Miller Robotic Interface II Owner's Manual
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Miller Robotic Interface II Owner's Manual

Controls welding power source for robotic welding applications
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Read and follow these instructions and all
safety blocks carefully.
Have only trained and qualified persons
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cover 5/94 – ST-801 077-A
OWNER'S
MANUAL
Robotic Interface II
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
1995 MILLER Electric Mfg. Co.
June 1995
Form: OM-172 324
Effective With Serial No. KF812826
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
PRINTED IN USA

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  • Page 1 Have only trained and qualified persons For help, call your distributor install, operate, or service this unit. Call your distributor if you do not understand or: MILLER Electric Mfg. Co., P.O. Box 1079, the directions. Appleton, WI 54912 414-734-9821 ...
  • Page 3 ARC WELDING SAFETY PRECAUTIONS WARNING ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The safety information given below is only a summary of the more complete safety information that will be found in the Safety Standards listed on the next page.

  • Page 4: Principal Safety Standards

    WELDING can cause fire or explosion. 6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off 7.

  • Page 5: Table Of Contents

    EMF INFORMATION Considerations About Welding And The Effects Of Low Frequency Electric And NOTE Magnetic Fields The following is a quotation from the General Conclusions Section of To reduce magnetic fields in the workplace, use the following procedures: the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric &...
  • Page 6 SECTION 10 – SETUP ..............10-1.

  • Page 7: Section 1 - Safety Information

    SECTION 1 – SAFETY INFORMATION mod1.1 2/93 Read all safety messages throughout this manual. Obey all safety messages to avoid injury. Learn the meaning of WARNING and CAUTION. Safety Alert Symbol Signal Word WARNING means possible death or serious injury can happen. WARNING CAUTION CAUTION means possible minor...

  • Page 8: Section 2 - Installation

    SECTION 2 – INSTALLATION 2-1. Connection Diagram Robot (Will Vary According To Application) Motor/Drive Assembly Positive (+) Voltage Sensing Lead The proper interface kit must be installed in the interface Gas Cylinder unit to allow it to be connected to the robot. Gas Hose Robot Control Robot Input/Output Cable...

  • Page 9: Rear Panel Connections

    2-2. Rear Panel Connections Receptacle Keyway 14-Pin Receptacle (Connec- tion To Welding Power Source) 17-Pin Receptacle (Connec- tion To Welding Power Source With 17-Pin Receptacle) 19-Socket Receptacle (Motor/ Shielding Gas Control Connection To Motor Drive Assembly) 10-Socket Receptacle (Op- Example Receptacle tional Remote Program Select Connection To Robot Control) To connect matching interconnect-...

  • Page 10: Connecting Optional Emergency Stop Push Button

    2-3. Connecting Optional Emergency Stop Push Button WARNING ELECTRIC SHOCK can kill. • Do not touch live electrical parts. • Turn Off robot, welding power source, and interface unit, and disconnect input power before inspecting or installing. swarn1.1* 2/93 Terminal strip 2T provides connec- tion points for an optional normally closed Emergency Stop (E-stop) push button.
  • Page 11 Pulse Panel Terms: Card Mode Is used to select use of the optional data card storage and retrieval capabilities. Process Mode Is used to select the type of process to be used, including Pulse, Adaptive Pulse, or Mig. Sequence Mode Is used to select and program the weld sequences which include preflow, run- in, weld, crater, burnback, and postflow.

  • Page 12: Section 4 - Operation

    Arc Start/Volt Sense When this feature is on, the system immediately shuts down if no arc voltage is Shutdown sensed. An error message is displayed. When this feature is off, wire feeds even when there is no arc voltage sensed. Wire Feed Mode Allows the selection of inches per minute or meters per minute for wire feed speed.
  • Page 13 Front Panel Display Reset Button After clearing an error, press this button to reset the display. Purge Button Push to energize gas valve. If a purge time value is programmed, the gas will flow for the programmed length of time. If a value is not pro- grammed, the gas flows until the Purge button is released.
  • Page 14 WARNING BUILDUP OF SHIELDING GAS can harm health or kill. • Shut off shielding gas supply when not in use. warn1.1 9/91 Shielding Gas Cylinder Valve Open valve on cylinder just before welding. Close valve on cylinder when fin- ished welding. sb5.1* 6/92 –...

