Miller Electric NSPR 8989 User manual

Millerﬁ

November

1990

FORM:

OM-135

582B

MODEL:

Robot

Interface

(per

NSPR

8989)

OWNERS

MANUAL

iMPORTANT:

Read

and

understand

the

entire

contents

both

this

manual

and

the

power

source

manual

used

with

this

unit,

with

special

emphasis

the

safety

material

throughout

both

manuals,

before

Installing,

operating,

maintaining

this

equipment.

This

unit

and

these

Instructions

are

for

use

only

persons

trained

and

experienced

the

safe

operation

welding

equip

ment.

not

allow

untrained

persons

Install,

operate,

maintain

this

unit.

Contact

your

distributor

you

not

fully

understand

these

Instructions.

MILLER

ELECTRIC

Mfg.

Co.

MIter

Group

Ltd..

Con~any

P.O.

Box

1079

Appleton,

54912

USA

Tel.

414-734-9821

PRINTED

U.S.A

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1992

(Equipment

with

serial

number

preface

KC

newer)

This

limited

warranty

supersedes

all

MILLER

warrantIes

and

exclusive

with

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTY



Subject

the

terms

and

conditions

below,

MILLER

Electric



Accessory

Kits

MIg.

Co.,

Appleton,

Wisconsin.

warrants

its

original

retail

purchaser

that

new 

Replacement

Parts

MIl.LER

equipment

sold

after

the

effective

date

this

limited

warranty

tree

fects

material

and

workmanship

the

tune

shipped

MILLER.

THIS

WAR-

PANTY

EXPRESSLY

LIEU

ALL

OTHER

WARRANTIES,

EXPRESS

MILLER

True

Blue

Limited

Warranty

shall

not

apply

to:

IMPLIED,

INCLUDING

THE

WARRANTIES

MERCHANTABILITY

AND

FIT

NESS-

Items

fUrnished

MILLER,

but

manufactured

Others,

such

engines

trade

accessories.

These

items

are

covered

the

manufacturers

warranty,

Within

Inc

warranty

periods

listed

below,

MILLER

wilt

repair

replace

any

war-

any

ranted

parts

components

that

fail

due

such

detects

material

workmanship.

MILLER

must

notified

writing

within

thirty

30)

days

such

detector

failure,

Consumable

components:

such

contact

tips,

cutting

noZzles.

contactors

which

time

MILLER

will

provide

instructions

the

warranty

claim

procedures

lobe

and

relays

followed.

Equipment

that

has

been

modified

any

parry

other

than

MILLER,

equip-

MILLER

shall

honor

warranty

claims

warranted

equipment

listed

below

the

rnent

that

has

been

improperly

installed,

improperly

Operated

misused

event

such

failure

within

the

warranty

time

periods.

All

warranty

time

periods

based

upon

industry

standards,

equiprnentwhich

has

not

had

reasonable

start

the

date

that

the

equipment

was

delivered

the

original

retail

purchaser,

and

necessary

maintenance,

equipment

which

has

been

used

for

operation

and

are

follows:

outside

the

specifications

for

the

eQuipment

Years

Parts

-3

Years

Labor

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

COMMER

CIAUINOUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

Original

main

power

rectifiers

THE USE

AND

MAINTENANCE

WELDING

EQUIPMENT

Years



Parts

and

Labor

the

event

warranty

claim

covered

this

warranty,

the

exclusive

remedies



Transformer/Rectifier

Power

Sources

shall

be.

MILLERS

option:

(I)

repair:

(2)

replacement:

Or,

where

authorIzed



Plasma

Arc

Cutting

Power

Sources

writing

MILLER

appropriate

cases.

(3)

the

reasonable

cost

repair

replace-



Semi-Automatic

and

AutOrr~atic

Wire

Feeders

Went

authorized

MILLER

service

station:

(4)

payment

credIt

for

the

pur



Robots

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

the

goods

Customers

risk

and

expense.

MILLERS

option

repair

replacement

Years



Parts

and

Labor

will

,Factory

Appleton,

Wisconsin,

MILLER

authorized

ser

vice

facility

determined

MILLER

Therefore

compensation

reimburse.

Engine

Driven

Welding

Generators

merrt

for

transportation

costs

any

kind

will

allowed

(NOTE

Engines

are

warranted

separately

the

engine

manufacturer)

Year



Parts

and

Labor

THE

EXTENT

PERMITTED

LAW,

THE

REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

EVENT

SHALL

MILLER

Motor

Driven

Guns

LIABLE

FOR

DIRECT,

INDIRECT,

SPECIAL,

INCIDENTAL

CONSEQUENTIAL



Process

Controllers

DAMAGES

)INCLUDfNG

LOSS

PROFIT),

WHETHER

BASED

CON-

Water

Coolant

Systems

TRACT,

TORT

ANY

OTHER

LEGAL

THEORY.

