Miller Electric Welding User's Manual
Contents
1. 23 SECTION 6 HF IN PLASMA ARC WELDING 24 SECTION 7 PARTS LIST Ee dee nee 26 OM 169 510 6 95 SECTION 1 SAFETY PRECAUTIONS AND SIGNAL WORDS 1 1 GENERAL INFORMATION AND SAFETY A General Information presented in this manual and on various la bels tags and plates on the unit pertains to equipment design installation operation maintenance and trou bleshooting which should be read understood and fol lowed for the safe and effective use of this equipment B Safety The installation operation maintenance and trouble shooting of plasma arc welding equipment requires practices and procedures which ensure personal safety and the safety of others Read and follow safety information in the Plasma Weld ing Console Owner s Manual and Welding Torch Own er s Manual as well as the other Owner s Manuals for this system to ensure the safe installation and operation of the Plasma Arc Welding system 1 2 SAFETY ALERT SYMBOL AND SIGNAL WORDS The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instruc tions This safety alert symbol is used with the signal words WARNING and CAUTION to call atten tion to the safety statements WARNING statements identify procedures or practices which must be followed to2. machine to rod 1 E T 146 002 TORCH GAUGE universal RC RE 169454 2 IS EE Re esa Rat sat Renfe Ert x ambae d 171042 SHIELD plasma welding torch 143 352 CLAMP o A O ete 4 169 453 BRACKET mtg 1 gees 1971 73 HOLDER Cables iret bee a a r Pun esti eo ha 141 409 INSULATOR plate 1 e 141449 5146 2 2er eret eR ae Ier eere LENS ore taf 139465 COVER y satire at Me nte Gael 134 464 LABEL warning general precautionary 1 enis 602 969 PLUG protective No 6 2 MA 146 696 HF FILTER BOX consisting of 1 1 140510 CIRCUIT CARD RF filter 1 134 201 STAND OFF SUPPORT PC card 312 375 4 PLG10 115092 CONNECTOR 4 SOCKETS consisting of
3. 169 510 June 1995 m Miller 6 Plasma Arc PAW Welding The Power of Blue Description Automatic Welding Robot PAW Interface Vete OWNER S MANUAL www Miller Welds com EMF INFORMATION NOTE 7 Magnetic Fields The following is a quotation from the General Conclusions Section of the U S Congress Office of Technology Assessment Biological Effects of Power Frequency Electric amp Magnetic Fields Background Paper OTA BP E 53 Washington DC U S Government Printing Office May 1989 there is now a very large volume of scientific findings based on experiments at the cellularlevel and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with and produce changes in biological systems While most of this work is of very high quality the results are complex Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework Even more frustrating it does not yet allow us to draw definite conclusions about questions of possible risk orto offer clear science based advice on strategies to minimize Considerations About Welding And The Effects Of Low Frequency Electric And To reduce magnetic fields in the workplace use the following procedures 1 Keep cables close together by twisting or taping them Arrange cables to one side and away from the operator 2 3 Do no
4. 1 xS ture d 113 746 CONNECTOR rect skt 24 18ga 2 PLG31 135 635 CONNECTOR 4 PINS consisting 1 D 114 656 CONNECTOR rect pin 24 18ga 2 PE cda 039 828 CONNECTOR circ clamp str rlf sz 14 145 1 IET 113 746 CONNECTOR rect skt 24 18ga 2 049 455 CABLE port No 18 2 c order by ft Oft 139 040 BUSHING strain relief 231 394 ID 733mtg hole 1 RC20 26 145 706 CIRCUIT CARD CONNECTOR 1 21 077 175 CONNECTOR circ 11 sz 20 rcpt 1 4 2 4 1697460 lt lt TIMERCW EGSISTOE oss cep AER RE RE ea 1 6T 038839 BLOCK term 20A BP 1 hot Uc in 169 462 CASE SECTION front bottom dt 199454 PANEL fean Loro cad a rb ERI UE id sphere Dueb TM NAMEPLATE order by model and serial number 1 aca 134 241 CABLE port 18 2 c order by ft 351 6 25 146 242 CONNECTOR circ
5. OM 169 510 Page 6 e Place a supplied external star washer over each screw and thread screws into mounting holes in side panel see Figure 3 7 Tighten screws until star washers flatten and penetrate through paint into metal surface Place remaining star washers over threaded portion of each screw extending out from side panel inside Robot Control and install nut on each screw Tighten nuts until star washers flatten and penetrate through paint into metal surface Reinstall and secure cover onto filter box Route high frequency cord inside Robot Con trol to Interlock board on left side panel of cabi net Route black and white leads to terminal block TB1 see Figure 3 9 Connect black lead to terminal 4 on TB1 Connect white lead to terminal 5 on TB1 Close and secure Robot Control cabinet door Disconnect friction terminals on leads of exist ing shock sensor cord from shock sensor leads at welding gun body see Figure 3 8 Remove existing shock sensor cord by discon necting plug from receptacle on robot Robot Control Side Panel Filter Box ST 152 641 Figure 3 7 Installation Of Securing Hardware For Filter Box q Route supplied 35 ft 10 5 m shielded shock r Connect plug on end of cord to filter box recep sensor cable under the torch cable securing tacle straps on the outside of the protective casing so s Connect friction connectors or plug on remain that the two leads with frict
