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cover 5/94 – ST-801 077-A

PRINTED IN USA



1995 MILLER Electric Mfg. Co.

Read and follow these instructions and all
safety blocks carefully.

Have only trained and qualified persons
install, operate, or service this unit.

Call your distributor if you do not understand
the directions.

Give this manual to the operator.

For help, call your distributor

or: MILLER Electric Mfg. Co., P.O. Box 1079,
Appleton, WI 54912 414-734-9821

OWNER’S

MANUAL

June 1995

Form:

OM-172 324

Effective With Serial No. KF812826

Controls Welding Power Source For Robotic Welding Applications

For GMAW, Standard GMAW-P, And Adaptive GMAW-P Welding

Requires Installation Of Interface Panel For Robot In Use

Welding Power Source Must Have 14-Pin Remote Control Capability

Programmable Weld Parameters

Overload Protection

Robotic Interface II

Содержание Robotic Interface II

Страница 1: ...e operator For help call your distributor or MILLER Electric Mfg Co P O Box 1079 Appleton WI 54912 414 734 9821 OWNER S MANUAL June 1995 Form OM 172 324 Effective With Serial No KF812826 Controls Weld...

Страница 2: ......

Страница 3: ...ce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Noise from some processes can damage hearing Chipping grinding and welds cooling throw off pieces of metal or...

Страница 4: ...nds and catch loose clothing 1 Keep all doors panels covers and guards closed and securely in place 2 Stop engine before installing or connecting unit 3 Have only qualified people remove guards or cov...

Страница 5: ...ge cables to one side and away from the operator 3 Do not coil or drape cables around the body 4 Keep welding power source and cables as far away as practical 5 Connect work clamp to workpiece as clos...

Страница 6: ...ing Memory 41 10 16 Selecting Arc Start Volt Sense Error Shutdown 42 10 17 Selecting Program Name Feature 42 10 18 Remote Program Select 43 10 19 Stick Check Selection 43 10 20 Jog Wire Feed Speed Sel...

Страница 7: ...Safety Instructions To Avoid Hazard 5 Hazard Symbol If Available 6 Safety Banner Read safety blocks for each sym bol shown 7 NOTE Special instructions for best oper ation not related to safety 2 NOTE...

Страница 8: ...gram Select Cable Optional 9 Gas And Motor Control Cable 10 Interface Unit 11 Welding Power Source 12 17 Socket Plug And Intercon necting Cord 13 14 Socket Plug And Intercon necting Cord 14 Negative W...

Страница 9: ...To connect interconnecting cord to receptacle align keyway insert plug and tighten threaded collar Cord for voltage sensing connec tion divides in two Secure ring ter minal on one cord to clamp and a...

Страница 10: ...ground Amperage Abk is the low weld current Background current preheats welding wire and maintains the arc When background current is too low the arc is unstable and hard to maintain Apk Peak Amperage...

Страница 11: ...to maintain voltage parameters Feedback from the arc is still used for other functions Be sure voltage sensing leads are connected or voltage feedback is available through the 17 pin receptacle via th...

Страница 12: ...xtinguisher nearby Do not locate unit over combustible surfaces Do not weld on closed containers Allow work and equipment to cool before handling ARC RAYS can burn eyes and skin NOISE can damage heari...

Страница 13: ...welding power source contactor is energized 5 Wirefeed On Light Lights when wirefeed motor is On 6 Gas On Light Lights when gas flow is On 7 Retract Button Push to retract welding wire without energi...

Страница 14: ...rface Into Welding System Put On Personal Safety Equipment Set All Controls And Verify Program Selection Turn On Shielding Gas Turn On Welding System Equipment Adjust Weld Parameters ssb6 1 9 92 Perfo...

Страница 15: ...dur ing setup see Section 10 1 Figure 5 1 Interface Unit B Pulse MIG Programs The eight pulse programs are shown in the table Each program can be used in standard pulse MIG or adaptive pulse MIG In a...

Страница 16: ...o not point gun towards any part of the body other people or any metal when programming The welding wire can be electrically live and move out of the gun during programming Ref ST 154 109 P r o c e s...

Страница 17: ...ct Button Press pulse panel parameter select button to move indicator in right win dow display 1 P r o c e s s C a r d S e q u e n c e Pr g 1 Pu l s e 03 5 S t e e l Ar g on Ox y 2 3 P r g 1 P u l s e...

