Miller Electric NSPR 8989 user manual

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November 1990 FORM: OM-135 582B
Millerfi
Interface
MODEL: Robot
NSPR
(per 8989)
OWNERS MANUAL
iMPORTANT: Read and understand the entire contents of both this manual
MILLER Co.
ELECTRIC
Mfg.
and manual used with this with
the source unit, on A MIter Group Ltd..
power special emphasis Con~any
the material both before or
safety throughout manuals, Installing, operating,
P.O. Box 1079
this This unit and these Instructions for use
are only WI 54912 USA
maintaining equipment. Appleton,
and In the of T

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ii Ui MILLERS TRUE BLUETM LIMITEDWARRANTY Effective 1992 January 1, with a serial number of KC or (Equipment preface newer) This limited all MILLER warrantIes and is exclusive with no other or warranties expressed or implied. warranty supersedes previous guarantees Kits LIMITEDWARRANTY to the terms and conditions below, MILLER Electric Accessory Subject retail Co., Appleton, Wisconsin. warrants to its original purchaser that new MIg. Replacement Parts sold after the effective date of th

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ERRATA SHEET After this manual was refinements in occurred. This sheet lists printed, equipment design exceptions later in this manual. to data appearing AMENDMENTTO SECTION INSTALLATION 3 - Amend Section 3-5B. ROBOT INTERFACE WELDING POWER SOURCE CONNECTIONS: REMOTE 17 Connections 3. For units used with Pulstar450 it is internal to connections in the robot welding power source, necessary change interface. Proceed as follows: ELECTRIC kill. WARNING: SHOCK can tk Do touch live electrical not _

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DVC SWITCH SETTINGS S2 Si 2 4 1 2 1 3 5 DELTAWELD 300 ON ON ON 0 ON ON DELTAWELD 451 DELTAWELD 651 0 ON ON MAXTRON 400 ON ON 300, MAXTRON ON ON ON 450 ON XMT200/300 ON ON ARC PAK35O ON ON ON ON ON ON SHOPMASTER 300 DIMENSION 400 ON ON O On For Soft Start. Turn Off Si -3. Optional On For Hot Start. Optional S~15o864A DVC DIP Switch Label 3-7. Figure Setting PCi Add Section 3-10. SETTING DIP SWITCHES ON VOLTAGE CONTROL BOARD and S2 control board PCi allow the command level for control DIP swi

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WARNING: ELECTRIC SHOCK can kill. a Do not touch live electrical parts. and and disconnect Shut down unit, source, wire feede~ Iockout/ welding power inputpower employing before circuit board modifications. procedures tagging making in consist of line disconnect switch fuses Lockout/tagging procedures padlocking open position, removing from fuse box, or off and circuit breaker or other device. shutting red-tagging disconnecting ELECTROSTATIC DISCHARGE can circuit boards. (ESD) damage i Put o

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Ret. SD148 322 3-8. Locations On Control Board PCi Figure Jumper Voltage AMENDMENTTO SECTION 7 ELECTRICAL DIAGRAMS Amend 7-1. Circuit For Robot Interface 8 on this Errata Diagram Diagram (see Sheet) page 7-2. Circuit For Delete Board PCi Diagram Diagram Voltage This no effective with Serial No. KC231 859 diagram longer applies Amend 7-3. Circuit For Motor Control Board PC2 6 and 7 this on Errata Diagram Diagram (see pages Sheet) Amend 7-4. Circuit For Interface Board PC3 9 on this Errata Diagr

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AMENDMENT TO SECTION 8 PARTS LIST follows: Amend Parts List as Dia. Part Replaced No. With Description Mkqs. Quantity 19- 028 291 028 291 & . . CAPACITOR, dia. is now 5 . .. (qty chg mkg. chg) (C2-4 C6-10) . Added CR4 095 521 RELAY, end 24VDC 4PDT 1 . . . . . . . 19- 049 970 048 588 1 . . . .. BRACKET, mtg relay 19- 079 844 079 844 . . . .. SPRING, (qty 2 chg) 19- 027811 027811 . . . SOCKET, 2 .. (qtychg) 19- 048 029 048 029 CLIP, 2 . . . .. (qty chg) 19- 026 202 026 202 . . . .. DIODE, 3 (qty

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ALL WAVEFOPIlS AT 300 IPW-MOTOP PUNNING ALL VOLTAGES MEASIJPED WITH PESPECT TO COM)OJ POINT J. EXCEPT ~4. MEASURE fi~ H WITH RESPECT TO POINT ~I(. '111_ _nrL fi ft_ill fi~ W S V V A A L~i ~ 052 R s J B 3V. 7-3. Circuit For Motor Control Board PC2 Diagram Diagram OM-135 582B 6 Page

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M F C P D 150 C?? Circuit No. 388-B SD-083 Diagram OM-135 5828 7 Page