6. 134860 CONNECTOR amp PINS consisting of 1 E 134 184 CONNECTOR rect pin 20 16ga JST SLM 41T 1 3E 4 117 160 PILOT LAMP consisting of 2 1415276 BULB LED red 28V min bayonet 1 144 629 BRACKET shock sensor and lights 1 io 134 518 HANGER cable assembly 1 TOR 134 529 INSULATOR cable hanger 1 EN 159 599 SUPPORT cable 1 ONSE 149 442 BRACKET mtg 1 TM 135090 INSULATING BRACKET 1 EN 170 395 BEOGK 1 eem 170396 CLAMP block angle 1 CES 170 397 2 BRACKET offset oic esr ole SR Eee ce e ET 137 063 SPRING ext 625 OD x 062 wire 4 500 19 1 119622 4 CABLE 5 otto EU Saba eae 134 011 INSULATOR bracket When ordering a co
7. i PLG21 aK c gt 28 COMMAND COMMON recie RC2 3 A H PLGIO D 104 X RCI 3 4 pO ENTA 05 CONTACTOR WT RC I 8 2 1 gt lt 2 gt ow 1 550 gt ge EC RC2 6 gt 60 K amp RCI 4 gea gt FW PCIO PLG3O FILTER BOARD 106 RCI PLGI 66 j WCR 107 RC2 PLGI2 RC3 GRN LEAD 2 714 pLasma e GAS SET T CRIO PILOT ARC 2 B 9 te 172 PILOT ENABLE reo uec SHIELD GAS ENABLE aes o GRN 60 RC26 GN eT 60 08 108 2 oes monou SB 169 458 Figure 5 2 Circuit Diagram For Robot PAW Interface Panel 3 108 6 21 9 8 4 66 6 1 TOA RC21 B OBB 6T A 238 6 BH RS 82 18 O O 660 6 TISA CRTI 7 GRN E GND PLG31 RC21 Di 2p JH bi j PON 8 4 499 9 9 5 5048 8 8 B E A xz f 2 amp 5 5 885 8 5 21 x 9 e 3 9 88 8 8 TIBA CRTI 4 Po4 FILTER BOARD Em ale TD1 feo 8
8. 1 mE 113 746 CONNECTOR rect skt 24 18 6 PLG20 115 093 CONNECTOR 4 SOCKETS consisting of 1 113 746 CONNECTOR rect skt 24 18 6 MU 600 340 CABLE port No 16 2 c order by ft Aft 139268 CONNECTOR circ 10skt rcpt 1 148 104 CASE SECTION front bottom rear 1 149 103 zza WRAPPER t Dae teta orc eerie Dubois d 139 040 BUSHING strain relief 231 394 ID x 733mtg hole 1 107 983 BLANK snap in nyl 500mtg hole 2 148 943 LIGHT BOX servo consisting 1 eie qu 134 171 CABLE shock sensor and lights consisting of 1 RC1 048282 CONNECTOR w SOCKETS consisting of 1 He ote 079 534 CONNECTOR circ skt push in 14 18ga Amp 66358 6 4 CR 604 571 CABLE port No 18 4 c order by ft dft TEL cores 010 116 GROMMET rbr 375 ID x 500mtg hole PLG1
9. 10 0 1 Sixtus s 138 033 CONNECTOR circ clamp str rlf sz 18 1 cre 073 516 CONNECTOR circ 11 skt plug 1 116 964 CONNECTOR circ clamp str rlf sz 20 22 1 Pun ieri ei 097 426 CABLE shld No 18 10 c order by ft D T 169 455 CABLE interconnecting 15ft consisting of 1 141 162 CONNECTOR PINS consisting of 1 iA ted 134 731 CONNECTOR circ push in 14 18ga 14 n 079 739 CONNECTOR circ clamp str rlf sz 17 20 1 pote 110015 CABLE port 18 7 c order by ft 156 th ides hy dae 048 598 CONNECTOR amp SOCKETS consisting of 1 079 534 CONNECTOR skt push in 14 18 16 079 739 CONNECTOR circ clamp str rlf sz 17 20 1 bod 169 464 CABLE interconnecting 15ft consisting of 1 TL 047 636 CONNECTOR amp PINS consisting of 1 dd g
10. avoid seri ous personal injury or loss of life CAUTION statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment IMPORTANT statements identify special instructions necessary for the most efficient operation of this equip ment SECTION 2 INTRODUCTION 2 1 DESCRIPTION The robot PAW interface panel is a control designed to be used with a Thermal Dynamics WC 100B plasma welding console and a plasma arc welding torch PWM 3A MILLER Computer Interface and 2 or MRV robot system for the Plasma Arc Welding PAW process SECTION INSTALLATION PAW Interface Panel Plug PLG21 Connects To Computer Interface Receptacle RC8 See Section 3 7 Ne Gas Set Pilot Arc Start Push Button Receptacle RC21 See Section 3 8 Receptacle RC20 See Section 3 8 Computer Interface Computer Interface Input Power Receptacle RC11 Location See Section 3 9 And Computer Interface Owner s Manual ST 800 732 Figure 3 1 PAW Interface Panel OM 169 510 Page 1 IMPORTANT When installing or operating plasma arc welding equipment refer to the Plasma Welding Con sole Owner s Manual and Welding Torch Owner s Manual for specific precautionary information that ap plies to this equipment 3 1 FIELD INSTALLATION INSTRUCTIONS FOR PAW INTERFACE PANEL TO COMPUTER IN TERFACE Figure 3 1 And Figure 3 2 WARNING ELECTRIC SHOCK ca
11. housing directly in front of torch cable support bracket using the existing mounting holes see Figure 3 7 Position supplied insulator plate be tween light box and robot align holes and secure with supplied hardware Connect plug on light box cord to nearby matching receptacle located on the side of the Axis 3 housing The receptacle on the light box is not used for this application 4 Install cable hanger assembly with tool balancer onto robot Axis 3 housing 5 The torch cable is enclosed in a black protective case Secure torch in torch clamp using supplied shim Position torch handle so that there is approximately 4 in 96 mm between the bottom of the torch clamp and the torch tip Clamp torch cable to tool balancer on cable hanger and route cable through support bracket IMPORTANT Before operating see Section 4 and ro bot Owner s Manual for instructions for absolute offset adjustment Install positioning gauge universal J bar for MRH or l bar for MRV2 onto robot output hub brack et Remove the shield cup and tip from torch and install the supplied brass tip gauge 6 Route remaining end of torch cable to the WC 100B welding panel for internal connections see Step 3 Section 3 6B 7 Install supplied high frequency filter box accord ing to instructions for MRH see Section 3 4A 3 5 GROUND CABLE CONNECTIONS Figure 3 10 And Figure 3 11 IMPORTANT f welding power source is equipped with a plastic ca
