Miller Electric NSPR 8989 Owner's Manual
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Miller Electric NSPR 8989 Owner's Manual

Miller Electric NSPR 8989 Owner's Manual

Miller owner's manual arc welding equipment robot interface (per nspr 8989)
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Millerfi
November 1990 FORM: OM-135 582B
MODEL: Robot Interface
(per
NSPR
8989)
OWNERS
MANUAL
iMPORTANT: Read and understand the entire
contents of
both this manual
and the power
source
manual used with this
unit,
with
special emphasis
on
the
safety
material
throughout
both
manuals,
before
Installing, operating,
or
maintaining
this
equipment.
This unit and these Instructions
are
for
use
only
by
persons trained
and
experienced
In the safe
operation
of
welding equip
ment. Do not allow
untrained persons
to
Install, operate,
or
maintain this unit.
Contact your distributor If
you
do
not
fully
understand these Instructions.
MILLER ELECTRIC
Mfg.
Co.
A
MIter
Group
Ltd..
Con~any
P.O. Box 1079
Appleton,
WI 54912 USA
Tel. 414-734-9821
PRINTED
IN
U.S.A

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Summary of Contents for Miller Electric NSPR 8989

  • Page 1 In the safe operation welding equip Install, operate, maintain this unit. fully understand these Instructions. MODEL: Robot Interface (per NSPR 8989) MILLER ELECTRIC Mfg. MIter Group Ltd.. Con~any P.O. Box 1079 only WI 54912 USA Appleton, Tel. 414-734-9821 PRINTED IN U.S.A...
  • Page 2 Remote Controls Effective 1992 January with serial number preface of KC MILLER exclusive with other warrantIes guarantees Kits below, MILLER Electric Accessory retail purchaser that Replacement limited warranty is tree MILLER. THIS WAR- MILLER True Blue AND FIT Items fUrnished accessories.
  • Page 3 ERRATA SHEET After this manual printed, refinements in later in this manual. to data appearing SECTION AMENDMENT TO INSTALLATION Amend Section 3-5B. ROBOT INTERFACE Connections For units used with Pulstar welding interface. Proceed follows: WARNING: ELECTRIC SHOCK Do not touch live electrical ______ Shut down unit,...
  • Page 4 DELTAWELD 300 DELTAWELD DELTAWELD 651 MAXTRON MAXTRON 450 XMT200/300 ARC PAK35O SHOPMASTER DIMENSION On For On For Section 3-10. SETTING DIP SWITCHES ON VOLTAGE CONTROL BOARD PCi DIP switch and S2 voltage control board PCi allow ling voltage output welding power another welding...
  • Page 5 WARNING: ELECTRIC SHOCK touch live electrical Shut down unit, welding tagging procedures before Lockout/tagging procedures from fuse shutting box, ELECTROSTATIC DISCHARGE properly grounded Transport circuit boards in proper Perform work only IMPORTANT: customer-supplied control. Loosen securing front screws Locate voltage control board PCi in lower left trol.
  • Page 6 Figure 3-8. AMENDMENT TO SECTION ELECTRICAL DIAGRAMS Circuit Amend Diagram 7-1. Diagram 7-2. Circuit Delete Diagram Diagram This effective with Serial No. KC231 859 diagram longer applies Circuit Amend Diagram 7-3. Diagram Amend Diagram 7-4. Circuit Diagram OM-135 582B Page Jumper Locations On Voltage...
  • Page 7 AMENDMENT TO SECTION PARTS LIST follows: Amend Parts List Part Dia. Replaced Mkqs. With 028 291 028 291 Added 095 521 049 970 048 588 079 844 079 844 027811 027811 048 029 048 029 026 202 026 202 137695 148320 +149 339 PLG25...
  • Page 8 Diagram OM-135 582B Page fi~ '111_ _nrL ft_ill fi fi~ 7-3. Circuit Diagram For Motor Control Board PC2 WAVEFOPIlS IPW-MOTOP PUNNING VOLTAGES MEASIJPED WITH PESPECT COM)OJ POINT EXCEPT MEASURE WITH RESPECT POINT ~I(.
  • Page 9 Circuit No. SD-083 388-B Diagram OM-135 5828 Page...
  • Page 10 C I S 4 T P 1 2 . . 0 0 0 0 0 0 0 0 0 0 I T O Ill? R C I / P L 0 I 4 R C 6 / P L G 2 S 8 0 * 8 0 6 5 7 V T L T A G E...
  • Page 11 Diagram 7-4. Circuit Diagram For Interface Board POIJER/GROUHO NETS FOR CHIPS i~GND 8 8.5140 I6~ISU Circuit Diagram No. SB-141 OM-135 311-A 5828 Page...

