October 1993 Form: OM-138 992D

OWNER’S
MANUAL

RCSP-XL

Read and follow these instructions and all Give this manual to the operator.
safety blocks carefully.
Have only trained and qualified persons
install, operate, or service this unit. For help, call your distributor
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
cover 7/93 – ST-139 884  1993 MILLER Electric Mfg. Co. PRINTED IN USA
 Effective January 1, 1997
(Equipment with a serial number preface of “KH” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin,
warrants to its original retail purchaser that new Miller
equipment sold after the effective date of this limited warranty
is free of defects in material and workmanship at the time it is
shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser,
or one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to
an International distributor.
1. 5 Years Parts – 3 Years Labor
* Original main power rectifiers
* Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Supplies
Warranty Questions? * Intellitig

 *
*
Robots
Engine Driven Welding Generators

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
* Remote Controls
* Accessory Kits
* Replacement Parts (No labor)
* Spoolmate 185
Miller’s True Blue Limited Warranty shall not apply to:
1. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
2. Consumable components; such as contact tips, cutting
nozzles, contactors, brushes, slip rings, relays or parts
that fail due to normal wear.
3. Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or
(2) replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the
goods at customer’s risk and expense. Miller’s option of
repair or replacement will be F.O.B., Factory at Appleton,

 (NOTE: Engines are warranted separately by the

Wisconsin, or F.O.B. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
    engine manufacturer.) reimbursement for transportation costs of any kind will be
allowed.
 
3. 1 Year — Parts and Labor
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Motor Driven Guns (w/exception of Spoolmate 185)
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Process Controllers REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE
* Positioners and Controllers FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Automatic Motion Devices PROFIT), WHETHER BASED ON CONTRACT, TORT OR
* Orbital Weld Heads ANY OTHER LEGAL THEORY.
* IHPS Power Sources ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
* Water Coolant Systems AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
* HF Units REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Grids OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Spot Welders PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
* Load Banks OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
* SDX Transformers MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
* Miller Cyclomatic Equipment EQUIPMENT FURNISHED BY MILLER IS EXCLUDED
* Running Gear/Trailers AND DISCLAIMED BY MILLER.
* Plasma Cutting Torches (except APT, ZIPCUT & Some states in the U.S.A. do not allow limitations of how long
PLAZCUT Models) an implied warranty lasts, or the exclusion of incidental,
* Deutz Engines (outside North America) indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
* Field Options provides specific legal rights, and other rights may be
(NOTE: Field options are covered under True Blue available, but may vary from state to state.
for the remaining warranty period of the product they
are installed in, or for a minimum of one year — In Canada, legislation in some provinces provides for certain
whichever is greater.) additional warranties or remedies other than as stated
herein, and to the extent that they may not be waived, the
4. 6 Months — Batteries limitations and exclusions set out above may not apply. This
Limited Warranty provides specific legal rights, and other
5. 90 Days — Parts and Labor rights may be available, but may vary from province to
* MIG Guns/TIG Torches province.
 TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS

1-1. General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 2 – INTRODUCTION
2-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 3 – INSTALLATION
3-1. Synergic Pulse Panel – Welding Power Source Connections . . . . . . . . . . . . . . . . . . . . . . . . . 1
3-2. Synergic Pulse Panel – Computer Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3-3. Connection For Nonpulse Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3-4. Connections For Remote Pulse/Nonpulse Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3-5. Field Installation Instructions For Synergic Pulse Panel RCSP-XL Onto
Computer Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SECTION 4 – ROBOT PROGRAM MODIFICATIONS

4-1. Amendment To Robot Owner’s Manual Section 4 – System Set Up . . . . . . . . . . . . . . . . . . . 4
4-2. Amendment To C1 Robot Owner’s Manual Section 5 – Teaching . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 5 – OPERATOR CONTROLS

5-1. Wire Size Select Switch And Standard Mode Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-2. Wire Size Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-3. Wire Type Select Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-4. Recommended Shielding Gas Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5-5. No Program Indicator Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SECTION 6 – SEQUENCE OF OPERATION

6-1. Gas Metal Arc Welding (GMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6-2. Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 7 – MAINTENANCE & TROUBLESHOOTING

7-1. Inspection And Upkeep . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7-3. Circuit Board Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 8 – ELECTRICAL DIAGRAMS

Diagram 8-1. Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Diagram 8-2. Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Diagram 8-3. System Circuit Diagram For Synergic Pulse Panel And Computer Interface . . . . . . . 18

SECTION 9 – PARTS LIST

Figure 9-1. Main Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

LIST OF CHARTS AND TABLES

Table 5-1. Synergic Pulse Panel Welding Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Table 7-1. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

OM-138 992D – 10/93

 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 arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be
installed, operated, and maintained only by qualified
persons in accordance with this manual and all safety
precautions listed in the Arc Welding Safety Precautions
in the welding power source Owner’s Manual.
SECTION 2 – INTRODUCTION
2-1. DESCRIPTION
The robot Synergic Pulse panel is a synergic control de-
signed to be used with the MAXTRON 450 welding pow-
er source, MILLER Computer Interface, and the robot
system. The unit is designed for Gas Metal Arc Welding
(GMAW) in both nonpulsed and pulsed dc arc welding
modes. The unit is shipped ready for pulsed welding.
The panel is considered a synergic control because the
parameters which determine arc power and arc length
are programmed so that they can be adjusted using a
single control as opposed to adjusting individual con-
SECTION 3 – INSTALLATION
3-1. SYNERGIC PULSE PANEL – WELDING POW-
ER SOURCE CONNECTIONS (Figure 3-1)
Obtain appropriate cords and make connections as fol-
lows:
A. REMOTE 14 Connections
1. Align keyway, insert 14-socket plug into matching
receptacle RC16 on panel, and rotate threaded
collar fully clockwise.
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 to 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.
trols. If pulse welding, arc power parameters are wire
feed speed, background amperage, peak amperage,
pulse frequency, and pulse width; arc length is a fine tun-
ing of pulse frequency. If non-pulse welding, arc power
parameters are wire feed speed, arc voltage, and induc-
tance; arc length is a fine tuning of arc voltage.
When used with its associated equipment, the robot
Synergic Pulse panel allows the operator to set welding
parameters for optimum welding conditions in a majority
of situations using various types and sizes of welding
wire and shielding gases.
2. Align keyway, insert 14-pin plug into matching
REMOTE 14 receptacle on welding power
source, and rotate threaded collar fully clockwise.
B. REMOTE 17 Connections
1. Align keyway, insert 17-socket plug into matching
receptacle RC17 on panel, and rotate threaded
collar fully clockwise.
2. Align keyway, insert 17-pin plug into matching
REMOTE 17 receptacle on welding power
source, and rotate threaded collar fully clockwise.
OM-138 992 Page 1
 Pilot Light