  • Page 15: Section 5 - Introduction To Programming

    SECTION 5 – INTRODUCTION TO PROGRAMMING 5-1. Programs A. General Interface Unit The interface unit is designed for use in pulse MIG welding (adaptive or standard), or MIG welding. The unit is factory-equipped with eight programs for pulse MIG weld- ing (see Figure 5-2).

  • Page 16: Pulse Panel Microprocessor Push Buttons

    5-2. Pulse Panel Microprocessor Push Buttons WARNING ELECTRIC SHOCK can kill. WELDING WIRE can cause puncture • wounds. Do not touch live electrical parts. • • Do not point gun towards any part of the body, other Control circuit and interface operational power are On when using or changing the microprocessor people, or any metal when programming.
  • Page 17 Parameter Display Moving Line Moving line is under value that can be changed. Pulse Panel Parameter Select Button Press pulse panel parameter select button to move indicator in right win- dow display. Pulse Panel P r g >P r o c e s s >...
  • Page 18 Use mode select button to select mode changed (see Figure 5-3). Use pulse panel parameter select button to select parameter to be changed (see Figure 5-4). Increase Button Press button to increase value that is underlined by the moving line. Decrease Button Press button to decrease value that is underlined by the moving line.

  • Page 19: Section 6 - Getting Started For Pulse Welding

    SECTION 6 – GETTING STARTED FOR PULSE WELDING WARNING ELECTRIC SHOCK can kill. ARC RAYS can burn eyes and skin; • NOISE can damage hearing. Do not touch live electrical parts. • • Wear welding helmet with correct shade of filter. Always wear dry insulating gloves.
  • Page 20 Mode Select Button When unit is turned On, Process is P r o c e s s >P r e f l o w the default mode, at other times, use mode select button to select C a r d 0 .
  • Page 21 Crater Parameters Display Parameter ranges are as follows: Seconds, 0-2.50 Sec. If value set is >C r a t e r C r a t e r C r a t e r zero (0), there is no Crater 0 . 0 0 S e c 0 .

  • Page 22: Section 7 - Teaching A Pulse Welding Program

    SECTION 7 – TEACHING A PULSE WELDING PROGRAM WARNING ELECTRIC SHOCK can kill. WELDING WIRE can cause puncture • wounds. Do not touch live electrical parts. • • Do not point gun towards any part of the body, other Control circuit and interface operational power are On when using or changing the microprocessor people, or any metal when programming.

  • Page 23: Teach Points Explained

    7-2. Teach Points Explained Example Of A Synergic Setting For 425 IPM With All Teach Points Set At 50 IPM Increments PWms PWms The teach mode allows the user to create point, and above the wire feed speed of the pulse parameters.

  • Page 24: Teaching A Pulse Welding Program

    7-3. Teaching A Pulse Welding Program READ SAFETY BLOCKS at start of WARNING Section 7 before proceeding. A. Selecting Teach Point Wire Feed Speed Process Display When unit is first turned On, Pro- cess is the default screen, at other times use mode select button to se- lect Process.
  • Page 25 B. Setting Teach Point Parameters On The Pulse Panel Increase/ Decrease T e a c h >P r o c e s s T e a c h T e a c h C a r d 4 5 0 I P M >4 5 0 I P M...
  • Page 26 NOTE Make copies of this chart for future use. Program # Wire Size/Type Program Name Card # Gun Model Flowrate PWms COMMENTS Preflow: Sec. Run-In Trim: IPM: Sec.: Crater Trim: IPM: Sec.: Postflow: Sec. OM-172 324 Page 20...