Страница 18: ...value that is underlined by the moving line 2 Decrease Button Press button to decrease value that is underlined by the moving line 1 2 Increase Decrease P r g 1 P u l s e 0 3 5 S t e e l A r g o n O...

Страница 19: ...ch points such as drive rolls Keep all doors panels covers and guards closed and securely in place MAGNETIC FIELDS FROM HIGH CUR RENTS can affect pacemaker operation Pacemaker wearers keep away Wearer...

Страница 20: ...0 S e c P r e f l o w 1 2 S e c Increase Parameter Select Parameter Select Parameter Select 2 P r o c e s s C a r d S e q u e n c e P r e f l o w 0 0 S e c Mode Select 1 Figure 6 2 Setting Preflow Seq...

Страница 21: ...ter Select Proceed to next figure Increase Trim Parameter Select Time Parameter Select C r a t e r 0 2 0 S e c 6 0 T r i m 1 5 0 I P M C r a t e r 0 0 0 S e c 5 0 T r i m 2 0 0 I P M C r a t e r 0 2 0...

Страница 22: ...5 Amperes ApK is the high pulse of welding current Peak current melts the welding wire and forms a droplet The droplet is forced into the weld puddle 2 AbK Background Current Of 10 200 Amperes AbK is...

Страница 23: ...set information is not appropriate for a specif ic application After the parameters for each teach point are established an arc must be struck and main tained for at least 5 seconds in teach mode Thi...

Страница 24: ...ease buttons to select On 3 IPM Teach Point The parameters associated with this wire feed speed teach point can be modified The wire feed speed value itself cannot be changed from this unit To set or...

Страница 25: ...ustomized programs Customized programs can be reverted back to factory set values through memory reset see Section 10 15 P r o c e s s C a r d S e q u e n c e Parameter Parameter Select 4 5 0 I P M 3...

Страница 26: ...e 20 Make copies of this chart for future use NOTE Program Wire Size Type Gas Program Name Card Gun Model Flowrate CFM IPM ApK AbK PPS PWms COMMENTS Preflow Sec Run In Trim IPM Sec Crater Trim IPM Sec...

Страница 27: ...ve Pulse welding proceed as shown 1 Pulse Panel Display Default display when unit is first turned On at other times use mode select button to select Process 1 Mode Select P r o c e s s C a r d S e q u...

Страница 28: ...ater Speed Crater Time Postflow Time Burnback Time Time Weld Stop Arc Start Arc Out Figure 8 1 Weld Cycle The type of robot being used is defined during the setup process see Section 10 The Robot type...

Страница 29: ...select Process Go to Figure 8 3 1 Mode Select Parameter Select Increase Decrease P r o c e s s C a r d S e q u e n c e P r g 1 P u l s e 0 3 5 S t e e l A r g o n O x y P r o c e s s C a r d S e q u e...

Страница 30: ...utton to se lect parameters 3 Preflow Parameters Display Preflow can be adjusted from 0 9 9 seconds If value set is zero 0 there is no Preflow sequence Go to Figure 8 4 3 Set Desired Time Increase Dec...

Страница 31: ...S e c 2 4 0 V o l t 9 0 I P M Decrease Parameter Select Wire Feed Speed Parameter Select Parameter Select Parameter Select S t a r t 0 5 S e c 1 8 0 V o l t 2 0 0 I P M Increase Proceed to next figure...

Страница 32: ...9 0 I P M Parameter Select Proceed to next figure Increase C r a t e r 0 1 2 S e c 1 8 0 V o l t 2 0 0 I P M Wire Feed Speed Voltage Parameter Select 1 Figure 8 6 Setting Crater Sequence Display 1 Bur...

Страница 33: ...ted from 0 9 9 seconds If value set is zero 0 there is no Postflow sequence 1 Parameter Select Set Desired Time Increase Decrease P o s t f l o w 0 0 S e c P o s t f l o w 0 0 S e c P o s t f l o w 1...

Страница 34: ...2 3 4 5 6 7 8 9 10 11 12 13 14 60 M Data Card Figure 9 1 Installing Data Card 9 2 Using The Data Card Use Mode Select button to select Card 1 Card Display 2 Write Used to transfer program data from un...

Страница 35: ...P r e s s N a m e Y e s 5 0 0 7 9 9 2 F r a m e _ P r e s s W r i t e D o n e P r g 1 t o C a r d P r g 1 P r e s s 1 P u l s e 0 3 5 S t e e l A r g o n O x y P r e s s N a m e Y e s 0 3 5 S t e e l...