Voltage Sensing
Receptacle RC15

Plug PLG14 To
Computer Interface
Receptacle RC14

Fuse
(see Section 7-2)

Plug PLG11 To
Computer Interface
Receptacle RC11

17-Pin
Receptacle RC17

14-Pin
Receptacle RC16 Robot Computer
Interface SC-139 884

Figure 3-1. Synergic Pulse Panel Connections

C. Voltage Sensing Cable Connection To Wire
Drive Assembly
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.
1. Align keyways, insert 4-socket plug on end of
Voltage Sensing Cable into receptacle RC15,
and rotate threaded collar fully clockwise.
2. Install and secure one lead with ring terminal to
weld cable terminal on wire drive assembly (see
wire dive assembly Owner’s Manual for location).
3. Connect remaining lead with ring terminal to the
workpiece.
as follows: align keyway, insert plug, and rotate
threaded collar fully clockwise.
B. Plug PLG11 Connections
Connect plug PLG11 from the panel to receptacle RC11
on the Computer Interface as follows: align keyway, in-
sert plug, and rotate threaded collar fully clockwise.
3-3. CONNECTION FOR NONPULSE WELDING
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down robot and welding power source,
and be sure equipment cannot be accidently
energized before inspecting or installing.
This unit is shipped from the factory ready for pulsed
welding. If nonpulsed welding is desired, proceed as fol-
lows:
1. Remove Synergic Panel top cover and side pan-
el. Do not disconnect wiring harness.

3-2. SYNERGIC PULSE PANEL – COMPUTER IN- 2. Locate terminal strip 2T in the Synergic Panel be-
TERFACE CONNECTIONS (Figure 3-1) low Logic Circuit Board PC2.

A. Plug PLG14 Connections 3. Move jumper link from 2T terminals B and C to 2T

terminals A and B.
Connect plug PLG14 from the panel to the Voltage
Sensing Receptacle RC14 on the Computer Interface 4. Reinstall unit top cover and side panel.
OM-138 992 Page 2
3-4. CONNECTIONS FOR REMOTE PULSE/NON-
PULSE CONTROL
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.
This unit is shipped from the factory ready for pulsed
welding. If selection of pulse/nonpulse is desired
through the use of the robot Program Module, proceed
as follows:
1. The fiber-optic cable that connects the Robot
Control and Computer Interface contains three
spare leads, two of which can be used for this
connection.
2. Remove Synergic Panel top cover and side pan-
el. Do not disconnect wiring harness.
3. Locate terminal strip 2T in the Synergic Panel be-
low Logic Circuit Board PC2 (see Figure 9-1).
4. Locate extra leads at fiber-optic cable in the Com-
puter Interface. Route leads to terminal strip 2T in
the Synergic Panel.
5. Crimp appropriate terminals on leads and con-
nect leads to terminals A and B on 2T in the Syn-
ergic Panel.
6. Reinstall unit top cover and side panel.
7. Open Robot Control and locate extra leads from
fiber-optic cable.
8. Connect leads to Robot Control normally-open
contacts according to instructions found in the ro-
bot Owner’s Manual Section 4 – System Set-Up:
Input/Output Terminal Block Connections.
9. To program pulse/nonpulse selection, see robot
Owner’s Manual Section 5.42.
3-5. FIELD INSTALLATION INSTRUCTIONS FOR
SYNERGIC PULSE PANEL RCSP-XL ONTO
COMPUTER INTERFACE (Figures 3-1 And
3-2)
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down welding power source and ro-
bot, and disconnect input power employ-
ing lockout/tagging procedures before be-
ginning this installation.
Lockout/tagging procedures consist of re-
moving input power plug from receptacle,
padlocking line disconnect switch in open
position, removing fuses from fuse box, or
shutting off and red-tagging circuit breaker or
other disconnecting device.
IMPORTANT: All 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.
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
• Transport circuit boards in proper static-
shielding carriers or packages.
• 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.
1. Remove Computer Interface top cover and side
panels.
2. Disconnect Synergic Pulse panel wiring harness
from panel Interface circuit board PC1.
3. Remove side panel from Synergic Pulse panel.
4. Install frame onto left side of Computer Interface
with sheet metal screws (see Figure 3-1).
5. Connect leads 25 and 27 to terminals T and U on
the Voltage Control Board in the Computer Inter-
face (polarity is not important).
6. Remove jumper links between terminals 1TE and
1TF, and terminals 2TB and 2TC in the Computer
Interface.
7. Make the following connections to the terminal
strips in the Computer Interface. Terminal strip 1T
leads must be routed through the grommet in the
center panel of the Computer Interface to the
right side of the unit (see Figure 3-2).
a. Connect lead 38 to 1TA.
b. Connect lead 39 to 1TB.
c. Connect lead 43 to 1TE.
d. Connect lead 55 to 1TF.
e. Connect lead 26 to 2TB.
f. Connect lead 45 to 2TC.
g. Connect lead 60 to 1TC.
h. Connect gray lead to Computer Interface chas-
sis ground terminal.
8. Position Synergic Pulse panel side panel so that
the wiring harness can be reconnected. Recon-
nect wiring harness to PC1.
9. Install side panel onto Synergic Pulse panel.
10. Reinstall Computer Interface right side panel.
11. Install supplied top cover onto the Computer In-
terface – Synergic Pulse panel.
OM-138 992 Page 3
 Left Side View Of Right Side View Of
Computer Interface Computer Interface
Communications
Board