  • Page 27: Changing To Adaptive Pulse Welding

    7-4. Changing To Adaptive Pulse Welding READ SAFETY BLOCKS at start of WARNING Section 7 before proceeding. Welding parameters are the same for both a Pulse and an Adaptive Pulse welding program. While welding adaptively, the unit uses feedback to attempt to maintain a constant arc length.

  • Page 28: Section 8 - Teaching A Mig Welding Program

    SECTION 8 – TEACHING A MIG WELDING PROGRAM WARNING ELECTRIC SHOCK can kill. WELDING WIRE can cause puncture • wounds. Do not touch live electrical parts. • • Control circuit and interface operational power are Do not point gun towards any part of the body, other people, or any metal when programming.

  • Page 29: Changing To Mig Welding

    8-1. Changing To MIG Welding Pulse Panel Display Default display when unit is first turned On, at other times use mode select button to select Process. Go to Figure 8-3. Mode Select >P r o c e s s >P r g C a r d P u l s e S e q u e n c e...

  • Page 30: Setting Sequence Mig Welding Parameters

    8-2. Setting Sequence MIG Welding Parameters READ SAFETY BLOCKS at start of WARNING Section 8 before proceeding. Pulse Panel Display When unit is turned On, Process is the default mode. Use mode select >P r o c e s s >P r g button to select Sequence.
  • Page 31 Start Parameters Display Parameter ranges are as follows: Seconds, 0-2.5 Sec. If value set is >S t a r t S t a r t S t a r t zero (0), there is no Run-In 0 . 2 S e c >0 .
  • Page 32 Crater Parameters Display Parameter ranges are as follows: Seconds, 0-2.50 Sec. If value set is zero (0), there is no Crater sequence. >C r a t e r 0 . 0 2 S e c Volts, 10.0-38.0 Volts. 2 4 . 0 V o l t Wire Feed Speed, 50 to 780 inches I P M per minute, IPM.
  • Page 33 Postflow Parameters Display Postflow can be adjusted from 0-9.9 seconds. If value set is zero (0), there is no Postflow sequence. >P o s t f l o w P o s t f l o w >P o s t f l o w 0 .

  • Page 34: Section 9 - Using The Optional Data Card

    SECTION 9 – USING THE OPTIONAL DATA CARD 9-1. Installing Data Card Label Peel backing from label and apply to data card with THIS SIDE UP by metal pins. Write the names of the programs stored on the card on the label. Write the name of the piece of equipment the card is used with on the label.
  • Page 35 NOTE All program types (Pulse, Adaptive Pulse, and MIG) can be stored on a data card and retrieved. Card Display Use Mode Select button to select Card. P r o c e s s Moving Line >C a r d Moving line is under value that can S e q u e n c e P r e s s...
  • Page 36 Use Mode Select button to select Card. Card Display P r o c e s s >C a r d Moving Line S e q u e n c e P r e s s Moving line is under value that can B e l o w be changed.
  • Page 37 Use Mode Select button to select Card. Card Display Moving Line Moving line is under value that can P r o c e s s be changed. >C a r d S e q u e n c e P r e s s Delete Display B e l o w Select program number to be de-...

  • Page 38: Setup Flow Chart

    SECTION 10 – SETUP 10-1. Setup Flow Chart Display Selections Features >R a n g e V o l t M i n Settings S e c u r i t y 1 0 . 0 V o l t A c c e s s To set up features that customize operation, use the setup displays.

  • Page 39: Using Setup Displays

    10-2. Using Setup Displays Front Panel Setup Display Front panel display during setup. Pulse Panel Mode And Para- meter Select Buttons Power Switch On Rear Panel Mode Parameter Select Select Press and hold down both buttons while turning On unit. Pulse Panel Setup Display Follow this procedure any time ac- cess is required.

  • Page 40: Selecting Welding Power Source Range

    10-3. Selecting Welding Power Source Range NOTE Welding power source minimum and maximum voltage values are always required. Amperage values are required for pulse welding. Range Display See welding power source Owner’s Manual for voltage and amperage ranges. Set values to match weld- ing power source ranges.