12. wiring water pipe and fixtures external phone and power lines S 0754 Figure 6 2 Sources Of High Frequency Radiation From Incorrect Installation OM 169 510 Page 24 Ground All Metal Objects And All Wiring In Welding Zone Using 12 AWG Wire 1 Plasma Arc Welding Power Source Ground metal machine case line discon nect device input supply and workpiece if required 2 Center Point Of Welding Zone Midpoint between high frequency source and welding torch 3 Welding Zone A circle 50 ft 15 m from center point in all directions 4 Torch And Work Cables Keep cables close together Workpiece If Required By Codes 5 Conduit Joint Bonding And Grounding Electrically join bond all conduit sections using copper straps or braided wire Ground conduit every 50 ft 15 m 6 Water Pipe And Fixtures Ground water pipe every 50 ft 15 m 7 External Power Or Telephone Lines Locate high frequency source at least 50 ft 15 m away from power and phone lines 8 Metal Building Panel Bonding Methods Bolt or weld building panels together install copper straps or braided wire across seams and ground frame 9 Grounding Rod Consult the National Electrical Code for specifications 10 Windows And Doorways Cover all windows and doorways with grounded copper screen of not more than 1 4 in 6 4 mm mesh 11 Overhead Door Track Ground the track F
13. 0 3 7 Interface Panel Computer Interface Connection 10 3 8 PAW Interface Panel Welding Power Source PAW Console Connections 11 3 9 Computer Interface Input Power 12 3 10 Gas Set Pilot Arc Start Push Button 1 12 3 11 Remote Gas Set Pilot Arc Start Switch lt 12 SECTION 4 ROBOT PROGRAM MODIFICATIONS 13 4 1 Setting Up Plasma Non Standard Torch For MRH Robot 13 4 2 Setting Up Plasma Torch For MRV2 Robot 13 4 3 Marking Position Of Torch Head Assembly 13 4 4 System Setup For MRH And MRV With C2 Robot 14 SECTION 5 ELECTRICAL DIAGRAMS 21 Figure 5 1 Circuit Diagram For Robot PAW System 21 Figure 5 2 Circuit Diagram For Robot PAW Interface Panel 22 Figure 5 3 Wiring Diagram For Robot PAW Interface Panel 22 Figure 5 4 Circuit Diagram For High Frequency Filter 23 Figure 5 5 Wiring Diagram For High Frequency Filter
14. 1 on the Computer Interface front panel as follows align keyway insert plug and ro tate threaded collar fully clockwise Connect input pow er plug on other end of cord to a 115 volts ac external supply 3 10 GAS SET PILOT ARC START PUSH BUTTON IMPORTANT Thoroughly purge plasma torch gas line before starting pilot arc This button starts shielding gas flow when the Run Set switch on the WC 100B welding panel is in the Set posi tion When the switch is in Run position pressing the button starts shielding gas flow and 5 seconds later plasma gas flows and the pilot arc ignites WARNING PLASMA ARC can cause injury Keep away from the torch tip Pilot arc can cause burns keep away from torch tip when pilot arc is present The pilot arc can be intermittent or continuous depending on the application ALWAYS point torch away from personnel and toward work when starting the pilot arc or leaving the pilot arc on continuously OM 169 510 Page 12 To purge the plasma torch gas line proceed as follows 1 Turnoninput powerto welding power source and WC 100B console 2 Place Run Set switch in the Set position 3 Press the Gas Set Pilot Arc Start push button IMPORTANT Gas flow and pilot arc stop when an Emergency Stop button is pressed 3 11 REMOTE GAS SET PILOT START SWITCH CONNECTIONS WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Shut down robot and welding power s
15. CH GMAW OBE 045 062 SYNERGIC 035 045 062 SERVO OF F GTAW 100 035 045 062 GTAW 300 035 045 062 USER REGISTER REGIST MO DI FY SC EDIT 6 Usethe 4 peorement LL key and forward gt or back lt DISPLAY SE LECT key to select GTAW 300 by setting a wire size selection AXIS ML 4 POWER SOURCE WIRE TEACH GMAW 035 045 062 SYNERGIC 035 045 062 SERVO OF F GTAW 100 035 045 062 GTAW 300 035 045 062 USER REGISTER REGIST MO DI FY SC EDIT 7 Press the F1 key for the REGIST function to register the change in Robot Control memory SELECT TYPE OF PARAMETER TEACH MODE BY FUNCTION KEY SERVO OFF SENSOR AR C S TOUCH S W CHARA S DATA gt 8 check settings press the F4 key for the W CHARA function OM 169 510 Page 16 AXIS ML 4 POWER SOURCE WIRE TEACH GMAW 035 045 062 SYNERGIC 035 045 062 SERVO GTAW 100 035 045 062 GTAW 300 035 045 062 USER REGISTER REGIST MO DI F Y SC EDIT 9 Press the F2 key to select the MODIFY function AXIS ML 4 RATING OF POWER SOURCE TEACH WTBD31 TYPE SEPA SYNER Y d RATING CURRENT 200A SERVO W FEEDER RATING 256i PUSH RECORD AFTER SETTING 10 Use the or pecrement lt 4 key to select RATING CURRENT parameter AXIS ML 4 RATING OF POWER SOU TEACH WTBD 31 TYPE SEPA SYNER RATING CURRENT SERVO OF F W FEE
16. DER RATING PUSH RECORD AFTER SETT RCE 200A 256i ING 11 Use the numerical keys to amperage to the maximum current output of the welding power source OM 169 510 Page 17 AXIS ML 4 RATING OF POWER SOURCE TEACH WTBD31 TYPE SEPA SYNER TIG RATING CURRENT 004A SERVO OFF W FEEDER RATING 56i PUSH RECORD AFTER SETTING 12 Press the RECORD key AXIS ML 4 DISP REF DISP REF TEACH 1 504A 1 5V 50i 2 0V 2 150A 5 1021 4 0V 3 200 6 0 1531 6 0V SERVO OFF 4 250A 7 5 2051 8 0 5 300 10 0V 2561 10 0V 13 Use the ivcREMENT A or L forward gt or back DISPLAY SE LECT key to change the scaling of the amperage and reference voltage AXIS ML 4 DISP REF DISP REF TEACH 1 0 0 50i 2 0 V 2 794A 2 0 102i 4 0 V 3 1904A 5 0V 153i 6 0V SERVO OFF 4 8 0 2051 8 0 5 375 10 0V 2561 10 0V OM 169 510 Page 18 14 Press the RECORD key SELECT TYPE OF PARAMETER TEACH MODE BY FUNCTION KEY SERVO OFF SENSOR AR C S TOUCH S W CHARA S DATA gt 15 Check settings of weld characteristics as follows a Press the F4 key to select the W CHARA function AXIS ML 4 POWER SOURCE WIRE TEACH GMAW 035 045 062 SYNERGIC 035 045 062 SERVO GTAW 100 035 045 062 GTAW S300 0 95 045 062 USER REGISTER REGIST MO DI F Y SC EDIT b Press the F2 key to select the MODI