Voltage Control
Board Power
Supply

Interface
Board
Terminal Strip 1T

Route Leads
Through This
Motor Grommet
Control Board

Terminal Strip 2T
SB-139 887-C

Figure 3-2. Electrical Installation

SECTION 4 – ROBOT PROGRAM MODIFICATIONS

IMPORTANT: The robot program must be changed to
accommodate synergic welding. The following informa-
tion pertains to the robot Owner’s Manual.
4-1. AMENDMENT TO ROBOT OWNER’S MANU-
AL SECTION 4 – SYSTEM SET UP
Before the Synergic Pulse panel will work, the robot sys-
tem data must be updated.For Robots with C1 control,
update System Data 4 (welding power source selection)
to SYNERGIC according to instructions in Section
4.22.1. For Robots with C2 control, use the following in-
structions to change weld characteristics:

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:

W E L C O M E T O
D I A G N O S I S M I L L E R C O O P E R A T I V E C O N T R O L
M I L L E R E L E C T R I C M f g . C o .
S T A R T D I A G N O S I S

’ 9 2 – 0 7 – 3 1
0 8 : 3 0

OM-138 992 Page 4

 W E L C O M E T O
D I A G N O S I S M I L L E R C O O P E R A T I V E C O N T R O L

S T E P O F I N I T I A L D I A G N O S I S
1 , 2 , 3 , 4 , 5 ,
’ 9 2 – 0 7 – 3 1
0 8 : 3 0

T E A C H M O D E

S E R V O O F F

T E A C H E D I T F I L E A L L O T L O C K >

2) Press > key to scroll to next screen.

T E A C H M O D E

S E R V O O F F

PA R M T E R C H E CK M A N A G E S Y S . S E T M E M O R Y >

3) Press F1 key to select Parameter.

S E L E C T T Y P E O F P A R A M E T E R
T E A C H M O D E B Y F U N C T I O N K E Y

S E R V O O F F

S Y S T E M S W I TC H W E L D I / O A U T O >

OM-138 992 Page 5

 4) Press > key to scroll to next screen.

S E L E C T T Y P E O F P A R A M E T E R
T E A C H M O D E B Y F U N C T I O N K E Y

S E R V O O F F

S E N S O R A R C –S T O U C H – S W – C H A R A S – D A T A >

5) Press F4 key to select Weld Characteristics.

A X I S M L 4 P OW E R S O U R C E W I R E
T E A C H
G M A W . 0 3 5 . 0 4 5 . 0 6 2
S Y N E R G I C . 0 3 5 . 0 4 5 . 0 6 2
S E R V O O F F G T A W – 1 0 0 . 0 3 5 . 0 4 5 . 0 6 2
G T A W – 3 0 0 . 0 3 5 . 0 4 5 . 0 6 2
U S E R R E G I S T E R
R E G I S T M O D I F Y S C _ E D I T

6) Use UP/DOWN cursor and DISPLAY SELECT keys to select SYNERGIC and wire size.

A X I S M L 4 P OW E R S O U R C E W I R E
T E A C H
G M A W . 0 3 5 . 0 4 5 . 0 6 2
S Y N E R G I C . 0 3 5 . 0 4 5 . 0 6 2
S E R V O O F F G T A W – 1 0 0 . 0 3 5 . 0 4 5 . 0 6 2
G T A W – 3 0 0 . 0 3 5 . 0 4 5 . 0 6 2
U S E R R E G I S T E R
R E G I S T M O D I F Y S C _ E D I T

7) Press F1 to Register change. Display appears as follows:

S E L E C T T Y P E O F P A R A M E T E R
T E A C H M O D E B Y F U N C T I O N K E Y

S E R V O O F F

S E N S O R A R C –S T O U C H – S W – C H A R A S – D A T A >

OM-138 992 Page 6

 8) To check settings, press F4 to select Weld Characteristics

A X I S M L 4 P OW E R S O U R C E W I R E
T E A C H
G M A W . 0 3 5 . 0 4 5 . 0 6 2
S Y N E R G I C . 0 3 5 . 0 4 5 . 0 6 2
S E R V O O F F G T A W – 1 0 0 . 0 3 5 . 0 4 5 . 0 6 2
G T A W – 3 0 0 . 0 3 5 . 0 4 5 . 0 6 2
U S E R R E G I S T E R
R E G I S T M O D I F Y S C _ E D I T

9) Press F2 to check Modify display.

A X I S M L 4 R A T I N G O F P OW E R S O U R C E
T E A C H $ W T B D 1 1
T Y P E S E P A . S Y N E R . T I G
A R C P OW E R R A T I N G 1 0 0 P
S E R V O O F F

P U S H R E C O R D A F T E R S E T T I N G

10) Press RECORD key and display will appear as follows:

A X I S M L 4 D I S P . R E F .
T E A C H 1 . 2 0 P 2 . O V
2 . 3 9 P 4 . 0 V
3 . 5 9 P 6 . 0 V
S E R V O O F F 4 , 7 9 P 8 . 0 V
5 . 1 0 0 P 1 0 . 0 V

11) Press the RESET key.

S E L E C T T Y P E O F P A R A M E T E R
T E A C H M O D E B Y F U N C T I O N K E Y

S E R V O O F F

S Y S T E M S W I TC H W E L D I / O A U T O >

OM-138 992 Page 7

 12) To check settings, use > key to scroll to next display.

S E L E C T T Y P E O F P A R A M E T E R
T E A C H M O D E B Y F U N C T I O N K E Y

S E R V O O F F

S E N S O R A R C –S T O U C H – S W – C H A R A S – D A T A >
13) Press F4 to select Weld Characteristics.