  • Page 41: Selecting Security Lock

    10-4. Selecting Security Lock NOTE Security lock works only when a data card is inserted (see Section 9-1). Security Display Use this display to lock a program’s weld parameters so that changes Access can not be made using pulse panel Setup controls.

  • Page 42: Selecting Or Changing Access Code

    10-5. Selecting Or Changing Access Code NOTE Access code works only when a data card is inserted (see Section 9-1). Code Display Access With code off, access to the setup Setup displays is not restricted. Display With code on, the operator must know and enter the access code to access or change any of the setup displays.

  • Page 43: Selecting Voltage Correction

    10-6. Selecting Voltage Correction Mig Type Display With DVC Voltage Correction On, the unit uses closed-loop feedback from the 17-pin cord or voltage sensing leads to maintain set volt- age parameters. With DVC Voltage Correction Off, feedback from the arc is not used for closed-loop feedback to main- tain voltage parameters.

  • Page 44: Selecting Purge Time

    10-8. Selecting Purge Time Purge Display The purge time can be varied be- Use Purge only when a weld tween 0.0 (zero) and 25.0 seconds. program is not running. Press M i g T y p e Mode Select Increase Access I n d u c t .

  • Page 45: Selecting Regular Or Hot Arc Start

    10-10. Selecting Regular Or Hot Arc Start NOTE Arc Start selection is not used when welding in non-pulsed MIG. Do not use the Hot Start setting for .035 in (9 mm) or smaller wire. Arc Start Display Use the Hot Start mode for pulse welding with 450 Ampere Inverter Model when high initial weld current is necessary to start large diameter...

  • Page 46: Selecting Units For Wire Feed Speed And Motor Type

    10-12. Selecting Units For Wire Feed Speed And Motor Type Wire Feed Display The displayed unit of wire speed (IPM or MPM) can be changed along with the wire feed motor type (Standard, Low Speed, or High Speed). Press A r c S t a r t Di s p l a y Mode Select Access...

  • Page 47: Selecting Display

    10-14. Selecting Display Display Select Display The display can show amps, actual reading or print out command.. Press W i r e f e e d Mode Select Access W i r e t y p e C o mm a n d Setup >D i s p l a y Display...

  • Page 48: Selecting Arc Start/Volt Sense Error Shutdown

    10-16. Selecting Arc Start/Volt Sense Error Shutdown Voltage Shutdown Display With Arc Start/Volt Sense on, the unit shuts down when no arc volt- age is sensed. If the unit shuts down, an error message appears (see Section 11-3). With Arc Start/Volt Sense off, the unit continues to feed wire even when there is no arc voltage sensed.

  • Page 49: Remote Program Select

    10-18. Remote Program Select NOTE Remote Program Select is in binary code, with “A” the least significant bit, and “C” the most significant bit. Program Display When Program is On, a remote de- vice may be used to select pro- grams.

  • Page 50: Jog Wire Feed Speed Selection

    10-20. Jog Wire Feed Speed Selection Jog IPM Display This feature is only used with Jog wire feed speed can be varied arc-On style robots. between 50 and 780 inches per minute, IPM. Press Mode Select P r o g r a m Access S t i c k I P M...

  • Page 51: Arc Failure Shutdown

    10-22. Arc Failure Shutdown Arc Fail Display This feature can be turned on and off. If the feature is On, a time can be selected after which the weld is aborted. Press Mode Select J o g I P M T i m e r T i m e r Access...

  • Page 52: Routine Maintenance

    SECTION 11 – MAINTENANCE & TROUBLESHOOTING WARNING ELECTRIC SHOCK can kill. HOT PARTS can cause severe burns. • • Do not touch live electrical parts. Allow cooling period before servicing gun or unit. • Turn Off robot, interface, and welding power source, and disconnect input power before inspecting, maintaining, or servicing.