17. FY function AXIS ML 4 RATING OF POWER SOURCE TEACH WTBD31 TYPE SEPA SYNER lt RATING CURRENT 300A SERVO W FEEDER RATING 256i PUSH RECORD AFTEH SETTING c Press the RECORD key OM 169 510 Page 19 AXIS ML 4 DISP REF DISP REF TEACH 1 5A 0 0 V 50i 2 0V 2 79A 2 0 V 102i 4 0 3 190A 5 153i 6 0 SERVO OFF 4 8 0 2051 8 5 7 10 0 2561 10 0 16 Press the RESET key SELECT TYPE OF PARAMETER TEACH MODE NCTION KEY SERVO OFF SENSOR AR 5 TOUCH S W CHARA S DATA gt 17 Press the TEACH MODE key to return to the beginning of the Teach mode TEACH SERVO OFF TEACH EDIT FILE ALLOT LOCK gt OM 169 510 Page 20 SECTION 5 ELECTRICAL DIAGRAMS 319v90333 W313WOHOV1 628 PURGE GAS LED WFS FEEDBACK 1 22N3 33M lt 1 228 s gt a EZNI gt gt gt 8 9 8 H v 15 3 3 FEEDBACK RCI4 A 5 169 456 7927 ES eg 777 gt 3 1180 28v 5 1578 277 gt oo lt gt H 2 lt gt 2 o0 lt 0 lt 00 58958 00000 0 oO lt moowuoryd oooodboooo mQoouuorz 5x Figure 5 1 Circuit Diagram For Robot PAW System OM 169 510 Page 21 25 26 RC20 RC2 5 AS B 22 22 COMMAND lt RCI 6 RC2 2 gt lt
18. N33 CN32 CN31 CN28 11 CN4 LED602 JP601 JP602 JP603 CN46 JP306 CN45 LED50 DSW1 O swt CN70 CN71 CN72 CN40 JP701 LED503 502 4 2 Interlock A Board 5 0729 S 0727 Figure 3 9 Function Control Terminal Block TB1 On Interlock Board Inside Robot Control OM 169 510 Page 8 Torch Cable Support Bracket Robot Control High Frequency Filter Box DC Welding Power Source Shock Sensor Ground Cable Rod No 1 PAW Computer Interface Coolant WC 100B System 115VAC Input Plasma Power Cord Welding Console Torch Outlet Cable Cable In Support Arm Protective Case C Lifting Bracket Ground Cable T ecuring Bo Location a Shock Sensor Cable Torch Braided Ground Cable Ground Rod No 2 ST 800 734 Figure 3 10 MRH2 Robot PAW System B MRV2 Models 1 Remove the outlet cable support arm and wire drive assembly from the robot Axis 3 housing 2 Install supplied torch cable support bracket onto robot Axis 3 housing using the existing mounting holes Position supplied insulator plate between bracket and robot align holes and secure with supplied hardware see Figure 3 11 3 Install supplied servo light box onto robot Axis
19. QUENCY RADIATION can interfere with radio navigation safety services computers and communications equipment Have only qualified person familiar with electronic equipment perform this installation The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation 9 notified by FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding as shown in Figure 6 3 to minimize the possibility of interference mod6 2 5 94 1 Plasma Arc Torch 2 High Frequency Voltage Used inside torch to ionize gap between electrode and tip to help f start the pilot arc 6 3 Electrode 2 High Frequency HF 4 Pilot Arc 5 Tip 6 Shield Cup Plasma Arc Welding PAW Ref 5 0753 Figure 6 1 High Frequency In Plasma Arc Welding PAW 1 Sources Of Direct ied s Welding Zone High Frequency Radiation High frequency source Plasma Arc Welding power source cables torch work clamp work piece and work table 2 Sources Of Conduction Of High Frequency Input power cable line disconnect device and input supply wiring 3 Sources Of Reradiation Of High Frequency Ungrounded metal objects light ing
20. Tighten screw and setscrew when torch tip is touching Scribe Marks lower bar Screw Scribe marks where torch tip touches lower bar Setscrew Lower Bar ST 146 220 Figure 4 1 Scribe Marks on Universal J Bar 5 Position lower bar of universal J bar so that it touches torch tip gauge and scribe marks on the J bar to indicate exact torch position as shown in Figure 4 1 6 Remove universal J bar and retain for future use 4 2 SETTING UP PLASMA TORCH FOR MRV ROBOT Figure 4 1 The plasma torch does not require any changes to data in PARMTER SYSTEM TOOL PARAMETER The stan dard l bar is used for adjusting torch position and for position recovery after a robot crash Mount plasma arc welding torch install tip gauge and follow mounting ad justment procedures according to instructions in Sec tion 4 System Set Up in the robot Owner s Manual Loosen torch clamp setscrews and position torch so that tip gauge touches l bar reference point Retighten set Screw After completing torch adjustment procedure remove tip gauge and reinstall cup onto end of torch 4 3 MARKING POSITION OF TORCH HEAD AS SEMBLY Figure 4 2 When the mounting adjustment procedure is complete place scribe marks on the torch head assembly and sleeve to mark the torch head assembly position for fu ture alignment adjustments OM 169 510 Page 13 MRV2 Robot MRH Robot Robot Robot Arm Sleeve Torch Head Assembly As
21. alt TUA PLGO 2 107 21 102A PLGN 6 Els 212 93 0546 204 205 Iri 5 gle 26A EXIT Hom PC10 3 wm2A RC20 8 TO5A PLGN 8 104A PLGN 3 3 3 83 88 B 1 20 18 lt 5 n Y BLK PLG21 2 80 C T osecao lt KWHT PLG21 C 9 5 6T 4 919 z a X 2 zz 1 GRN B EXIT CRT als 9 TIR L i go Ek g JIi2A RC21 H 4 21 5 5 E 86 5 21 1 3 TIA RC21 F 9g 953 8 8 JOSA TD1 1 d 23C 6T C CE SB 169 459 A Figure 5 3 Wiring Diagram For Robot PAW Interface Panel OM 169 510 Page 22 6A PLGIO 8 7A PLGIO 4 8A PLGIO 3 RCI gt lt lt WHT IN gt lt lt lt 2 5 gt lt gt Wenige A D gt lt lt 1 6 5 I E gt KRI 7 RCI PLGIO RC2 PLG20 gt lt lt lt 4 RC3 gt lt lt 3 IN SA 146 608 A Figure 5 4 Circuit Diagram For High Frequency Filter RCS RCI PLGIO RC2 1 1 aatre D Saree eatre 2 PeT AR N SA 146 609 B Figure 5 5 Wiring Diagram For High Frequency Filter OM 169 510 Page 23 SECTION 6 HF IN PLASMA ARC WELDING WARNING HIGH FRE