A X I S M L 4 P OW E R S O U R C E W I R E
T E A C H
G M A W . 0 3 5 . 0 4 5 . 0 6 2
S Y N E R G I C . 0 3 5 . 0 4 5 . 0 6 2
S E R V O O F F G T A W – 1 0 0 . 0 3 5 . 0 4 5 . 0 6 2
G T A W – 3 0 0 . 0 3 5 . 0 4 5 . 0 6 2
U S E R R E G I S T E R
R E G I S T M O D I F Y S C _ E D I T
14) Press F3 to view scaling of output voltage for Arc Power function.

W I R E C U R R E
T E A C H M O D E > 1 . 2 0 0 i . 1 6 0 A
2 . 3 0 0 i . 2 4 0 A
3 . 4 0 0 i . 3 1 0 A
S E R V O O F F 4 . 5 0 0 i . 4 0 0 A
5 . 6 0 0 i . 5 0 0 A

W . I . C O N V E R T O N O F F
15) Press RECORD key and display will appear as follows:

S E L E C T T Y P E O F P A R A M E T E R
T E A C H M O D E B Y F U N C T I O N K E Y

S E R V O O F F

S Y S T E M S W I TC H W E L D I / O A U T O >

16) Press the RESET key.

OM-138 992 Page 8
If the Synergic Pulse panel WIRE SIZE SELECT Switch If the arc start function data will be the next data re-
is in the STANDARD position, robot system data must corded after previous taught data, the display will ap-
be updated. For Robots with C1 control, update System pear as shown:
Data 4 to GMAW according to instructions in Section
4.22.1. For Robots with C2 control, use above instruc-
tions to reset unit for GMAW. P 0 0 1 S 0 0 5 M 4

IMPORTANT: For Robots with C2 control, see Section Q P 6 0

5.18 of the Robot Owner’s Manual for information on
programming for synergic welding.
Previous Current
Recorded Recorded
Data Data
4-2. AMENDMENT TO C1 ROBOT OWNER’S
MANUAL SECTION 5 – TEACHING
1) Press the ARC START key to teach the arc start
Amend Section 5.12.8 Teaching The Arc Start Function function, and a typical display will appear as
shown:
When using the Synergic Pulse panel, the synergic
mode arc start parameters and displays differ from regu-
P 0 0 1 S 0 0 3 M 4
lar GMAW welding displays.
2 5 P –1 L 0 3 9 i 0 . 5 S

5.12.8 Teaching The Arc Start Function

IMPORTANT: Two or more arc start functions can be
taught in series and only one arc end function taught to
end the welding operation (see Section 5.12.9). After
the arc start function data is taught, an asterisk is put by
the next sequence movement data taught (linear or cir-
cular arc) to show that the movement data is part of a
welding function. Welding is possible within the range of
linear or circular arc movement data only. Welding pa-
rameter values can be changed in Automatic mode dur-
ing the welding operation by using the DISPLAY SE-
LECT keys to choose the desired parameter(s) for value
changes.
If the first sequence movement data of a program is the
only taught data recorded before entering the second
sequence data, the display will appear as shown:
Arc Power Arc Length Welding Speed Preflow Time
In Percent In IPM In Seconds
IMPORTANT: When using a program initially pro-
grammed with System Data 4 set to GMAW, the Arc
Length display may show unusual alpha-numeric sym-
bols. The program needs to be converted to SYNERG-
IC. Use the DISPLAY SELECT key to move to the Arc
Length parameter. Press the Increase (INC.) or De-
crease (DEC.) key to clear the display for entry of valid
parameters (–5 to +5).
2) To change the welding parameter values, press
the forward DISPLAY SELECT key for each weld-
ing parameter value until the appropriate letter (P,
L, i, S) after the value to be changed flashes.

Manual Operating Speed

P 0 0 1 S 0 0 3 M 4

2 5 P –1 L 0 3 9 i 0 . 5 S
P 0 0 1 S 0 0 1 M 6

P 6 0
Table 5-2. Ranges And Increments Of Arc Start
Welding Parameter Values
Current Recorded Data
(May Also Be Q Data) Arc power parameters are wire feed speed, background
amperes, peak amperes, pulse frequency, and pulse
IMPORTANT: The display examples used with state- width. Arc length is a fine tuning of pulse frequency.
ments such as “will appear as shown” may not match ex-
actly with actual Program Module displays because of Welding Parameter Setting Range Increment
different program number, job number, sequence num- Arc Power 0 to 100 P 1P
ber, line number, manual operating speed, recorded
data, or moving speed for Automatic mode. Not all Arc Length –5 to +5 L 1L
cases can be given for actual display data, and the ex- Welding Speed 4 to 234 ipm 1 ipm
amples are only for a reference to supplement instruc-
tions. Preflow Time 0 to 9.9 sec. 0.1 sec.

OM-138 992 Page 9

 3) Enter a number value or press the Increase 1) Press the ARC END key to teach the arc end
(INC.) or Decrease (DEC.) key to change the function, and a typical display will appear as
welding parameter value until the desired value shown:
appears (if the QUICK INCREASE-DECREASE
key is pressed at the same time, changing of the P 0 0 1 S 0 0 5 M 4
data is performed rapidly).
1 8 P –1 L 0 . 2 S 0 . 5 S

P 0 0 1 S 0 0 3 M 4

2 8 P –1 L 0 3 9 i 0 . 5 S Arc Power Arc Length Crater Fill Time Postflow Time

In Percent In Seconds In Seconds

IMPORTANT: When using a program initially pro-

IMPORTANT: Before pressing the RECORD key, the
robot axes can be moved manually using the Axis keys
to allow changing axes position and/or welding gun/
torch angle.
4) Press the RECORD key, the sequence number
will advance one step to register the current data
in the program, and the display will appear as
shown:
P 0 0 1 S 0 0 4 M 4
grammed with System Data 4 set to GMAW, the Arc
Length display may show unusual alpha-numeric sym-
bols. The program needs to be converted to SYNERG-
IC. Use the DISPLAY SELECT key to move to the Arc
Length parameter. Press the Increase (INC.) or De-
crease (DEC.) key to clear the display for entry of valid
parameters (–5 to +5).
2) To change the welding parameter values, press
the forward DISPLAY SELECT key for each weld-
ing parameter value until the appropriate letter (P,
L, S, S) after the value to be changed flashes.