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230 Y SPEED 42 H H JO /0/ 54 S CIS4TP12.. 1AOOTER FEEOBAO< FEED L L /00 52 000 U 14 SC-i 2 K /2 K 5 6 ~ 69 WIRE 0000 PC9 U J 0 J8 68 3 No. >>~< H 0 H 0 78 84 1>> B>) p ~ S 2 0 0 0 JI 0 76 F 75 F /1 Diagram E 72 J5 000 GE o 75 65 S. E 184 C 0 C 0 12 J2 C Circuit - 0 4 B 52 B 88 0C I A 52 STICK P H ITO 2T /5 - A P v____v____v_.J 9d00/REGSO - PC6 ,k19 J A SENRE/WIRE ~ KC231859 ON 0 A~ F A A-S IIJCH ~\ A No. ___________ u ~ I j<)(L Serial /04 1/05 ~ CS,~jC41j~, 2 < c< B PCI With RC9 10 S

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POIJER/GROUHO NETS FOR CHIPS RI i~GND 8 IS) UI 8.5140 I6~ISU Circuit No. SB-141 Diagram 311-A 7-4. Circuit Diagram For Interface Board PC3 Diagram OM-135 5828 9 Page

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OM-135 5829-11/90 RECEIVING-HANDLING Before checkcartonfor dam- Use the to record the Model unpackingequipment, following any spaces Designa~ that have occurred File tion and Serial or Number of unit. The infor age may during shipment. any Style your with the claims for loss or carrier. mation is located on the data card or the damage delivering nameplate. Assistance for claims be obtained or filing settling may from the distributor and/or the manutactur- Model equipment ________________________

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Section No. No. Page SECTION 6 MAINTENANCE & TROUBLESHOOTING 6-1. Routine Maintenance 8 6-2. Overload Protection 9 Of Hub 6-3. Reinstallation 9 Assembly PC4 Meter 6-4. Board Check 9 Display 6-5. Circuit Board Precautions 10 Handling 6-6. 11 Troubleshooting 6-7. Use Of For Indicator 13 Lights Troubleshooting SECTION 7- ELECTRICAL DIAGRAMS 7-1. Circuit For Robot Interface 14 Diagram Diagram 7-2. Circuit For Board PCi 15 Diagram Diagram Voltage 7-3. Circuit Motor Control Board PC2 16 Diagram Diagr

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- AND SIGNALWORDS SECTION 1 SAFETY PRECAUTIONS AND SIGNAL SAFETY 1-2. SAFETY ALERT SYMBOL INFORMATION AND 1-1. GENERAL WORDS AGenera I The alert and words are symbol signal following safety thismanual to call attentiontoand iden used Ia- throughout Information in this manual and on various presented and instructions. different levels of hazard special the unit to tify and on pertains equipment bels, tags, plates and installation, maintenance, design, operation, ~ This alert is used with the safe

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SECTION 3INSTALLATION 3-1. SITE SELECTION 3. The cords must be routed so that interconnecting are not or strained they caught, pinched, during Select an installation site which the provides following: operations. welding 1. Correct unit input supply (see nameplate) power 4. One weld cable must be routed to the Gas/ output Current control. Sensing 2. Shielding gas supply (if applicable) 5. wire must be routed that it so does notcon Welding 3. Water supply (if applicable) tact the weld control or

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3-3. GAS/CURRENT SENSING CONTROL INTER A. Robot Interface Gas/Current Control Sensing CONNECTIONS Connections (Figure 3-2) WARNING: ELECTRIC SHOCK kill. can 1. insert Align keyways, into 14-pinAmp plug matching a Do not touch live electrical RC9 on robot receptacle interface, and rotate parts. threaded collar clockwise. fully Shut down unit, and welding power source, and disconnect robot, input power employing 2. insert Align keyways, into 16-pinAmp plug matching before inter lockout/taggi

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Nut 3-6. ROBOTINTERFACE-ROBOTCONTROLUNIT CONNECTIONS 3-2 And (Figures 3-4) WARNING: ELECTRIC SHOCK can kill. Sensing a Do Lead not touch live electrical Ring parts. Terminal Shut down unit, and welding power source, Location and disconnect robot, input power employing Cable Lug before inter lockout/taggingprocedures making Location connections. consist of Lockout/tagging procedures padlock line disconnect switch in re ing open position, fuses from fuse box, or off and moving shutting TA-109

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Socket V: control connection. 2. For Voltage negative () robot control unitswhen 115 24 24 or vac, or vdc is used (Figure 3-5): Socket W: Wire feed connection. speed positive (+) a. Route cord strain relief on side through right Socket X: Wire feed connection. speed wiper of robot and make panel interface, con proper Socket Y: Wire feed connection. speed negative () nections to 1TL and 1TM. IMPORTANT: The sockets in the remaining receptacle b. Obtain a 115 or 24 or 24 vdc isolation vac, relay

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Of Hub Tension 3-8. WELDING WIRE INSTALLATION C. 3-1) (Figure 3-6) Adjustment (Figure A. Installation Of Wire Spool-Type Check the hub tension the wire by rotating spool slowly The wire should but hub tension or reel. unwind freely, 1. Remove retaining ring. should be sufficient to wire taut and back keep prevent 2. wire onto hub that wire feeds oft Slide of so spool when the wire feed If is lash required, stops. adjustment bottom of spool. of the hub loosen or the hex nut on the end tighten sup