Page 2 - From Miller to You
Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local Miller distributorto receive the latest full line catalog orindividual catalog sheets. To locate your nearestdistributor or service agency call 1-800-4...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards ...
Page 5 - SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.
OM-884 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This ...
Page 7 - Additional Symbols For Installation, Operation, And Maintenance; Principal Safety Standards
OM-884 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or nearcombustible surfaces. D Do not install unit near flammables. D Do not overload building wiring – be sure power supply system isproperly sized, ...
Page 8 - EMF Information
OM-884 Page 4 1-5. EMF Information Considerations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is some concern about suchfields. However, after examining mor...
Page 9 - Signification des symboles; Dangers relatifs au soudage à l’arc; UN CHOC ÉLECTRIQUE peut tuer.
OM-884 Page 5 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 procédureprésente des risques de danger ! Ceux-ci sont identifiéspar des symboles adjacents aux directives. Y Identifie un message...
Page 10 - LE BRUIT peut affecter l’ouïe.
OM-884 Page 6 Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS DE L’ARC peuvent pro-voquer des ...
Page 13 - SECTION 2 – INSTALLATION; Specifications; Mounting Hole Layout
OM-884 Page 9 SECTION 2 – INSTALLATION 2-1. Specifications Dimensions Weight Component Height Width Depth Net Ship Robot Interface 22-1/2 in. (572 mm) 16-1/2 in. ♦ (419 mm) 6-1/4 in.* (159 mm) 38 lbs. (17 kg) Gas/Current Sensing Control 4-1/2 in. (108 mm) 5-1/2 in. (140 mm) 10-1/2 in. (267 mm) 5 lbs...
Page 17 - 4-Socket Receptacle RC17 Information
OM-884 Page 13 2-9. 24-Socket Receptacle RC17 Information Socket* Socket Information A Provides connection to 2TA; for customer use. B Current Detect output to robot control unit with respect to Socket D; isolated CR1 contacts rated1A at 120 VAC. D Current Detect output to robot control unit with re...
Page 21 - SECTION 3 – OPERATION; Safety Equipment
OM-884 Page 17 2-14. Installing Optional Reel-Type Wire ST-161 000-A / ST-152 463 / Ref. ST-157 999-A 1 Retaining Ring 2 Lock 3 Spanner Nut 4 Wire Retainer 5 Welding Wire 6 Wire Reel 7 Hub Remove retaining ring. Pull lockand turn. Remove spanner nut, wireretainer, and wire reel from hub. To install ...
Page 23 - Indicator Lights
OM-884 Page 19 3-4. Indicator Lights Ref. ST-119 645-A 1 Gas Indicator Light Gas sight turns on when the gasvalve is energized to indicateshielding gas flow. 2 Contactor Indicator Light Contactor light turns on when the welding power source contactor isenergized to indicate that weldoutput is availa...
Page 24 - Burnback Control
OM-884 Page 20 3-5. Burnback Control Ref. ST-119 647-C / SB-191 630 Burnback circuitry keeps weldingwire from sticking to workpieceafter arc is extinguished. Thiscircuitry keeps weld output onwelding wire from 0 to 0.25 secondsafter wire has stopped feeding. Thisdelay action permits welding wire tob...
Page 25 - SECTION 4 – SEQUENCE OF OPERATION; Input/Output Signals
OM-884 Page 21 SECTION 4 – SEQUENCE OF OPERATION 4-1. Input/Output Signals ST-094 382-B Robot interface receives inputsignals for contactor control, gascontrol, jog, welding volts, and wirespeed. It also receives a signal toinitiate a check to see if wire is stuckto workpiece at end of a weld. Robot...
Page 26 - SECTION 5 – MAINTENANCE & TROUBLESHOOTING; Routine Maintenance; Months; Replacing The Hub Assembly
OM-884 Page 22 SECTION 5 – MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replaceunreadablelabels. Clean andtightenweldterminals. Repair orreplacecrackedweldcable. Check14-pincord. Check gashose andfittings. Checkguncable. Replacecrackedpar...
Page 27 - Overload Protection
OM-884 Page 23 5-3. Overload Protection Ref. ST-800 185-A / ST-119 644-B If fuse F1 opens, the robot interfaceshuts down. To check or changeF1, proceed as follows: 1 Fuse Holder Cover 2 Fuse F1 (See Parts List ForRating) 3 Circuit Breaker CB1 CB1 protects the wire feed motorfrom overload. If CB1 ope...
Page 28 - Display Board PC4 Meter Check
OM-884 Page 24 REAR VIEW OF DISPLAY BOARD PC4 Input Command For Wire Speed IPM Meter 0.8V = 800 IPM Input Command For Volts Meter –0.5V = 50V Power Supply For Wire Speed IPM Meter 5VDC Power Supply For Volts Meter And Ammeter 5VDC 5-4. Display Board PC4 Meter Check Ref. ST-117 838-B / Ref. ST-119 64...
Page 29 - Troubleshooting
OM-884 Page 25 5-5. Troubleshooting Y Disconnect power before troubleshooting Trouble Remedy No arc voltage control. Check and secure output control connections (see Section 2-4). Check and secure arc sensing connections (see Section 2-7). Check robot command voltage at Isolation Board PC5. Command ...
Page 30 - Use Of Indicator Lights For Troubleshooting
OM-884 Page 26 5-6. Use Of Indicator Lights For Troubleshooting Gas Indicator Light On Off Gas flows: Gas does not flow: Gas flows: Gas does not flow: System normal (on.) Check gas valve operation. Check gas valve operationand gas line for leaks. System normal (off). Check interface board PC3. Conta...
Page 31 - SECTION 6 – ELECTRICAL DIAGRAMS; Figure 6-1. Circuit Diagram For Robot Interface
OM-884 Page 27 SECTION 6 – ELECTRICAL DIAGRAMS 151 242-E Figure 6-1. Circuit Diagram For Robot Interface
Page 32 - SECTION 7 – PARTS LIST
OM-884 Page 28 SECTION 7 – PARTS LIST SC-119 647-A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Fig 7-2 5 30 31 32 33 34 35 36 . Hardware is common andnot available unless listed. Figure 7-1. Control Box Description Part No. Dia. Mkgs. Item No. Figure 7-1. Control Bo...
Page 38 - Notes
Page 39 - (Equipment with a serial number preface of “LA” or newer)
Warranty Questions? Call1-800-4-A-MILLERfor your localMiller distributor. miller_warr 7/00 Your distributor also givesyou ... ServiceYou always get the fast,reliable response youneed. Most replacementparts can be in yourhands in 24 hours. SupportNeed fast answers to thetough welding questions?Contac...
Page 40 - Please complete and retain with your personal records.; For Service
PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00 Miller Electric Mfg. Co. An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters–USAUSA Phone: 920-735-4505 Auto-AttendedUSA & Canada FAX: 920-735-4134International FAX: 920-735-4125 European Head...