C 1 A S
P 0 0 1 S 0 0 5 M 4

1 8 P –1 L 0 . 2 S 0 . 5 S

Amend Section 5.12.9 Teaching the Arc End Function

When using the Synergic Pulse panel, the synergic
mode arc end parameters and displays differ from regu-
lar GMAW welding displays.
5.12.9 Teaching The Arc End Function
Table 5-3. Ranges And Increments Of Arc End
Welding Parameter Values
Arc power parameters are wire feed speed, background
amperes, peak amperes, pulse frequency, and pulse
width. Arc length is a fine tuning of pulse frequency.

When the arc end function data is the next data recorded Welding Parameter Setting Range Increment
after previous taught data, the display will appear as Arc Power 0 to 100 P 1P
shown:
Arc Length –5 to +5 L 1L
Crater Fill Time 0 to 9.9 sec. 0.1 sec.
P 0 0 1 S 0 0 5 M 4
Postflow Time 0 to 9.9 sec 0.1 sec.
A S * L 3 9 i
3) Enter a number value or press the Increase
(INC.) or Decrease (DEC.) key to change the
welding parameter value until the desired value
Previous Current appears (if the QUICK INCREASE-DECREASE
Recorded Recorded
Data Data key is pressed at the same time, changing of the
data is performed rapidly).
IMPORTANT: The display examples used with state-
ments such as “will appear as shown” may not match ex- P 0 0 1 S 0 0 5 M 4
actly with actual Program Module displays because of 2 8 P –1 L 0 . 2 S 0 . 5 S
different program number, job number, sequence num-
ber, line number, manual operating speed, recorded
data, or moving speed for Automatic mode. Not all IMPORTANT: Before pressing the RECORD key, the
cases can be given for actual display data, and the ex- robot axes can be moved manually using the Axis keys
amples are only for a reference to supplement instruc- to allow changing axes position and/or welding gun/
tions. torch angle.
OM-138 992 Page 10
 4) Press the RECORD key, the sequence number
will advance one step to register the current data
in the program, and the display will appear as
shown:
SECTION 5 – OPERATOR CONTROLS
5-1. WIRE SIZE SELECT SWITCH AND STAN-
DARD MODE INDICATOR LIGHT
The WIRE SIZE SELECT Switch and the WIRE TYPE
SELECT Switch set the output range of the welding
power source and robot wire drive for the specific type
and size of wire chosen. Together, the switches deter-
mine the relationship of the various arc power parame-
ters.
If the unit is operated in a pulse condition, arc power pa-
rameters are wire feed speed, background amperes,
peak amperes, pulse frequency, and pulse width. Arc
length is a fine tuning of pulse frequency.
If the unit is operated in a nonpulse condition, arc power
parameters are wire feed speed, arc voltage, and induc-
tance. Arc length is a fine tuning of arc voltage.
When the WIRE SIZE SELECT Switch is placed in the
STD position, the STANDARD MODE Indicator Light will
come on, indicating that the Synergic Pulse panel is in
standard mode and cannot be used to set the output pa-
rameters for the welding power source or robot wire
drive. When the control is in standard mode, the robot
needs to be reset to the GMAW mode through System
Data 4.
IMPORTANT: Position the WIRE SIZE SELECT Switch
in the .045 position when welding with .047 in. diameter
welding wire.
5-2. WIRE SIZE INDICATOR LIGHTS (Figure 5-1)
The top light indicates whether the unit is set to pulse
(light on) or is in STD (light off). The remaining lights turn
Standard Mode
Indicator Light
Wire Type
Selector Switch
No Program
Indicator Light
Figure 5-1. Operator Controls
P 0 0 1 S 0 0 6 M 4
* L A E
on when the corresponding wire size is selected by the
WIRE SIZE SELECT switch.
5-3. WIRE TYPE SELECT SWITCH (Figure 5-1)
The WIRE TYPE SELECT Switch is functional when the
WIRE SIZE SELECT Switch is not in STD. The WIRE
TYPE SELECT Switch and the WIRE SIZE SELECT
Switch set the output range of the welding power source
and robot wire drive for the specific type and size of wire
chosen. Together, the switches determine the relation-
ship of the various arc power parameters.
If the unit is operated in a pulse condition, arc power pa-
rameters are wire feed speed, background amperes,
peak amperes, pulse frequency, and pulse width. Arc
length is a fine tuning of pulse frequency.
If the unit is operated in a nonpulse condition, arc power
parameters are wire feed speed, arc voltage, and induc-
tance. Arc length is a fine tuning of arc voltage.
5-4. RECOMMENDED SHIELDING GAS INDICA-
TOR LIGHTS (Figure 5-1)
The RECOMMENDED SHIELDING GAS Indicator
Lights represent the types of shielding gases recom-
mended for use with the Synergic Pulse panel. The pan-
el is programmed to select the shielding gas that will pro-
vide optimum welding conditions in a majority of situa-
tions for the type and size of wire selected on the WIRE
SIZE SELECT and WIRE TYPE SELECT switches.
Wire Size
Indicator Light
Wire Size
Selector Switch
Recommended Shielding
Gas Indicator Lights
SB-139 885-A
OM-138 992 Page 11
After selecting the wire size and type, the indicator light
for the recommended shielding gas will come on. If a
light does not come on, and the NO PROGRAM Indica-
tor light does not come on, refer to Table 5-1 for the rec-
ommended shielding gas.
If the NO PROGRAM Indicator Light comes on with or
without a RECOMMENDED SHIELDING GAS Indicator
Light, reselect the wire type and size to be used (see
Sections 5-1 and 5-3).
5-5. NO PROGRAM INDICATOR LIGHT (Figure
5-1)
The Synergic Pulse panel has been programmed to pro-
vide optimum welding conditions in a majority of situa-
tions using various types and sizes of welding wire and
various shielding gases. The NO PROGRAM Indicator
Light allows the operator to determine if the unit has
been programmed for the conditions set by the WIRE
TYPE SELECT and WIRE SIZE SELECT switches. If
the NO PROGRAM Indicator light comes on, the control
is not programmed for the conditions set by the two
switches; therefore, it will be necessary to reselect the
type and size of wire to be used.
IMPORTANT: Use of a nonrecommended shielding gas
could change weld characteristics.