22. dels 1 If applicable remove the existing wire feed mo tor reed relay mounting bracket and stabilizer brace from the robot refer to robot Owner s Manual for bracket and brace locations Rein stall the two lifting brackets only see robot Own er s Manual and Figure 3 10 2 If applicable remove the wire feed hub support from the robot refer to robot Owner s Manual for hub support location Install supplied torch cable support bracket in location where hub support was secured see Figure 3 10 3 torch cable is enclosed in a black protective case Secure torch in torch clamp IMPORTANT Before operating see Section 4 and ro bot Owner s Manual for instructions for absolute offset adjustment When doing this procedure remove the shield cup and tip from torch and install the supplied brass tip gauge 4 applicable remove the existing clamps sus pended from the outlet cable support arm and re place them with the two supplied clamps Route torch cable through new clamps so there is about 3 1 2 ft 1 m of cable between the top of the shock sensor and the first clamp see Figure 3 10 5 Route torch cable through torch cable support bracket tray and secure with rubber straps 6 Route remaining end of torch cable to the WC 100B welding panel for internal connections see Step 3 Section 3 6B 7 The supplied high frequency filter box prevents noise interference at the shock sensor circuit in the Robot Cont
23. down robot and welding power source and disconnect input power employing lock out tagging procedures before inspecting or installing Lockout tagging procedures consist of pad locking line disconnect switch in open position removing fuses from fuse box or shutting off and red tagging circuit breaker or other discon necting device 4 1 SETTING UP PLASMA NON STANDARD TORCH FOR MRH ROBOT Figure 4 1 Itis necessary to use the robot Owner s Manual in addi tion to this manual to complete the proper installation of the torch IMPORTANT Follow entire procedure in presented or der 1 Check System Data settings against the test sheet supplied with the unit These should match before beginning installation 2 Mount plasma arc welding torch according to Section 3 3 of this manual Make sure that sup plied brass tip gauge and holder have been installed on torch 3 Dotoolcenter point adjustment according to Sec tion 4 6 of the robot Owner s Manual 4 The universal J bar is included to record exact torch position so thatitis possible to recover posi tion in case of a robot crash Install universal J bar as follows a Remove 2 screws and cover plate from bottom of Axis 5 gear housing b Install universal J bar onto Axis 5 by aligning in dex pin with hole in housing and securing with supplied screws Attaches To Bottom Of Axis 5 Housing Rod Scribe around rod below lower bar to record height
24. e Computer Interface front panel Make connections as follows align keyway insert plug and rotate threaded collar fully clockwise 3 8 dzoo pe cmm PLASMA SHIELD ST 800 736 Figure 3 12 Terminal Strip TB1 Location Inside WC 100B Console PAW INTERFACE PANEL WELDING POW ER SOURCE PAW CONSOLE TIONS Figure 3 1 Figure 3 10 Figure 3 11 WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Shut down robot and welding power source and disconnect input power employing lock out tagging procedures before inspecting or installing Lockout tagging procedures consist of padlock ing line disconnect switch in open position re moving fuses from fuse box or shutting off and red tagging circuit breaker or other disconnect ing device Make connections to units as follows 1 Locate supplied cord with matching plug for weld ing power source Remote 14 receptacle and con nect plug to receptacle Connect plug on remaining end of cord from Re mote 14 receptacle to receptacle labeled Power Supply Control on rear of WC 100B console Locate supplied cord with matching plug for PAW interface panel receptacle RC20 and connect plug to receptacle 4 Connect plug on remaining end of cord from re ceptacle RC20 to receptacle labeled Remote Control on front of WC 100B console Locate supplied cord with matching plug for PAW interface
25. e Figure 3 2 a Remove jumper link between terminals B and C on terminal strip 2T b Connectlead 26 from the Interface panel to ter minal B on terminal strip 2T c Connectlead 60 from the Interface panel to top mounting screw on filter FL1 d Connect green lead from the Interface panel to the ground stud located directly above terminal strip 2T IMPORTANT Hemove the outside star washer from the ground stud to make room for the green lead terminal e Remove plug PLG3 from receptacle RC1 on In terface Board 4 f Connect plug PLG10 from the PAW Interface panel to Interface Board PC4 receptacle RC1 where plug PLG3 was removed in Step 4e plug PLG3 is not connected for this application Left Side View Of Computer Interface Motor Control Board PC2 Ground Stud Location Terminal Strip 2T Voltage Control Board PC1 Interface Board PC4 PC4 Switch S1 Location PC4 Receptacle RC1 Location Mounting Screw Location Filter FL1 Ret ST 139 887 C Figure 3 2 Computer Interface Internal Connections OM 169 510 Page 2 Robot Arm Shock Sensor Leads Insulator Plate Shock Sensor Welding Gun Body Mounting Bracket Mounting Bracket S 5 Cp ST 800 733 Figure 3 3 MRH2 Shock Sensor Unit Assembly And Installation Output Hub L Bracket Bracket Insulating Block Shock Sensor Leads hock Weldi