Страница 36: ...l B e L o s t L o s e N o P r e s s R e a d D o n e C a r d P r g 1 t o P r g 1 P r e s s 1 P u l s e 0 3 5 S t e e l A r g o n O x y P r e s s 1 P u l s e 0 3 5 S t e e l A r g o n O x y P r e s s W...

Страница 37: ...P r e s s B e l o w WA R N I NG D e l e t e C a r d P r g 2 L o s e Y e s P r e s s D e l e t e C a r d P r g 2 L o s e N o P r e s s C a r d P r g 2 D e l e t e d P r e s s 2 M I G P r e s s 3 M I G...

Страница 38: ...99 Hours 10 11 0 999 999 Cycles No Reset Reset 1 Display Selections 2 Features 3 Settings To set up features that customize operation use the setup displays Features that can be customized are as fol...

Страница 39: ...this procedure any time ac cess is required Once in the setup displays use the Mode Select but ton to select a particular display To save any or all of the changes made while in the setup displays and...

Страница 40: ...e is 0 to 50 amperes 5 Maximum Amperage Display Available When System Set For Pulse Mig Range is 150 to 999 amperes 1 Access Setup Parameter Select Press Mode Select R a n g e S e c u r i t y A c c e...

Страница 41: ...fig ure the operator could change the value of trim 10 and wire feed speed 100 ipm from programmed values If the settings are left at 0 the operator cannot change values from those programmed P r o g...

Страница 42: ...ress Parameter Select button to enter access code When the cor rect letter is entered the indicator automatically moves to the next character When the final access code letter is entered the display a...

Страница 43: ...voltage sensing leads are connected or voltage feedback is available through the 17 pin recep tacle via the welding power source 1 Increase Vo l t a g e Co r r e c t i o n D V C O n S e c u r i t y A...

Страница 44: ...e welding power source and the feed back signal is sent through the 17 pin cord to the feeder If the 17 Pin setting is used it is rec ommended that the voltage sens ing terminals on the welding power...

Страница 45: ...e the arc is started Do not use Hot Start unless using 450 Ampere Inverter Model 1 Increase P u r g e V o l t a g e A r c S t a r t A r c T i m e Ar c S t a r t Ty p e S t a n d a r d Ar c S t a r t T...

Страница 46: ...p l a y I P M Mo t o r T y p e H i g h S p d Parameter Select Increase Increase Decrease Press Mode Select Access Setup Display Figure 10 12 Wire Feed Display 10 13 Selecting Wire Type If wire type i...

Страница 47: ...ry program settings All other program and setup information re mains the same 3 System Reset Press Parameter Select button to reset programs and setup to origi nal factory settings System Arc Time and...

Страница 48: ...sed D i s p l a y M e m o r y S h u t d o w n N a m e Ar c S t a r t Vo l t S e n s e O n 1 Ar c S t a r t Vo l t S e n s e O f f Increase Press Mode Select Access Setup Display Figure 10 16 Voltage S...

Страница 49: ...panel S h u t d o w n N a m e P r o g r a m S t i c k Rem o t e Pr o g r a m O f f Rem o t e Pr o g r a m O n Increase 1 Press Mode Select Access Setup Display Figure 10 18 Program Display 10 19 Stic...

Страница 50: ...interface has control of weld se quences There are two analog channel for the robot to use The robot has control of arc on but the interface has control of weld se quences There are no analog channel...

Страница 51: ...ion is set 0 1 9 9 volts from desired weld voltage arc volt age or arc length variations outside of the range for a period of time longer than that set by the Arc Error timer causes either the error r...

Страница 52: ...l power before maintaining 3 Months OR Blow Out Or Vacuum Inside Replace Unreadable Labels 6 Months 3 Months Tape Or Replace Cracked Weld Cable 14 Pin Cord Gas Hose Gun Cable Replace Cracked Parts Dur...

Страница 53: ...May be caused by an inability to es tablish an arc in the pulse schedule or a lack of voltage feedback 4 No Tach Sensed Error Display The motor tachometer feedback is not reaching the control May be c...

Страница 54: ...ct Error Display Weld current has been detected in the earth ground connection May be caused by a conductor mak ing connection to the unit chassis 5 Wire Stick Error Display The welding wire has stuck...