Table 5-1. Synergic Pulse Panel Welding Schedules

PULSE WELDING
Wire Type
Wire
STL1 STL2 NI SS1 SS2 AL1 AL2 SI BR CUST.
Size
.030 * * * * * * * * *
.035 * 98Ar/2 02 75Ar/25 98Ar/2 02 * Ar Ar Ar *
HE
.045 * 98Ar/2 02 75Ar/25 98Ar/2 02 * Ar Ar Ar 98Ar/2 02
HE
.062 * * * * * Ar Ar * *

NONPULSE WELDING
Wire Type
Wire
STL1 STL2 NI SS1 SS2 AL1 AL2 SI BR CUST.
Size
.030 CO2 75Ar/25 * SPCL 98Ar/2 O2 * * * *
CO2
.035 CO2 75Ar/25 * SPCL 98Ar/2 O2 Ar Ar Ar *
CO2
.045 CO2 75Ar/25 * SPCL 98Ar/2 O2 Ar Ar * CO2
CO2
.062 * * * * * Ar Ar * *
*The Synergic Pulse panel is not programmed for type and size of welding wire indicated.

DEFINITION OF TABLE 5-1 DATA

Wire Type:
STL1 = Mild Steel (Used with C02 shielding gas
for short circuit welding from minimum
to maximum wire feed speed.)
STL2 = Mild Steel (In PULSE mode, STL2 is
used with 98 Ar/2 02 shielding gas for
pulse spray welding from minimum to
maximum wire feed speed. In NON-
PULSE mode, STL2 is used with 75
Ar/25 CO2 shielding gas for short circuit
welding from minimum to maximum
wire feed speed.)
NI = High Nickel Alloy
OM-138 992 Page 12
SS1 = Stainless Steel (In PULSE mode, SS1 is
used with 98 Ar/2 02 shielding gas for
spray transfer welding from minimum to
maximum wire feed speed. In NON-
PULSE mode, SS1 is used with Tri-Mix
shielding gas for short circuit transfer
welding from minimum to maximum
wire feed speed.)
SS2 = Stainless Steel (SS2 is used with 98
Ar/2 02 shielding gas for spray transfer
welding from minimum to maximum
wire feed speed.)
AL1 = 4043 Aluminum
AL2 = 5356 Aluminum Shielding Gas:
SI BR = Silicon-Bronze CO2 = Carbon Dioxide
*CUST = Position usually reserved for program- 75 Ar/25 CO2 = 75% Argon
. ming a welding schedule not included in 25% Carbon Dioxide
the standard programming of the unit.
At this time, the welding schedule pro- SPCL = Tri-Mix: 90% Helium
grammed for this position is as follows: 7.5% Argon
2.5% Carbon Dioxide
*PULSE Welding = .045 409 flux-cored
stainless steel welding wire AR = Argon
*NONPULSE Welding = .045 AWS 98 Ar/2 02 = 98% Argon
class E71T-1 flux-cored welding wire 2% Oxygen
**75 Ar/25 HE = 75% Argon
25% Helium
**This shielding gas is not included on nameplate of the
Synergic Pulse panel.