26. eehrt 079 535 CONNECTOR circ pin push in 14 18 0 14 TAMEN 079 739 CONNECTOR circ clamp str rlf sz 17 20 1 TOME 120 104 CABLE shld No 18ga 6 c order by ft 15 146 211 CONNECTOR circ 8 pin plug 1 073 296 CONNECTOR circ clamp str rlf sz 20 22 1 141 224 CABLE pwr interface consisting of 11 152 370 CONNECTOR SOCKETS consisting of 1 aes 079 534 CONNECTOR circ skt push in 14 18ga 14 pre E 143 922 CONNECTOR circ clamp str rlf sz 17 20 1 DE 604 825 CABLE port No 18 3 c 16 Tm 073 690 PLUG str grd 2P3W 15 125V 1 em 073 476 CLAMP strap rbr 5 holes 375 wide 4 625 lg 10 OM 169 510 Page 26 SECTION 7 PARTS LIST Mkgs No Description Quantity Spectrum Interface Continued E 169 452 SHOCK SENSOR w cover consisting of 1 mo 602 173 SCREW set stl sch 10 32 x 250 2 TH 141 564 CABLE
27. g parts HOT SURFACES can cause severe burns Allow cooling period before servicing To assemble and install the shock sensor unit refer to Figure 3 3 or Figure 3 4 and proceed as follows A MRH Models 1 If applicable remove existing gun torch and insu lator plate from robot arm OM 169 510 Page 4 2 Install supplied insulator plate to robot arm with screws removed in Step 1 3 Assemble shock sensor mounting bracket and torch clamp as shown in Figure 3 3 4 Install shock sensor unit to the insulator plate installed in Step 2 with supplied screws B MRV2 Models 1 If applicable remove existing shock sensor from robot arm 2 Assemble shock sensor mounting bracket and torch clamp as shown in Figure 3 4 3 Install shock sensor unit to robot insulating block with screws removed in Step 1 3 3 HIGH FREQUENCY TORCH CABLE The Pilot mode switch on the WC 100B console pro vides a selection for the pilot arc mode of operation If plasma arc welding is performed with the switch in the NORMAL position the optional shield sleeving should be installed on the torch cable PROTECTION FOR The optional shield sleeving is for covering the torch cable to prevent high frequency from interfering with ro bot operations IMPORTANT When installing shield sleeving be sure end with lead and attached ring terminal is at console end of the torch cable To install shield sleeving proceed as follows 1 Unscrew s
28. ground cable to welding power source case unless welding power source is equipped with a plastic case then no connection is necessary 3 6 TORCH CABLE INTERNAL CONNECTIONS TO PLASMA WELDING CONSOLE Figure 3 12 WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Shut down robot and welding power source and disconnect input power employing lock out tagging procedures before inspecting or installing Lockout tagging procedures consist of padlock ing line disconnect switch in open position re moving fuses from fuse box or shutting off and red tagging circuit breaker or other disconnect ing device MOVING PARTS can cause serious injury Keep away from moving parts HOT SURFACES can cause severe burns Allow cooling period before servicing OM 169 510 Page 10 To make torch cable internal connections proceed as follows 1 Remove WC 100B wrapper 2 Route torch cable through strain relief on front panel 3 Connect 2 cables and 2 hoses to torch mounting panel The color coded cables and hoses match the color coded connectors as follows a Red to red b Yellow to yellow c Black to black d Green to green 4 Reinstall WC 100B wrapper 3 7 PAW INTERFACE PANEL COMPUTER IN TERFACE CONNECTION Figure 3 1 Figure 3 10 And Figure 3 11 Connect plug PLG21 attached to cord extending from the PAW Interface panel front panel to weld current relay receptacle RC8 on th
29. igure 6 3 Correct Installation OM 169 510 Page 25 Dia Part Mkgs No Description Quantity Specirum Interface CR10 11 052 964 RELAY 24VDC DPDT 2 01 169465 DIODE w leads 1 D2 169 467 DIODE w leads 1 PB1 113333 1 PC10 140510 CIRCUIT CARD RF filter 1 RA ERR NATI 110 375 STAND OFF SUPPORT card 6 4 PLG10 115094 CONNECTOR amp SOCKETS consisting of 1 113 746 CONNECTOR rect skt 24 18ga 4 PLG11 115092 CONNECTOR 4 SOCKETS consisting of 1 MOT 113 746 CONNECTOR rect skt 24 18ga 8 PLG12 115093 CONNECTOR 4 SOCKETS consisting of 1 113 746 CONNECTOR rect skt 24 18ga 6 PLG21 047 544 CONNECTOR 4 plug 1 PLG30 131 054 CONNECTOR 4 SOCKETS consisting of
30. ion connectors are ing end of cord to shock sensor leads or recep located near the shock sensor tacle at shock sensor Shock Sensor Leads Welding Gun Body ST 141 731 ST 137 518 Figure 3 8 Welding Gun Torch Shock Sensor Leads OM 169 510 Page 7 TB1 IN ESTOP 2 ESTOP ESTOP 4 o o SHOCK 5 SHOCK 6 r INCOM INCOM N 8 LAMP 9 t AUTO 110 9 TEACH 11 STH 12 ST42 113 ST43 14 STOP 15 SV 16 V ON Terminal Block TB1 CC COO oe 9 CN68 CN69 CN67 D O S 9 S S S O O O O O G G G OG CN80 2 1A LED301O 8 LED2020 CN73 LED203O 37 CN22 LED204O LED205O JP301 LED303 LED302 1 0101 LED305 LED304 JP501 JP304 JP303 JP302 a CN47 OLED401 OLED402 LED601 LED603 OLED404 O LED405 O LED406 C
31. leeve from torch head assembly see Figure 3 5 2 Disconnect fittings and remove torch head as sembly 3 Insert torch cable into shield sleeving at end with lead and attached ring terminal 4 Slide shield sleeving over torch cable until end of torch cable exits opposite end of shield sleeving 5 Reconnect fittings from torch cable to torch head assembly match color coded markings 6 Check for coolant leaks atfittings by turning on re circulating coolant system Tighten fittings if nec essary Sleeve Green And Black Connections Yellow And Red Connections Torch Head Assembly ST 800 836 Figure 3 5 Connections At Torch Head Assembly 7 Screw sleeve onto torch head assembly 8 Secure shield sleeving to torch cable using sup plied clamp 3 4 TORCH AND TORCH CABLE INSTALLATION TO ROBOT Figure 3 3 Thru Figure 3 11 WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Shut down robot and welding power source and disconnect input power employing lock out tagging procedures before inspecting or installing Lockout tagging procedures consist of padlock ing line disconnect switch in open position re moving fuses from fuse box or shutting off and red tagging circuit breaker or other disconnect ing device MOVING PARTS can cause serious injury Keep away from moving parts HOT SURFACES can cause severe burns Allow cooling period before servicing A MRH Mo
