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OM-884 117 005G
February 2000
Processes
Automatic Welding
Description
Automatic Welding Interface
A.B.B. Robot Interface
Gas Control
Hub And Spindle
Visit our website at
www.MillerWelds.com
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From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that bu
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TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Welding
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ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays Always ventilate confined spaces or use that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator. weld. 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 Z87.1 li
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1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. Do not install or place unit on, over, or near Keep away from moving parts such as fans. combustible surfaces. Keep all doors, panels, covers, and guards Do not install unit near flammables. closed and securely in place. Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING UNIT can cau
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1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding 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 17 3. Do not coil or drape cables around your body. years of resea
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SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION som _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous au
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LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation. (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées Veiller toujours à bien aérer les espaces
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1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. Ne pas placer l’appareil sur, au-dessus ou à proxi- Rester à l’écart des organes mobiles comme le mité de surfaces infllammables. ventilateur. Maintenir fermés et fixement en place les portes, Ne pas installer l’appareil à proximité de produits inflammables panneaux, recouvrements et dispositifs de Ne pa
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1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. Règles de sécurité en soudage, coupage et procédés conne
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SECTION 2 – INSTALLATION 2-1. Specifications Dimensions Weight Component Height Width Depth Net Ship 22-1/2 in. 16-1/2 in.♦ 6-1/4 in.* 38 lbs. 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) Spool Support 13-3/4 in. 8-3/4 in. 8-1/2 in. 6 lbs. (349 mm) (222 mm) (216 mm) (2.7 kg) Assembly+ +Spool Support without optional wire reel. ♦Add 2-1/4 in. (57 mm) for brake resist
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2-3. Connection Diagram 2 1 Robot Interface 3 1 2 115 Volts AC/Contactor And Output Control Cord 3 Welding Power Source RC17 14 4 Weld Cables RC13 5 Shielding Gas Supply 6 Electrode (Welding Wire) 7 Work 4 RC12 8 Wire Drive Assembly 9 Motor Control Cord RC9 10 Gas Control 11 Gas Control Cord 5 12 Arc Sensing Cord 11 12 13 Arc Failure Connection Inside Robot Control Unit 14 Robot Interface Connections 10 To Robot Control Unit 13 6 9 8 7 Ref. S-0290 2-4. Robot Interface Connections 1 Gas Control R
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2-5. Shielding Gas Connection To Regulator/Flowmeter 1 2 3 1 6 OR Argon Gas 5 2 4 3 Tools Needed: 7 8 1-1/8, 5/8 in CO Gas 2 ssb3.1 5/94 – ST-158 697-A Obtain gas cylinder and chain to running Install so face is vertical. Make sure flow adjust is closed when gear, wall, or other stationary support so opening cylinder to avoid damage to the cylinder cannot fall and break off valve. flowmeter. 5 Gas Hose Connection 1 Cap 7CO Adapter 2 Fitting has 5/8-18 right-hand threads. Ob- 2 Cylinder Valve ta
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2-7. Arc Sensing Connections Locate arc sensing cord, and connect 4-socket plug to receptacle RC12 on robot interface. To make connection, 1 align keyway, insert plug, and tighten threaded collar. 1 Positive Weld Output Terminal On Welding Power Source 2 Weld Cable Lug Location 4 3 Arc Sensing Lead Ring 5 Terminal Location Connect lead with ring terminal to 6 2 welding power source Positive (+) weld output terminal as shown. 4 Flat Washer 5 Lock Washer 6 Nut Connect lead with clamp to welding 3
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2-9. 24-Socket Receptacle RC17 Information Socket* Socket Information A Provides connection to 2TA; for customer use. Current Detect output to robot control unit with respect to Socket D; isolated CR1 contacts rated B 1A at 120 VAC. Current Detect output to robot control unit with respect to Socket B; isolated CR1 contacts rated D 1A at 120 VAC. Contactor Control; +24 volts dc input from robot control unit with respect to Socket J (Circuit E Common). Jog Forward; +24 volts dc input from robot co
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2-10. Arc Failure Light Connections 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. For robot control units when 24 vdc is used: 1 Route cord through strain relief on right side panel of Robot Control Unit Robot Interface robot interface, and make proper connections to 1TL Common Terminal Weld Alarm Terminal and 1TM. If So Equipped If So Equipped Signal 2 Route and co
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2-11. Matching Digital Voltage Control (DVC) Board To Welding Power Source 1 DVC Board PC1 2 DIP Switch 1 2 DVC SWITCH SETTINGS S2 S1 121234 5 DELTAWELD 300 ON ON ON DELTAWELD 451, 450 O ON ON DELTAWELD 651, 650 O 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 Tools Needed: DIMENSION 400 ON ∆∆ ON Non-Conductive PULSTAR 450 ON O – On For Optional Soft Start. Turn Off S1 -3. ∆ – On For Optional Hot Start. S-150 864-C Ref. ST-119
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2-12. Hub Assembly Installation 1 Spool Support 2 2 Hub Support Shaft 3 Retaining Ring 4 Hub Assembly 3 5 Brake Washer 6 Fiber Washer 4 7 Hex Nut Install hub assembly as shown. Tighten hex nut until a slight drag is felt while turning hub. 5 6 7 1 Tools Needed: 9/16 in ST-126 870-A 2-13. Installing Spool-Type Wire And Adjusting Hub Tension 1 Retaining Ring 2 Wire Spool 3 Hole In Spool 1 4 Hub 2 Remove retaining ring and slide spool onto hub. Turn spool until hub pin fits hole in spool. Reinstall