Units

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR.



Grids

PANTY,

GUARANTY

REPRESENTATION

PERFORMANCE.

AND

ANY

Spot

Welders

REMEDY

FOR

BREACH

CONTRACT

TORT

ANY

OTHER

LEGAL



Load

Banks

THEORY

WHICH.

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

IMPLICATION.



SOX

Transformers

OPERATION

LAW,

CUSTOM

TRADE

COURSE

DEALING,

IN.

. .

CLUDING

ANY

IMPLIED

WARRANTY

MERCHANTABILITY

FITNESS

unning

ear

rai

era

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

ANY

AND

ALL

EQUIPMENT



Field

Options

FURNISHED

MILLER

EXCLUDED

AND

DISCLAIMED

MILLER.

(NOTE.

Field

options

are

covered

under

True

Blue

for

the

remaining

warranty

period

the

product

they

are

installed

in,

for

minimum

Some

states

the

U.S.A.

not

allow

limitations

how

long

implied

warranty

one

year



whichever

greater.)

lasts,

the

exclusion

incidental,

indirect,

special

consequential

damages,

the

above

limitation

exclusion

may

not

apply

you

This

warranty

provides

ape

Months



Batteries

cifiC

legal

rights,

and

Other

rights

may

available,

but

may

vary

from

state

state.

Days



Paris

and

Labor

Canada,

legislation

some

provincea

provides

for

certain

additional

warranties



MIG

Guns/TIC

Torches

remedies

other

than

stated

herein,

and

the

extent

that

they

may

not

Waived,

the

limitations

and

exclusions

set

out

above

may

not

apply.

This

Limited

Plasma

Cutting

Torches

Warranty

provides

specific

legal

rights.

and

olher

rights

may

available,

but

may



Remote

Controls

vary

from

province

province.

~1~

ERRATA

SHEET

After

this

manual

was

printed,

refinements

equipment

design

occurred.

This

sheet

lists

exceptions

data

appearing

later

this

manual.

AMENDMENT

SECTION

3

INSTALLATION

Amend

Section

3-5B.

ROBOT

INTERFACE

WELDING

POWER

SOURCE

CONNECTIONS:

REMOTE

Connections

For

units

used

with

Pulstar

450

welding

power

source,

necessary

change

internal

connections

the

robot

interface.

Proceed

follows:

WARNING:

ELECTRIC

SHOCK

can

kill.

______



not

touch

live

electrical

parts.



Shut

down

unit,

welding

power

source,

and

robot,

and

disconnect

input

power

employing

lockouVtagging

procedures.

Lockout/tagging

procedures

consist

padlocking

line

disconnect

switch

open

position,

removing

fuses

from

fuse

box,

shutting

off

and

red-tagging

circuit

breaker

other

disconnecting

device.

Open

front

panel

access

door.

Locate

lead

REMOTE

receptacle

RC16.

Cut

lead

receptacle

possible.

Splice

lead

REMOTE

receptacle

RC13

Cover

splice

with

electrical

tape

other

insulation.

and

secure

front

panel

access

door.

CAUTION:

WELDING

POWER

SOURCE

may

not

respond

with

output

corresponding

set value.



sure

welding

power

source

main

control

board

has

been

modified

use

volt

command.

See

welding

power

source

Owners

Manual

for

modification

procedure.

Add

Figure

3-7.

Voltage

Control

Board

DIP

Switch

Setting

Label

CAUTION:

INCORRECT

DVC

BOARD

DIP

SWITCH

POSITION

can

cause

equipment

malfunction.



DVC

DIP

switch

factory

set

for

operation

with

Delta

weldﬁ

451

welding

power

source.

See

Figure

3-7

for

DVC

DIP

switch

setting

when

using

another

welding

power

source.

DVC

SWITCH

SETTINGS

DELTAWELD

300

ON ON

DELTAWELD

451

0ON

DELTAWELD

651

MAXTRON

300,

400

MAXTRON

450

XMT200/300

ON ON

ARC

PAK35O

ON ON

SHOPMASTER

300

ON ON ON

DIMENSION

400

Figure

3-7.

DVC

DIP

Switch

Setting

Label

Add

Section

3-10.

SETTING

DIP

SWITCHES

VOLTAGE

CONTROL

BOARD

PCi

DIP

switch

and

voltage

control

board

PCi

allow

setting

the

proper

command

signal

voltage

level

for

control

ling

voltage

output

welding

power

source.

change

factory

set

position

DIP

switches

from

Deltaweldﬁ

451

another

welding

power

source,

proceed

follows:

WARNING:

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.