32. mponent originally displaying a precautionary label the label should also be ordered Recommended Spare Parts OPTIONAL BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS OM 169 510 Page 27 Notes
33. n kill Do not touch live electrical parts Shut down robot and welding power source and disconnect input power employing lock out tagging procedures before beginning this installation Lockout tagging procedures consist of pad locking line disconnect switch in open position removing fuses from fuse box or shutting off and red tagging circuit breaker or other discon necting device CAUTION ELECTROSTATIC DISCHARGE ESD can damage circuit boards Put on properly grounded wrist strap BE FORE handling circuit boards Perform work only at a static safe work area INCORRECT INSTALLATION or misaligned plugs can damage circuit board Be sure that plugs are properly installed and aligned EXCESSIVE PRESSURE can break circuit board Use only minimal pressure and gentle move ment when disconnecting or connecting board plugs and removing or installing board IMPORTANT directions such as left or right are with respect to the operator facing the Computer Inter face front panel Retain all hardware removed during this procedure for reinstallation unless specifically told otherwise 1 Remove Computer Interface top cover and left side panel Remove side panel from PAW Interface panel Install PAW Interface frame onto left side panel of Computer Interface with sheet metal screws re moved in Step 1 see Figure 3 1 4 Make the following internal connections to the Computer Interface se
34. ng Gun Shock Sensor Body Angle Bracket im C lamp Lj i Torch Mounting Angle Bracket Bracket AS OQ Torch Clamp ST 800 778 Figure 3 4 MRV2 Shock Sensor Unit Assembly And Installation OM 169 510 Page 3 g Connect lead 23 from PAW interface panel to terminal A on terminal strip 2T h Route plug 30 31 from PAW interface panel through center baffle in computer interface Dis connect plug PLG10 from plug PLG11 and con nect PLG 30 31 to PLG 10 11 5 Locate switch S1 on Interface Board PC4 see Figure 3 2 Remove varnish and potting com pound from S1 and place the two DIP switches on 61 in the following positions a S1 1 Disable Voltage Ramp in OFF position b 51 2 Disable Stick Checking in ON position 6 Reinstall side panel onto PAW Interface panel 7 Install supplied top cover onto the Computer In terface PAW Interface panel 3 2 SHOCK SENSOR UNIT ASSEMBLY AND INSTALLATION TO ROBOT Figure 3 3 And Figure 3 4 WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Shut down robot and welding power source and disconnect input power employing lock out tagging procedures before inspecting or installing Lockout tagging procedures consist of padlock ing line disconnect switch in open position re moving fuses from fuse box or shutting off and red tagging circuit breaker or other disconnect ing device MOVING PARTS can cause serious injury Keep away from movin
35. ource and disconnect input power employing lock out tagging procedures before inspecting or installing Lockout tagging procedures consist of padlock ing line disconnect switch in open position re moving fuses from fuse box or shutting off and red tagging circuit breaker or other disconnect ing device To make remote Gas Set Pilot Arc Start switch connec tions proceed as follows 1 Remove side panel from PAW Interface panel 2 Route one end of a 2 conductor customer sup plied cord through strain relief on rear of PAW In terface panel 3 Installing terminal connectors for connecting to terminal strip 6T onto leads at end of cord inside PAW Interface panel Install a normally open mo mentary contact switch to remaining end of cord 4 Connectleadsto terminals 6 and 6TD Tighten strain relief 5 Reinstall side panel onto PAW Interface panel IMPORTANT The remote Gas Set Pilot Arc Start switch operates the same as the front panel push button switch see Section 3 10 SECTION 4 ROBOT PROGRAM MODIFICATIONS IMPORTANT The robot program must be changed to accommodate plasma arc welding The program is fac tory set to accommodate factory installed plasma arc welding equipment The following information pertains to the robot Owner s Manual and must be followed when field installing plasma arc welding equipment WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Shut
36. panel receptacle RC21 and connect plug to receptacle Remove wrapper from WC 100B console Route cord to rear of WC 100B console Insert cord through strain relief and route end of cord to ter minal strip TB1 see Figure 3 12 Remove jumper leads from terminals on TB1 as follows a 10 and 11 b 12 13 13 and 14 Connect terminal connectors on remaining end of cord to terminals as follows Green lead to terminal 5 Orange lead to terminal 6 Brown lead to terminal 10 Blue lead to terminal 11 White lead to terminal 12 Black and red leads to terminal 13 0oo0c0p OM 169 510 Page 11 g Yellow lead to terminal 14 9 Route cable from welding power source negative weld output receptacle through opening in rear of WC 100B console Route end of cable to shunt located where torch cable bus bar is con nected and connect cable to shunt at end oppo site from bus bar 10 Route cable from welding power source positive weld output receptacle and connect end of cable to workpiece 11 Reinstall WC 100B wrapper a Remove paint from around right front screw hole on right side of wrapper b Connect ring terminal located on end of lead from shield sleeving to wrapper using screw that secures right front side of wrapper 3 9 COMPUTER INTERFACE INPUT POWER CONNECTIONS Figure 3 1 Figure 3 10 And Figure 3 11 Connect plug on supplied input power cord to 14 pin in put power receptacle RC1
