. 2 2
..35. Fl *012 655 FUSE, mintr gl 1OA 250V 1
36. 089032 LENS, red 4341
071006.. CABLE, motor (consisting of)
047636 HOUSING PLUG & PINS, (consisting of) 1
079 535 TERMINAL, male 1 pin 18-14 wire 14
079 739 CLAMP, cable strain relief sz 17 .703 OD 2
073139 CABLE, No. 16 6/c (order by ft) lOft
071 892 RECEPTACLE w/SOCKETS, (consisting of)
079534 TERMINAL, female lskt 18-14 wire 14
048144.. TERMINAL, male plug keying 2
056462 HOSE, gas (consisting of) 1
604550 HOSE, nprn brd No. 1 x .187 ID (order by ft) lift
010606 FITTING, hose brs nut .625-18RH 1
056108.. FITTING, hose brs ferrule .425 ID x .718 Ig 1
056851 FITTING, hose brs barbed nipple 3/l6tbg I
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-884 Page 23
 2
~

12

14 13 SD-119 648-C

Figure 8-2. Control Panel, w/Components

OM-884 Page 24
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 8-2. Control Panel, w/Components (Fig 8-1 Item 23)

..
1 . ..
PC2 . . . .
071 642 ..
CIRCUIT CARD, motor speed dig 1
.
2 . . .
RC5 . . . .
073 730 . .
TERMINAL, header 22 pin 1
..
3 009 335 ..
STAND-OFF, No. 4-40 x 5/8 2
..
4 112 473 ..
PANEL, mtg components 1
.
5 605 741 . .
CLIP, mtg resistor 5/16 ID 4

..
6 . ...
R3 .. . .
079 497 ..
RESISTOR, WW fxd 25W 2K ohm 1
.
7 . ...
Ri ... .
030 651 .. RESISTOR, WW fxd 25W 10 ohm
.
8 . ...
T2 . . .
116 847 ..
TRANSFORMER, control 1

..
9 ..
CR1 ... .
109 006 ..
RELAY~ end 24VAC DPDT 1
..
10 . ...
Ti .. . .
116 848 ..
TRANSFORMER, control 1
ii . .
1T,2T . .
038 783 . .
BLOCK, term 20A 12P 2
601 219 . .
LINK, jumper 2
.
12 110391 . .
GUIDE, mtg circuit card 3
..
13. ..
PC5 .. .
118550 .
CIRCUIT CARD, isolation/amp
PLG28-30 .
135 787 .
HOUSING PLUG & SOCKETS, (consisting of) 1
081 378 . . . .
TERMINAL, female iskt 22-18 wire 7
.
14 110 375 ..
STAND-OFF SUPPORT, PC card No. 6 screw 8
.
15 048 029 . .
CLIP, retaining socket relay
..
16 049 970 .
BRACKET, mtg relay I
..
17 027 811 ..
SOCKE1~ relay 14 pin 1
.
18 . ..
CR2 . . . .
095 521 ..
RELAY, end 24VDC 4PDT 1
..
19 079 844 ..
SPRING, holddown relay
..
20. ..
PC8 . . . .
116528 ..
CIRCUIT CARD, voltage 1
PLG21 . . .
081 380 . . TERMINAL, header 14 pin 1
081 378 . .
TERMINAL, female iskt 22-18 wire 14
PLG22 . . .
090 469 . .
TERMINAL, header 10 pin 1
081 378 . .
TERMINAL, female iskt22-18 wire 10
PLG23 . . .
135 557 . .
HOUSING PLUG & SOCKETS, (consisting of) 1
079 747 . . . .
TERMINAL, contact header 24-18 wire 2
..
21 . ..
PCi . . . .
148 320 .
CIRCUIT CARD, voltage control 1
PLG14 . . .
079 748 . .
HOUSING, term header 18 pin
079 747 . . TERMINAL, contact header 24-18 wire 18
PLG25 . . .
131 054 ..
HOUSING RECEPTACLE & SOCKETS, (consisting of)
113 746 . . . . TERMINAL, female lskt 2
..
22 . ..
PC3 ..
+141 308 ..
CIRCUIT CARD, interlace 1
PLG18 . . .
135 559 ..
HOUSING PLUG & SOCKETS, (consisting of) 1
079 747 . . . .
TERMINAL, contact header 24-18 wire 12
PLG19 . . .
079 748 . . HOUSING, term header 18 pin 1
079 747 .
TERMINAL, contact header 24-18 wire 18
..
23 . ...
Cl .. . .
031 692 ..
CAPACITOR, elctlt 750uf 200VDC 1
..
24 006 426 ..
CLAMP, capacitor 2 in dia 1
..
25 . ...
T3 .. . .
116 849 .. TRANSFORMER, control 1
042 452 . .
CLIP, component .687dia mtg adh back 2
..
26 . ..
SRi . . .
035 704 ..
RECTIFIER, integ 30A 600V 1
..
27 083 147 .. GROMMET, scr 8-10 push in 2

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-884 Page 25
 Item Part
No. No. Description Quantity

Figure 8-3. Hub & Spindle Assembly

072 094 ..
HUB & SPINDLE, (consisting of) 1
2... 058428 .... HUB, spool 1
.3... 058 628 . . . .
WASHER, steel brake 2
.4... 010 191 .. ..
WASHER, fiber .656 ID x 1.500 OD x .l25thk 2
.5... 135 205 . . . .
NUT, sti slflkg hex reg .625-11 1
.6... 057 971 . . . .
WASHER, flat sti keyed 1 .500dia x .l25thk 1
.7... 010 233 ....
SPRING, compression 1
.8... 072 292 ....
SHAFT, spool support 1
058 427 ....
RING, retaining spool 1
10... 092 989 ..
SUPPORT, spindle (consisting of) 1
121 316 .... LABEL, warning general precautionary 1

10
8

6
4

3
ST.070 884.A

Figure 8-3. Hub & Spindle Assembly

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-884 Page 26
 Item Dia. Part
No. Mkgs. No. Description Quantity

137 114 Figure 8-4. Control Box, Gas/Current Sensor

134327 LABEL, warning general precautionary 1

.
+079 682 WRAPPER 1
REED 140786 SWITCH, reed 1
1~b9 021 CASE SECTION, bottom/front/sides 1
115 104 CONNECTOR, clamp cable 1/2 in 1
..6 010 494 BUSHING, snap 1.375 ID x 1 .75Omtg hole 2
.7 057 358 BUSHING, snap ID x 1 .37mtg hole 2
..8 010 604 .
FITTING, hose brs bushing .25ONPT x .625-18 2
602 934 .
FITTING, pipe coupling .25ONPT 1
10 079 573 FITTING, pipe nipple L .25ONPT x 6 1
11 079 574 BRACKET, mtg component 2
.
12 RC7. 047 637 HOUSING RECEPTACLE & SOCKETS, (consisting of) 1
079 534 TERMINAL, female 14
13 ....D1. 026 202 DIODE, rect 1A 400V SP 1
14 ....5T. 038 839 BLOCK, term 20A 5P
15 ...GS1. 109 293 VALVE, 24VDC 2 way 1/4 IPS port 1/8 orf .1
16 RC16 090 246 RECEPTACLE w/PINS, (consisting of) .1
079535 TERMINAL, male 16

7~

14

11

ST109 680.A

Figure 8-4. Control Box, Gas/Current Sensor

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM.884 Page 27