SECTION 6 – SEQUENCE OF OPERATION

WARNING: ELECTRIC SHOCK can kill;
MOVING PARTS can cause serious injury;
IMPROPER AIRFLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
• Do not touch live electrical parts.
• Keep all covers and panels in place while op-
erating.
• Do not touch welding wire or any metal part in
contact with it while welding.
The welding wire and all metal parts in contact
with it carry weld output when the welding pow- 6-1.
er source contactor is energized.
1.
Warranty is void if any of the equipment is oper-
ated with any portion of the outer enclosure re-
moved. 2.
ARC RAYS, SPARKS, AND HOT SURFACES
can burn eyes and skin; NOISE can damage 3.
hearing.
• Wear correct eye, ear, and body protection. 4.
FUMES AND GASES can seriously harm
your health.
• Keep your head out of the fumes. 5.
• Ventilate to keep from breathing fumes and
gases. 6.
• If ventilation is inadequate, use approved 7.
breathing device.
WELDING WIRE can cause puncture 8.
wounds.
• Do not point gun toward any part of the body, 6-2.
any conductive surface, or other personnel.
1.
HOT METAL, SPATTER, AND SLAG can
cause fire and burns. 2.
• Watch for fire.
• Keep a fire extinguisher nearby, and know
3.
how to use it.
• Do not use near flammable material.
• Allow work and equipment to cool before
handling.
MAGNETIC FIELDS FROM HIGH CURRENTS
can affect pacemaker operation.
• Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
See Arc Welding Safety Precautions in the weld-
ing power source Owner’s Manual for basic
welding safety information.
GAS METAL ARC WELDING (GMAW)
Install and connect robot system according to its
Owner’s Manuals.
Connect panel according to Section 3.
Position WIRE SIZE SELECT Switch for size wire
used (see Section 5-1).
Position WIRE TYPE SELECT Switch for type
wire used (see Section 5-3).
Place welding power source front panel adjust-
ment control(s) to the maximum setting.
Turn on shielding gas at its source.
Energize robot system.
Begin welding.
SHUTTING DOWN
Stop welding.
Shut down robot system.
Turn off shielding gas at the source.
WARNING: HIGH CONCENTRATION OF
SHIELDING GAS can harm health or kill.
• Shut off gas supply when not in use.
OM-138 992 Page 13
 SECTION 7 – MAINTENANCE & TROUBLESHOOTING
IMPORTANT: Every six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See Parts List for part number of pre-
cautionary labels.
7-1. INSPECTION AND UPKEEP
Usage and shop conditions will determine the frequency
and type of maintenance. At minimum, inspect equip-
ment every three months as follows:
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,
maintaining, or servicing.
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.
Maintenance and troubleshooting to be per-
formed only by qualified persons.
1. Inspect all interconnecting cords for damage to or
breaks in the insulation jacket, particularly at the
plugs. Repair or replace the cord(s) as neces-
sary.
2. Remove grease and dirt from components and
moisture from electrical parts and cables.
7-2. OVERLOAD PROTECTION
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,
maintaining, or servicing.
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.
INCORRECT FUSE can damage unit.
• Use only replacement fuse of same size,
type, and rating (see Parts List).
OM-138 992 Page 14
Fuse F1 protects the unit from overload. If fuse F1
should open, the Synergic Pulse panel would not func-
tion. To replace fuse F1, proceed as follows:
1. Depress and rotate fuse holder cover counter-
clockwise.
2. Pull out fuse with cover when fuse holder cover is
free.
3. Insert new fuse into fuse holder cover.
4. Install new fuse with fuse holder cover back into
unit.
5. Depress and rotate fuse holder cover clockwise
until cover is secure.
7-3. CIRCUIT BOARD HANDLING PRECAUTIONS
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,
maintaining, or servicing.
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.
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards.
• Transport circuit boards in proper static-
shielding carriers or packages.
• 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: The circuit boards in this unit-–Interface
Circuit Board PC1, Logic Circuit Board PC2, and
Memory Circuit Board PC3-–are installed stacked on
top of each other on the inside of the operator control
panel. PC2 is at the bottom of the stack (closest to the
operator control panel), PC3 is in the middle, and PC1 is
at the top of the stack.
7-4. TROUBLESHOOTING
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,
maintaining, or servicing.
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.
Troubleshooting of internal parts to be per-
formed only by qualified persons.
It is assumed that proper installation has been made ac-
cording to Section 3 of this manual, the operator is famil-
iar with the function of controls, the unit was working
properly, and that the trouble is not related to the welding
process. The following chart is designed to diagnose
and provide remedies for some of the troubles that may
develop in this unit.
Use this chart in conjunction with the circuit diagram
while performing troubleshooting procedures. If the
trouble is not remedied after performing these proce-
dures, the nearest Factory Authorized Service Station/
Service Distributor should be contacted. In all cases of
equipment malfunction, the manufacturer’s recommen-
dations should be strictly followed.

Table 7-1. Troubleshooting

TROUBLE PROBABLE CAUSE REMEDY

No weld output. POWER Switch on welding Place POWER Switch on welding power source
power source in OFF position. in ON position.
Fuse(s). Check fuse on Computer Interface and Synergic
Pulse panel. Replace necessary parts.
Welding gun. See welding gun Owner’s Manual.
No control of weld output. Control cords not secure. Secure all connections between Synergic Pulse
panel, Computer Interface, welding power
source, and wire drive assembly.
Voltage Sensing Cable connec- Check routing of voltage sensing cable and se-
tions. cure connections.
Work connection loose or in- Check work connection for good metal-to-metal
complete due to rust, paint, etc., contact.
on surface of workpiece.
Synergic Pulse panel not pro- Reselect wire type and wire size to be used.
grammed for weld conditions
set by WIRE SIZE SELECT and
WIRE TYPE SELECT switches
(NO PROGRAM Indicator light
will be on.)
Computer Interface. See Computer Interface Owner’s Manual.
Synergic Pulse panel controls Interface Circuit Board PC1 See Section 7-3 and contact nearest Factory Au-
not functional. thorized Service Station/Service Distributor.
Memory Circuit Board PC3. See Section 7-3 and contact nearest Factory Au-
thorized Service Station/Service Distributor.
Logic Circuit Board PC2. See Section 7-3 and contact nearest Factory Au-
thorized Service Station/Service Distributor.
Erratic weld; incorrect weld Incorrect settings on WIRE Reselect wire type and wire size to be used.
characteristics. TYPE SELECT and/or WIRE
SIZE SELECT switches.
Incorrect arc length. Adjust ARC LENGTH control on the robot Pro-
gram Module.
Voltage Sensing Cable connec- Check routing of voltage sensing cable and se-
tions. cure connections.
Work connection loose or in- Check work connection for good metal-to-metal
complete due to rust, paint, etc., contact.
on surface of workpiece.

OM-138 992 Page 15

OM-138 992 Page 16

SECTION 8 – ELECTRICAL DIAGRAMS

Circuit Diagram No. SB-161 499
Diagram 8-1. Circuit Diagram
OM-138 992 Page 17

Wiring Diagram No. SC-161 630

Diagram 8-2. Wiring Diagram
 Diagram 8-3. System Circuit Diagram For Synergic Pulse Panel And Computer Interface
OM-138 992 Page 18
Circuit Diagram No. SD-161 495

OM-138 992 Page 19

 16 17

12 13 14 15 18
19
11 20

OM-138 992 Page 20

10 21
22
8
9
23
8
7 24
6
25
5
4
1 2
3 26
27
34 28
33 32 31 30 29
35
36
37
38
39
SECTION 9 – PARTS LIST

40
41
42
43
44
58
14

35 45
57
56 46
55
54
53 52 51 50 49 48 47
SD-139 886-A

Figure 9-1. Main Assembly

 Item Dia. Part
No. Mkgs. No. Description Quantity
042 581 Figure 9-1. Main Assembly
042 582