  • Page 13: Table Of Contents

    Before unpacking equipment, check carton age that may have occurred during shipment. claims for loss with the delivering damage Assistance for filing settling claims may be obtained from the distributor and/or the equipment Transportation Department. When requesting information about this the Model and Serial provide...
  • Page 14 Section SECTION MAINTENANCE TROUBLESHOOTING & 6-1. Routine Maintenance 6-2. Overload Protection Reinstallation Of Hub 6-3. Board PC4 Meter 6-4. Display Circuit Board 6-5. Handling 6-6. Troubleshooting 6-7. Indicator Lights SECTION ELECTRICAL DIAGRAMS Circuit Diagram 7-1. Diagram 7-2. Circuit Diagram Diagram Diagram 7-3.

  • Page 15: General Information And

    SECTION SAFETY GENERAL INFORMATION AND SAFETY 1-1. enera in this manual and Information presented pertains plates the unit bels, tags, maintenance, installation, operation, design, which should be read, understood, troubleshooting followed for the safe and effective Safety installation, operation, maintenance, welding equipment requires practices shooting which...
  • Page 16 SITE SELECTION 3-1. Select installation site which provides Correct input supply (see power Shielding supply (if applicable) Water supply (if applicable) ventilation and fresh air Adequate No flammables clean and area Proper that avoids temperature extremes cold Proper airflow around unit Adequate open and space...
  • Page 17 SENSING CONTROL 3-3. GAS/CURRENT CONNECTIONS (Figure 3-2) WARNING: ELECTRIC SHOCK not touch live electrical Shut down unit, welding power and disconnect robot, input lockout/tagging procedures before connections. Lockout/tagging procedures consist of line disconnect switch in open fuses from fuse moving box, red-tagging circuit breaker...

  • Page 18: Arc Failure

    Sensing Lead Ring Terminal Location Figure Sensing Connections At Wire 3-3. Voltage Drive Assembly 3-5. ROBOT INTERFACE WELDING SOURCE CONNECTIONS (Figure There three cords supplied for interconnections be the robot interface and tween welding amine and select the proper cords for the nections.
  • Page 19 Socket Voltage control negative () Socket Wire feed speed positive Socket Wire feed speed wiper connection. Socket Wire feed speed negative () IMPORTANT: The remaining sockets used. ___________________________ Figure 3-4. Front View Of 24-Socket Receptacle With Socket Designations 3-7. ARC FAILURE LIGHT TERMINAL STRIP CON NECTIONS (Figure 3-5) WARNING: ELECTRIC SHOCK...

  • Page 20: Burnback Control

    WELDING INSTALLATION 3-8. WIRE Installation Spool-Type Wire Remove retaining ring. Slide of wire onto hub spool bottom of spool. until hole in spool aligns Rotate spool Slide spool onto hub until it seats of the hub. flange hub. Reinstall retaining ring onto Wire Reel And Reel- Installation Of...