37. rol To install the filter proceed as follows OM 169 510 Page 5 Robot Control LEFT SIDE RIGHT SIDE Blank Cover Plates Both Rows Blank Cover Plates 5 0782 Figure 3 6 View Of Left And Right Sides Of Robot Control WARNING ELECTRIC SHOCK can Kill ELECTROSTATIC DISCHARGE ESD can damage circuit boards Do not touch live electrical parts Shut down welding power source and Robot Control and disconnect input power employ ing lockout tagging procedures before in specting high frequency filter Lockout tagging procedures consist of padlock ing line disconnect switch in open position re moving fuses from fuse box or shutting off and red tagging circuit breaker or other disconnect ing device Put on properly grounded wrist strap BE FORE handling circuit boards or making con nections inside Robot Control Transport circuit boards in proper static shielding carriers or packages Perform work only at a static safe work area Open Robot Control cabinet door using the two supplied keys and rotate the power switch han dle beyond the OFF position to the Reset Open position Select and remove a blank cover plate from Ro bot Control for installing high frequency filter see Figure 3 6 Remove screws securing cover to high fre quency filter box and remove cover from box Insert cord attached to box through opening in Robot Control side panel where cover plate was removed
38. se only one ground cable is necessary for connecting to robot base See Figure 3 10 or Figure 3 11 and install three sup plied flat braided ground cables as follows 1 Connect one end of the ground cables to the cus tomer supplied ground rod see robot Owner s Manual 2 Connectremaining end of one ground cable to ro bot base as follows a Locate unused threaded hole on robot base b To ensure good electrical conduction scrape away enough paint from around the hole so that the ground cable terminal will touch bare metal c Attach ground cable terminal to base with sup plied 12 mm bolt OM 169 510 Page 9 Cable Servo Hanger Torch Cable Weldi T eldin Light In Protective Gun 3 Robot Control ox Case Body Torch Cable Support Bracket High Frequency Filter Box Shock Sensor DC Welding Cable Power Source Ground Rod No 1 Braided Ground PAW Computer Cable Interface Ground Sensor Cable vdd Shock Torch Rod No 2 System Plasma Braided Welding Ground 115VAC Input Console Cable Power Cord 47 Coolant WC 100B ST 800 735 A Figure 3 11 MRV2 Robot PAW System 3 Route remaining end of another ground cable to the plasma welding console Connect ground cable together with the lead from the shield sleev ing after completing internal connections see Section 3 8 4 Route remaining end of the last ground cable to the welding power source Connect
39. sembly ST 800 747 A Figure 4 2 Marking Position Of Torch Head Assembly 4 4 SYSTEM SETUP FOR MRH AND MRV WITH C2 ROBOT CONTROL Set welding power source specifications in user parameters for the Plasma Arc Welding PAW process according to the following instructions 1 Turn on Robot Control input power by placing the power switch handle on the Robot Control cabinet door in the ON position and the following displays will appear as shown WELCOME TO DIAGNOSIS MILLER COOPERATIVE CONTROL MILLER ELECTRIC Mfg Co START DIAGNOSIS 92 07 31 08 30 WELCOME DIAGNOSIS MILLER COOPERATIVE CONTROL STEP OF INITIAL DIAGNOSIS 1 2 375 4 5 92 07 31 08 30 OM 169 510 Page 14 SERVO OF F TEACH EDIT FILE ALLOT LOCK gt 2 Press the FUNCTION APPLICATION gt key for additional functions to appear on the display PARMTER CH MANAGE SYS SET MEMORY gt 3 Press the F1 key for the PARMTER function SELECT TYPE OF PARAMETER TEACH MODE BY FUNCTION KEY SERVO OF F SYSTEM SWITCH WELD 170 AUTO gt 4 Press the FUNCTION APPLICATION gt key for additional functions to appear on the display SELECT TYPE OF PARAMETER TEACH MODE BY FUNCTION KEY SERVO OF F SENSOR AR 5 TOUCH S W CHARA S DATA gt 5 Press F4 key for the W CHARA function to set welding characteristics OM 169 510 Page 15 AXIS ML 4 POWER SOURCE WIRE TEA
40. t coil or drape cables around the body 4 Keep welding power source and cables as far away as practical Connect work clamp to workpiece as close to the weld as possible About Pacemakers The above procedures are among those also normally recommended for pacemaker wearers Consult your doctor for or avoid potential risks complete information mod10 1 4 93 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS AND SIGNAL WORDS 1 1 1 General Information And Safety 1 1 2 Safety Alert Symbol And Signal Words 1 SECTION 2 INTRODUCTION 1 2 1 Descriptlon peer eene perm tee cB titer SECTION 3 INSTALLATION eA eb oo whee oa das nius 1 3 1 Field Installation Instructions For PAW Interface Panel To Computer Interface 2 3 2 Shock Sensor Unit Assembly And Installation To 4 3 3 High Frequency Protection For Torch 4 3 4 Torch And Torch Cable Installation To Robot 5 3 5 Ground Cable Connections 9 3 6 Torch Cable Internal Connections To Plasma Welding Console 1
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