. . . 1 . . . . . . . . . . . . . . . 139 463 . . . DOOR, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . 145 412 . . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . F1 . . . . . *012 655 . . . FUSE, mintr cer 10A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . . . . . . 046 432 . . . HOLDER, fuse mintr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . PLG14 . . . . 073 686 . . . CONNECTOR, circ 4skt plug MS-3106A-14S-2S . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 039 828 . . . CONNECTOR, circ clamp str rlf AN-3057-6 . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 134 241 . . . CABLE, shld No. 18ga 2/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1ft
. . . 8 . . . . . . . . . . . . . . . 139 040 . . . BUSHING, strain relief .231/.394 ID x .733mtg hole . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . PL1 . . . . . 074 188 . . . LIGHT, ind red lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 10 . . . . . . . . . . . . . . 140 127 . . . PLATE, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 11 . . . . . . . . . . . . . . 139 455 . . . CASE SECTION, front/bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 12 . RC15,PC4 . . 139 405 . . . RECEPTACLE, w/components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 13 . . . . . 1T . . . . . . 038 855 . . . BLOCK, term 20A 2P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 14 . . PLG3,6 . . . 131 054 . . . HOUSING RECEPTACLE & SOCKETS, (consisting of) . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . 113 746 . . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 15 . . . PLG7 . . . . 115 092 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 113 746 . . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. . 16 . . . . . . . . . . . . . . 079 844 . . . SPRING, hold down relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 17 . . . . CR1 . . . . . 093 558 . . . RELAY, encl 120VAC 4PDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 18 . . . . . . . . . . . . . . 027 811 . . . SOCKET, relay 14 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 19 . . . . . . . . . . . . . . 049 970 . . . BRACKET, mtg relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 20 . . . . . . . . . . . . . . 048 029 . . . CLIP, retaining skt relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 21 . . . . PC5 . . . . . 138 383 . . . CIRCUIT CARD, offset supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 22 . . . . . . . . . . . . . . 110 375 . . . STAND-OFF SUPPORT, PC card No. 6 screw . . . . . . . . . . . . . . . . . . . . . . . 4
. . 23 . . . . . . . . . . . . . . 134 464 . . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 24 . . . . . . . . . . . . +139 465 . . . COVER, (used with 1 option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 24 . . . . . . . . . . . . +140 125 . . . COVER, (used with 2 options) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 25 . . . . . . . . . . . . . . 139 454 . . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 26 . . . PLG8 . . . . 115 091 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 113 746 . . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
. . 27 . . . . . T1 . . . . . . 139 459 . . . TRANSFORMER, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 28 . . . RC17 . . . . 097 867 . . . CONNECTOR, circ 17 pin rcpt MS-3102A-20-29P . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 039 885 . . . CONNECTOR, circ protective cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 29 . . . . FL1 . . . . . 084 171 . . . FILTER, line pwr 115/250V 50-400Hz at 2A . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 30 . . . RC16 . . . . 152 492 . . . RECEPTACLE w/PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 134 731 . . . . . CONNECTOR, circ pin push-in 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . 31 . . . . . . . . . . . . . . 139 041 . . . BUSHING, strain relief .455/.629 ID x 1.115mtg hole . . . . . . . . . . . . . . . . . . 1
. . 32 . . . . . . . . . . . . . . 110 015 . . . CABLE, port No. 18 7/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4ft
. . 33 . . . PLG11 . . . . 152 370 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 079 534 . . . . . CONNECTOR, circ skt push-in 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . 34 . . . . . . . . . . . . . . 079 739 . . . . . CONNECTOR, circ clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 35 . . . . . . . . . . . . . . 115 359 . . . CAP, peaked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 36 . . . . . . . . . . . . . . 115 358 . . . KNOB, arrow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 37 . . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . 1
. . 38 . . . . . . . . . . . . . . 145 016 . . . BRACKET, mtg circuit card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 39 . . . . . . . . . . . . . . 115 440 . . . STAND-OFF, No. 6-32 x .687 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 40 . . . . PC2 . . . . . 145 344 . . . CIRCUIT CARD, logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 41 . . . . . . . . . . . . . . 119 261 . . . WASHER, flat nyl .140 ID x .312 OD x .032thk . . . . . . . . . . . . . . . . . . . . . . . 16
. . 42 . . . . . . . . . . . . . . 097 132 . . . STAND-OFF, No. 6-32 x .375 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 43 . . . . . . . . . . . . . . 115 443 . . . STAND-OFF, No. 6-32 x .750 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . 44 . . . . PC1 . . . . . 138 264 . . . CIRCUIT CARD, interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 45 . . . PLG5 . . . . 114 366 . . . CONNECTOR, rect 13skt plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 46 . . . PLG1 . . . . 115 269 . . . CONNECTOR, rect 7skt plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 47 . . . PLG2 . . . . 105 673 . . . CONNECTOR, rect 6skt plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 48 . . . . PC3 . . . . . 156 690 . . . CIRCUIT CARD, memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 49 . . . PLG9 . . ♦131 059 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 114 656 . . . . . CONNECTOR, rect pin 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
OM-138 992 Page 21
 Item Dia. Part
No. Mkgs. No. Description Quantity
042 581 Figure 9-1. Main Assembly (Continued)
042 582
. . 50 . . . PLG12 . . . . 115 093 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 113 746 . . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . 51 . . . . . 2T . . . . . . 038 861 . . . BLOCK, term 20A 3P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 601 219 . . . LINK, jumper term blk 20A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 52 . . . . PC6 . . . . . 143 960 . . . CIRCUIT CARD, selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 53 . . . PLG20 . . . . 135 557 . . . HOUSING PLUG & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 079 747 . . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . 54 . . . PLG10 . . ♦089 222 . . . CONNECTOR, rect 11skt plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 55 . . . . . . . . . . . . . . 098 691 . . . STAND-OFF, No. 6-32 x .500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 56 . . . . . . . . . . . . . . 112 062 . . . LENS, rnd red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . 57 . . . . . . . . . . . . . . 115 360 . . . KNOB, arrow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 58 . . . . . . . . . . . . . . 089 899 . . . LATCH, slide flush style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

*Recommended Spare Parts.

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
♦Part of PC2 (Item No. 40) Circuit Card, Logic
BE SURE TO PROVIDE MODEL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-138 992 Page 22

Notes