  • Page 21: Section 4- Operator Controls

    SECTION Gas Indicator Light Contactor Indicator Light 4-1. POWER SWITCH (Figure 4-1) the POWER switch the ON position energizes Placing the robot interface. The interface must weld. Placing the POWER switch tion shuts down the interface. JOG PUSH BUTTONS 4-2. (Figure 4-1) push buttons...
  • Page 22 SECTION Wire Feed Speed 0-1OV Volts 0-1OV Output 0-1OV 0-500 Amps Peak Robot control Unit Computer Gas Control Interface Contactor Control Wire Stuckilouch Sense Output Voltage Shielding Sense Voltage Stick/Touch Wire Figure INPUT SIGNALS FROM ROBOT CONTROL 5-1. UNIT (Figure 5-1) The robot interface receives input signals control,...
  • Page 23 MOVING PARTS can cause Keep away from moving parts. HOT SURFACES can cause Allow before cooling period performed only by qualified Maintenance persons. all hose and Repair replace, required, give particular attention frayed lation and where it enters equipment. areas Remove grease and from grime...
  • Page 24 Retaining Ring spanner OPTIONAL Input Command For Ammeter -.O.1V 100A Open robot interface door. access Locate display board PC4. Check voltage according Figure meter supply and command power correct and meter is not working, replace Section 6-5 and (see contact nearest thorized Service Station).
  • Page 25 CAUTION: ELECTROSTATIC DISCHARGE (ESD) damage circuit boards. properly grounded BEFORE handling circuit boards. Transport circuit boards shielding carriers packages. Perform work only static-safe work INCORRECT INSTALLATION circuit board. plugs damage that plugs properly sure aligned. EXCESSIVE PRESSURE board. only minimal pressure and when disconnecting ment...

  • Page 26: Wire Speed

    TROUBLE control. Output voltage sensing Voltage Incorrect robot command Wire Incorrect robot command speed (1PM) meter zero. goes Motor Board PC2 Unit does Fuse Fl operate. Circuit breaker CB1 No meter display. Meter Display No wire feed. Robot Relay Motor Board PC2 Wire feeds maximum Tach board...