Страница 55: ...15 volts dc present on interface board PC5 with respect to dc circuit common Off If LED 3 is off and LED s 1 2 4 and 5 are on replace interface board PC5 If LED 3 is off and LED s 1 2 4 and 5 are off...

Страница 56: ...OM 172 324 Page 50 SECTION 12 ELECTRICAL DIAGRAMS Figure 12 1 Circuit Diagram For Robotic Interface Unit...

Страница 57: ...OM 172 324 Page 51 SD 171 360 A...

Страница 58: ...OM 172 324 Page 52 Figure 12 2 Circuit Diagram For Microprocessor Board PC1...

Страница 59: ...OM 172 324 Page 53 SD 161 039 A...

Страница 60: ...OM 172 324 Page 54 Figure 12 3 Circuit Diagram For Motor Board PC3...

Страница 61: ...OM 172 324 Page 55 SD 083 388 B...

Страница 62: ...OM 172 324 Page 56 Figure 12 4 Circuit Diagram For Customer Interface Board PC4...

Страница 63: ...OM 172 324 Page 57 SD 166 275...

Страница 64: ...OM 172 324 Page 58 Figure 12 5 Circuit Diagram For Interface Board PC5...

Страница 65: ...OM 172 324 Page 59 SD 165 466...

Страница 66: ...OM 172 324 Page 60 Figure 12 6 Circuit Diagram For Filter Board PC6 SB 159 412...

Страница 67: ...OM 172 324 Page 61 Figure 12 7 Circuit Diagram For Display Board PC7 SC 165 462 A...

Страница 68: ...OM 172 324 Page 62 Figure 12 8 Circuit Diagram For Data Card Board PC8 SA 156 626 A Figure 12 9 Circuit Diagram For Pulse Display Board PC8 SA 158 163...

Страница 69: ...OM 172 324 Page 63 NOTES...

Страница 70: ...OM 172 324 Page 64 SECTION 13 PARTS LIST 3 1 2 4 5 6 7 8 9 10 11 12 17 13 14 15 16 2 18 20 19 ST 801 142 24 23 22 21 Figure 13 1 Case Section w Components...

Страница 71: ...18ga 6 PLG18 162 382 CONNECTOR SOCKETS consisting of 1 113 746 CONNECTOR rect skt 24 18ga 20 15 155 629 CABLE ribbon 14posn 3 000 in 1 16 126 689 STAND OFF No 6 32 x 1 500 lg 4 17 PC5 165 463 CIRCUIT...

Страница 72: ...7 PANEL control inner 1 8 PC8 156 623 CIRCUIT CARD ASSEMBLY data card 1 PLG60 153 501 CONNECTOR SOCKETS consisting of 1 147 995 CONNECTOR rect skt 22 18ga 6 9 DSPL2 158 160 CIRCUIT CARD ASSEMBLY side...

Страница 73: ...1 5 134 201 STAND OFF SUPPORT pc card 4 6 166 354 PANEL mtg cmpts 1 7 PC4 166 272 CIRCUIT CARD ASSEMBLY interface 1 PLG3 158 768 CONNECTOR rect 24P S 2 row plug 1 113 746 CONNECTOR rect skt 24 18ga 2...

Страница 74: ...OM 172 324 Page 68 1 2 3 4 3 5 6 7 8 9 10 11 12 13 ST 801 145 Figure 13 4 Panel Rear w Components...

Страница 75: ...irc 10skt rcpt 1 13 FL1 084 171 FILTER line pwr 115 250V 1 172 821 CABLE motor gas consisting of 1 153 886 CONNECTOR circ 19 pin plug 1 039 734 CONNECTOR circ clamp str rlf 1 600 797 CABLE port No 16...

Страница 76: ...324 Page 70 5 6 7 8 9 10 11 12 Includes Items 13 16 1 17 18 19 20 21 22 24 25 26 27 28 29 23 29 30 31 13 14 32 33 34 15 16 14 32 33 34 35 36 37 38 39 40 41 4 3 2 ST 801 153 Figure 13 5 Motor Drive As...

Страница 77: ...132 611 OPTICAL ENCODER 1 28 153 631 CIRCUIT CARD digital tach 1 131 203 CONNECTOR PINS consisting of 1 114 656 CONNECTOR rect pin 24 18ga 3 29 172 807 MOTOR gear 1 8hp 115VDC 2000RPM consisting of 1...

Страница 78: ......

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