Shut

down

unit,

welding

power

source,

and

wire

feeder,

and

disconnect

input

power

employing

lockout/

tagging

procedures

before

setting

DIP

switches.

Lockout/tagging

procedures

consist

padlocking

line

disconnect

switch

open

position,

removing

fuses

from

fuse

box,

shutting

off

and

red-tagging

circuit

breaker

other

disconnecting

device.

ELECTROSTATIC

DISCHARGE

(ESD)

can

damage

circuit

boards.



Put

properly

grounded

wrist

strap

BEFORE

handling

circuit

boards.



Transport

circuit

boards

proper

static-shielding

carriers

packages.



Perform

work

only

static-safe

work

area.

Loosen

screws

securing

front

access

door,

and

open

door.

Locate

voltage

control

board

PCi

lower

left

portion

component

mounting

panel

inside

robot

interface

con

trol.

Set

position

DIP

switches

and

according

label

inside

unit

and

Figure

3-7

for

appropriate

welding

power

source.

and

secure

access

door.

Add

Section

3-11.

VOLTAGE

CONTROL

BOARD

MODIFICATION

FOR

EARLY

MODEL

WELDING

POWER

SOURCE

the

robot

interface

control

used

with

early

model

Deltaweld

450

650

welding

power

source

prior

serial

number

JJ400026,

proceed

follows:



For

Optional

Soft

Start.

Turn

Off

-3.



For

Optional

Hot

Start.

S~15o864A

OM-135

5828

Page

WARNING:

ELECTRIC

SHOCK

can

kill.



not

touch

live

electrical

parts.



Shut

down

unit,

welding

power

source,

and

wire

feede~

and

disconnect

input

power

employing

Iockout/

tagging

procedures

before

making

circuit

board

modifications.

Lockout/tagging

procedures

consist

padlocking

line

disconnect

switch

open

position,

removing

fuses

from

fuse

box,

shutting

off

and

red-tagging

circuit

breaker

other

disconnecting

device.

ELECTROSTATIC

DISCHARGE

(ESD)

can

damage

circuit

boards.

Put

properly

grounded

wrist

strap

BEFORE

handling

circuit

boards.

Transport

circuit

boards

proper

static-shielding

carriers

packages.



Perform

work

only

static-safe

work

area.

IMPORTANT:

customer-supplied

cord

(Miller

#042562)

required

connect

the

welding

power

source

the

weld

control.

Loosen

screws

securing

front

access

door,

and

open

door.

Locate

voltage

control

board

PCi

lower

left

portion

component

mounting

panel

inside

robot

interface

con

trol.

Mark

and

disconnect

leads

from

voltage

control

board

PCi.

Mark

and

disconnect

plugs

from

PCi.

Note

position

circuit

board

and

remove

from

unit.

Place

circuit

board

stationary

work

surface

that

component

side

facing

up.

Locate

jumpers

thru

surface

board

(see

Figure

3-8).

Use

sharp

tool

remove

sealant

coating

from

all

jumper

locations,

and

remove

foil

jumper

between

pads

J2,

J4,

J6,

and

J8.

Apply

small

amount

solder

bridge

the

foil

pads

jumper

Ji, J3,

J5,

and

J7.

10.

Apply

sealant

coating

over

all

jumper

locations.

11.

Reinstall

circuit

board

into

unit

its

original

position.

12.

Reconnect

marked

leads

and

plugs

appropriate

locations.

Receptacle

RC1

leads

76,

77,

and

must

changed

plug

PLG1

connected

receptacle

RC1

voltage

con

trol

board

PCi

follows:

IMPORTANT:

See

receptacle

RC1

designations

etched

circuit

board

identify

plug

openings.

Locate

and

disconnect

plug

PLG14

from

receptacle

RC1

voltage

control

board

PCi.

Mark

and

remove

leads

76, 77,

and

from

plug

PLG1

inserting

end

small,

flat-tip

screwdriver

into

window

side

plug

bend

down

locking

tab,

and

pull

contact

attached

lead

from

plug.

Bend

locking

tabs

lead

contacts

Out

thatthey

secure

contacts

when

inserted

into

plug.

Insert

lead

contacts

into

plug

follows:

Lead

plug

opening

10.

Lead

plug

opening



Lead 78

plug

opening

Reconnect

plug

PLG14

receptacle

RC1

voltage

control

board

PCi.

and

secure

access

door.

Add

Figure

3-8.

Jumper

Locations

Voltage

Control

Board

PCi

OM-1355828Page3

Ret.