  • Page 27: Indicator Lights

    USE OF INDICATOR LIGHTS FOR TROUBLESHOOTING 6-7. Gas flows: does System normal Check gas (on.) ~ 1 ~ Contactor closed: Contactor open: Check System normal (on). interconnecting cords. Check interface board PC3. Wire feeds: Wire does System normal Check circuit breaker CB1 (on).
  • Page 28 m I m C) -l 0 0 0 - A S C - i D i a g r a m C i r c u i t F L H / 1 . 5 . 5 6 6 6 5 . 5 . 5 0 0 0 0 0 0 0 0 0 0 F F 0 4 2 6 5 .
  • Page 29 I ~I ~T~T T~T T Circuit Diagram No. C-135 518 Circuit Diagram 7-2. Diagram Board PCi Voltage OM-135 Page...
  • Page 30 U J ~ S C A S f l T ~ 4 - . o 1 m W i n . T o g a I A S ~ . J . . U A S ~ S T O D W Y f l i n T O i ~ .
  • Page 31 Diagram PC2O AA-AF PC24 fl\ ,ri #C23 Diagram POUE~IGROUND ~ETS F~ CkI#S 4.GAD 8~.ISU 8.GAD 7-4. Circuit Diagram For Interface Board PC3 L~O3 8C21 7-5. Circuit Diagram Display Board PC4 IS.. Circuit Diagram No. SB-141 311 AAAAA #C22 Circuit Diagram No.
  • Page 32 Lii~ BYPASS FOR POWER AND GROU~ lIEN *24V Circuit Diagram No. B-132 087-A Circuit For Arc Failure Board PC5 Diagram 7-6. Diagram .l5U PQI~R/GRIYJND ~IS POR dRIPS 9~.l5U l~GND 8140 Circuit SB-140 Diagram Circuit For Touch Sense/Wire Stick Board PC6 Diagram 7-7.
  • Page 33 Dia. Part Mkgs. Main 031 692 CAPACITOR, 006426 CLAMP, C2-4 028 291 CAPACITOR, CIRCUIT 011 991 109 006 RELAY,encI24VACDPDT 052964 RELAY, 095033 RELAY, 049 970 BRACKET 079 844 SPRING, SOCKET 027811 CLIP, 048 029 DIODE, 026202 *012 655 FUSE, 046432 HOLDER, PB1-3 021 105...
  • Page 34 Part Dia. Mkgs. Main HOUSIN.3 PLUG & PLG28 115 091 113 746 TERMINAL, 092 159 HOUSING, PLG5O 081 378 TERMINAL, RESISTOR, 030 651 CLIP, 605741 RESISTOR, 030949 HEATSINK,rect TUBING,stl.275lDx1.000 010199 079683 HEATSINK, 056 170 SHIELD, 010 193 TUBING, 057 084 BUSHING, RESISTOR, 079 497...
  • Page 35 Dia. Part Mkgs. MaIn TERMINAL, 1338640008989 CABLE, 097868 PLUG, CLAMP, 116 964 604910 CABLE, PLUG, HOSE, 056 462 604 550 HOSE, 010 606 FITTING, 056 108 FITTING, FITTING, 056 851 CONTROL DIODE, 026 202 109293 ~VALVE,24VDC2wayi/4IPSport1/8ort HOUSING RECEPTACLE & 047 637 ~TERMINAL,femalelskti4-i8wire 079534 RC1 6...
  • Page 36 Q~N- Figure OM-135 582 Page 8-1. Circuit Card, Voltage Control PCi >- E::::J- c:::~ C RS _______ SB-135 520-8...
  • Page 37 4 1 2 15 1 3 2 1 4 4 2 2 4 2 5 Dia. Part kqs. 137 695 096 275 A51,52,54 009159 -4,53, 55-59,68 122 723 C50,60, 69-73 000 340 031 677 000 861 005 023 009 577 053 992 C64,65 118 460...
  • Page 38 C.) 01 01 I) -u ca 3 8 0 - E S C - c 9 3 D i g i t a l S p e e d M o t o r C a r d , C i r c u i t 8-2.
  • Page 39 Dia. Part Mkgs. 071 642 FIgure A50-53 009159 IC,Iiriear358 039 482 CAPACITOR, 031 699 CAPACITOR, 073 739 CAPACITOR, C52,61 035 833 CAPACITOR, C53,62 CAPACITOR, CAPACITOR, C55,66-75,77 031 643 073 549 CAPACITOR, CAPACiTOR, 007 742 CAPACITOR, 035 561 C63,64 CAPACITOR, 044 602 031 721 CAPACITOR, CR50...
  • Page 40 Dia. Part kgs. Figure 009 159 CAPACITOR, C1-7,15 083 973 CAPACITOR, CAPACITOR, 031 677 C11,12 CAPACITOR, 000 348 072 130 CAPACITOR, CAPACITOR, 000 859 CAPACITOR, 095 521 RELAY, CR3-6 099 018 RELAY, SPRING, 079 844 091 861 SOCKET, 01,13-17 028 35i DIODE, D2-8 026 202...
  • Page 41 Dia. Part Mkgs. FIgure 000 348 CAPACITOR, C3-5 073739 CAPACITOR,cer.1uf5OVDC 028 351 DIODE, LCD1-3 108453 METER,digital LED1 2,4,5 089 028 LED, LED,5330A19200MCD LED3 097763 R1-5 030 028 RESISTOR, 030 140 POTENTIOMETER, R6,8,11 003272 RESISTOR,CF.25Wlmegohm R7,9,10 RC2O 081 381 TERMINAL, RC21-23 109 161 TERMINAL, RC24...
  • Page 42 Dia. Part Mkgs. 132 090 FIgure 009159 IC,Iinear35B 039 482 CAPACITOR, 000 348 CAPACITOR, CAPACITOR, 031 677 CAPACITOR, 099 018 RELAY, 026 202 DIODE, D2,3 028 351 DIODE, RESISTOR, 092 648 037 200 TRANSISTOR, RESISTOR, 009 173 POTENTIOMETER, 035825 RESISTOR,CF.25WlKohm 038 584 RESISTOR, R5,7...
  • Page 43 Dia. Part Mkgs. 140 021 Figure 009 159 linear 358 090 573 CAPACITOR, 000 348 CAPACITOR, 039 482 CAPACITOR, 122 723 CAPACITOR, CR1-3 004 855 RELAY, Dl-3,5-8 026202 DIODE, DIODE, 037 449 J1,2 092648 RESISTOR, Ql ,2 TRANSISTOR, RESISTOR, 035 827 ,5,7 R2,3 035 826...

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