  • Page 53: Front Panel Error Displays

    11-3. Front Panel Error Displays Memory CRC Error Display Corrupted program data has been detected or loaded. The “X” value in- dicates the program number. May be caused by incompatible in- M e m o r y P r g formation on the data card or bad memory.
  • Page 54 Stop Weld Cycle Error Display An error has been detected and the robot hasn’t stopped the weld cycle, causing the interface unit to stop the weld cycle and wait for the robot to stop. S t o p W e l d C y c l e Error Card Read Display E r r o r...
  • Page 55 Diagnostic LED’s Cover Remove cover. Interface Board PC5 Diagnostic LED’s are visible inside unit, located on edge of Interface Board PC5 facing front of unit. Refer to Table 11-1 for information on diagnostic LED’s. Reinstall cover after checking diag- nostic LED’s. LED4 LED7 LED8...

  • Page 56: Section 12 – Electrical Diagrams

    SECTION 12 – ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram For Robotic Interface Unit OM-172 324 Page 50...
  • Page 57 SD-171 360-A OM-172 324 Page 51...
  • Page 58 Figure 12-2. Circuit Diagram For Microprocessor Board PC1 OM-172 324 Page 52...
  • Page 59 SD-161 039-A OM-172 324 Page 53...
  • Page 60 Figure 12-3. Circuit Diagram For Motor Board PC3 OM-172 324 Page 54...
  • Page 61 SD-083 388-B OM-172 324 Page 55...
  • Page 62 Figure 12-4. Circuit Diagram For Customer Interface Board PC4 OM-172 324 Page 56...
  • Page 63 SD-166 275 OM-172 324 Page 57...
  • Page 64 Figure 12-5. Circuit Diagram For Interface Board PC5 OM-172 324 Page 58...
  • Page 65 SD-165 466 OM-172 324 Page 59...
  • Page 66 SB-159 412 Figure 12-6. Circuit Diagram For Filter Board PC6 OM-172 324 Page 60...
  • Page 67 SC-165 462-A Figure 12-7. Circuit Diagram For Display Board PC7 OM-172 324 Page 61...
  • Page 68 SA-156 626-A Figure 12-8. Circuit Diagram For Data Card Board PC8 SA-158 163 Figure 12-9. Circuit Diagram For Pulse Display Board PC8 OM-172 324 Page 62...
  • Page 69 NOTES OM-172 324 Page 63...

  • Page 70: Figure 13-1. Case Section W/Components

    SECTION 13 – PARTS LIST ST-801 142 Figure 13-1. Case Section w/Components OM-172 324 Page 64...
  • Page 71 Item Dia. Part Mkgs. Description Quantity Figure 13-1. Case Section w/Components ... . 071 642 CIRCUIT CARD ASSEMBLY, motor speed control ....

  • Page 72: Figure 13-2. Panel, Front W/Components

    Item Dia. Part Mkgs. Description Quantity Figure 13-2. Panel, Front w/Components . . . DSPL1 . . . 165 459 CIRCUIT CARD ASSEMBLY, display .......

  • Page 73: Figure 13-3. Panel, Center W/Components

    Item Dia. Part Mkgs. Description Quantity Figure 13-3. Panel, Center w/Components ....099 037 EDGE TRIM, style 62-1/16 black w/clips (order by ft) ....

  • Page 74: Figure 13-4. Panel, Rear W/Components

    ST-801 145 Figure 13-4. Panel, Rear w/Components OM-172 324 Page 68...
  • Page 75 Item Dia. Part Mkgs. Description Quantity Figure 13-4. Panel, Rear w/Components ....171 363 PANEL, rear ........... . .
  • Page 76 ST-801 153 Figure 13-5. Motor & Drive Assembly OM-172 324 Page 70...
  • Page 77 Item Part Description Quantity Figure 13-5. Motor & Drive Assembly ..046 779 DRIVE ASSEMBLY, wire (consisting of) ........

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