SD148

322

AMENDMENT

SECTION

7

ELECTRICAL

DIAGRAMS

Amend

Diagram

7-1.

Circuit

Diagram

For

Robot

Interface

(see

page

this

Errata

Sheet)

Delete

Diagram

7-2.

Circuit

Diagram

For

Voltage

Board

PCi

This

diagram

longer

applies

effective

with

Serial

No.

KC231

859

Amend

Diagram

7-3.

Circuit

Diagram

For

Motor

Control

Board

PC2

(see

pages

and

this

Errata

Sheet)

Amend

Diagram

7-4.

Circuit

Diagram

For

Interface

Board

PC3

(see

page

this

Errata

Sheet)

Figure

3-8.

Jumper

Locations

Voltage

Control

Board

PCi

OM-135

582B

Page

AMENDMENT

SECTION

8

PARTS

LIST

Amend

Parts

List

follows:

**First

digit

represents

page



digits

following

dash

represent

item

no.

+Eff

w/KB1

13874.

Parts

page

may

not

represent

actual

board.

SURE

PROVIDE

MODEL

AND

NSPR

NUMBER

WHEN

ORDERING

REPLACEMENT

PARTS.

Dia.

Part

Replaced

Mkqs.

No.

With

Description

Quantity

19-

CR4

028

291

. .

Added

028

291

095

521

. .

CAPACITOR,

(qty

chg

dia.

mkg.

chg)

(C2-4

now

C6-10)

RELAY,

end

24VDC

4PDT

19-

20-

PCi

PC4

PLG25

049

970

079 844

027811

048 029

026 202

137695

117

836

Added

048

588

079 844

027811

048 029

026 202

148320

+149

339

117

037

BRACKET,

mtg

relay

SPRING,

(qty

chg)

SOCKET,

(qtychg)

CLIP,

(qty

chg)

DIODE,

(qty

chg)

(added

D4)

CIRCUIT

CARD,

(qtychg)

CIRCUIT

CARD,

meter

(Eff

w/KB113874)

HOUSING,

term

hdr

2skt

20-

RC13

109

768

111

122

094

480

141

162

134

731

. .

073 739

RECEPTACLE,

MS-3102A-20-27P

(Effw/KC217109)

HOUSING

PLUG

PINS,

(consisting

of)

TERMINAL,

male

18-14

wire

CLAMP,

cable

strain

relief

20-

116

964

111

123

Deleted

. .

152

370

079

534

. .

CLAMP,

(now

md.

w/housing

plug

pins)

HOUSING

PLUG

SOCKETS,

(consisting

of)

TERMINAL,

female

lskt

18-14

wire

20-

079 739

CLAMF~

strain

relief

21-

072 292

. .

154

098

SHAFT,

spool

support

21-

Added

141

700

605941

RING,

retaining

ext

.625shaftx

.O5Othk

(mci.

w/hub

spindle

assy)

WASHER,flatstl.64OIDx1.OOD

(md.

w/hub

spindle

assy)

OM-135

582B

Page

ALL

WAVEFOPIlS

300

IPW-MOTOP

PUNNING

ALL

VOLTAGES

MEASIJPED

WITH

PESPECT

ﬁ~

COM)OJ

POINT

EXCEPT

~4.

MEASURE

WITH

RESPECT

POINT

~I(.

'111_

_nrL

ﬁ

ft_ill

ﬁ~

L~i

052

3V.

Diagram

7-3.

Circuit

Diagram

For

Motor

Control

Board

PC2

OM-135

582B

Page

C??

Circuit

Diagram

No.

SD-083

388-B

OM-135

5828

Page

150

~

p5~(

AiPS/

C.)

DO.~tTA#~

v~~t

IETEP

RCI6

Li

1111

liii

-o

PC9

2

PCI

PC4

ID)

Ill?

-I

18311

8910

657

VTLTAGE

80*80

1-18

124

RCI/PL0I4 RC6/PLG2S

CIS4TP12..

ITO

0000

/00

/0/

0C

000

1AOOTER

FEEOBAO<

>>~<

1>>

B>)

PC3

INTERFA~

BOARD

A-H

IS)

9dB

AA-AIJ

RCI9

PCI

ARC

VI3T5

RC9

AOl

GAS

CI3ITROI_

,k19



PC6

ARt/T~Lu

/04

A-S

9d00/REGSO

IIJCH

SENRE/WIRE

STICK

1/05

SENSE

j<)(L

PCI

___________

CS,~jC41j~,

v____v____v_.J

184

WIRE

FEED

SPEED

Circuit

Diagram

No.

SC-i

230

Diagram

7-i.

Circuit

Diagram

For

Robot

Interface

Effective

With

Serial

No.

KC231859

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