3 System Installation

3.1 What’s in the Box

Before you begin installation, verify that all of the following components are present and undamaged:

Item	Description
Miller Auto DeltaWeld™ 350 Basic	Welding power source (115 lb / 52.2 kg)
Auto DeltaWeld Basic Fixed Wire Drive	Wire feeder (16.6 lb / 7.5 kg)
ArcConnect™ Cable, 90 Degree	Connects wire drive to power source
Auto DeltaWeld Base and Spool Support	Mounting base for wire spool
Cover, Spool 12 in. Assembly LH	Spool protection cover
Kit, Industrial MIG 4/0	Work cable and clamp
Tregaskiss RA1 Cobot MIG Gun	Robotic MIG torch
Gun Mount Assembly, 45 Degree	Torch-to-robot mounting bracket
KUKA Insulating Disc	Electrical isolation disc
Nozzle 5/8 in. Bore, 1/8 in. Recess	Torch nozzle
Acculock Robotic Diffuser Slip	Gas diffuser
0.035 Acculock Contact Tips	Contact tips for 0.035 in. wire
Kit, Drive Roll .035/.045 V-Groove 4 Roll	Drive rolls for solid wire
E70S-6 .035 x 33 lb. Spool	Welding wire spool

If any items are missing or damaged, contact Standard Bots support before proceeding.

Items you need to supply:

• Shielding gas (typically 75/25 Ar/CO₂ for mild steel with ER70S-6 wire) and a regulator with flowmeter.
  
• Appropriate input power connection (208/230/460V three-phase or 230V single-phase, 60 Hz).
  
• Ethernet cable if the included 6.7 ft (2 m) cable is not long enough. Miller offers industrial-grade shielded cables: Part 300734 (9.8 ft / 3 m) or Part 300736 (32.8 ft / 10 m).
  
• Welding table or fixture appropriate for your application.
  
• Safety equipment for the cell (screens, curtains, fire extinguisher, etc.) as determined by your risk assessment.

3.2 Power Source Placement

Position the Auto DeltaWeld 350 on a flat, stable surface within cable reach of both the robot and the facility power outlet. The power source weighs 115 lb (52.2 kg) — use proper lifting techniques or a hoist.

Keep the following in mind when choosing a location:

• Allow at least 12 inches of clearance on all sides for airflow. The DeltaWeld uses Wind Tunnel Technology™ and Fan-On-Demand™ cooling that pulls air through the unit. Restricted airflow can cause thermal overload.
  
• Position the power source where it won’t be hit by sparks, spatter, or grinding debris.
  
• Ensure the operator can see the status LED lights on the front of the unit from outside the cell.
  
• Keep the power source dry. Do not install outdoors or in areas exposed to rain, standing water, or excessive condensation.

Dimensions: 18.55 in. H × 15.35 in. W × 29.15 in. D (471 × 390 × 740 mm).

Mounting: The bottom of the power source has a bolt pattern with mounting holes at 14 in. × 21 in. and 23.5 in. spacing. Refer to the Miller owner’s manual for the detailed mounting drawing.

3.3 Input Power Connection

WARNING — Only a qualified electrician should connect the power source to facility power.

The Auto DeltaWeld 350 accepts the following input power configurations:

• 208V / 230V / 460V, three-phase, 60 Hz
  
• 230V, single-phase, 60 Hz

Verify that the facility breaker and wiring meet the input current requirements listed in the Miller owner’s manual for your specific voltage configuration. Ensure the unit is properly grounded per local electrical codes.

After connecting input power, verify correct operation by powering on the unit and confirming the status LED lights illuminate on the front panel.

3.4 Wire Drive Installation

The Auto DeltaWeld Basic Fixed Wire Drive mounts either to the robot arm or to a fixed position near the welding cell.

Mounting the Wire Drive

1. Select a mounting location that minimizes the torch cable length between the wire drive and the torch. Shorter cable runs improve wire feeding performance.
   
2. Attach the wire drive using the five 1/4”-20 threaded holes on the bottom of the unit. Mounting dimensions are 7.5 in. × 6 in. with a 3.75 in. × 3 in. inner pattern.
   
3. Install the base and spool support, then mount the wire spool. Attach the spool cover to protect the wire from contamination.

Installing Drive Rolls

1. Open the drive assembly by pushing down the pressure knobs.
   
2. Install the .035/.045 V-Groove drive rolls from the included kit. The V-groove profile is designed for solid wire like the ER70S-6 included with the system.
   
3. Verify the correct groove is facing the wire path if using the dual-size reversible rolls.
   
4. Close the drive assembly and set the drive roll tension. Start with light tension and increase only as needed — excessive tension can deform the wire and cause feeding problems.

Feeding the Wire

1. Cut the end of the wire at a sharp angle to ease feeding.
   
2. Feed the wire through the inlet guide, through the drive rolls, and into the torch liner.
   
3. Run the wire through until it extends approximately 1/2 in. (13 mm) past the contact tip.

Connecting the ArcConnect Cable

1. Route the 90-degree ArcConnect cable from the wire drive to the power source.
   
2. Connect the cable to the ArcConnect port on the rear of the DeltaWeld 350. Ensure the connector is fully seated and locked.
   
3. Connect the other end to the wire drive motor. This cable carries both drive motor power and high-speed communication between the power source and wire drive.

3.5 Torch Installation & Cable Routing

Mounting the Torch to the RO2

1. Attach the KUKA Insulating Disc to the RO2 tool flange. This disc electrically isolates the torch from the robot arm, which is critical for preventing welding current from traveling through the robot’s joints and bearings.

WARNING — Do not skip the insulating disc. Operating without it can damage the robot.

2. Attach the Gun Mount Assembly (45 Degree) to the insulating disc.
   
3. Mount the Tregaskiss RA1 Cobot MIG Gun to the gun mount assembly. Tighten all fasteners securely.
   
4. Install the Acculock Robotic Diffuser Slip, nozzle (5/8 in. bore, 1/8 in. recess), and a 0.035 Acculock contact tip.

Cable Routing

Route the torch cable along the robot arm, securing it with cable ties or the cable management system. Follow these guidelines:

• Avoid sharp bends in the cable — maintain a minimum bend radius as specified in the Tregaskiss documentation.
  
• Leave enough slack at each robot joint to allow full range of motion without pulling or pinching the cable.
  
• Jog the robot through its expected range of motion after routing the cable to verify there are no snag points, excessive tension, or pinch hazards.
  
• Keep the torch cable separated from any other cables on the robot arm to avoid interference.

3.6 Work Cable Connection

Connect the work cable and clamp from the Industrial MIG 4/0 kit:

1. Attach one end of the work cable to the work terminal on the rear of the DeltaWeld 350 power source. Tighten the lug connection securely.
   
2. Attach the work clamp to the workpiece or welding fixture. The clamp must make clean, bare metal-to-metal contact — remove any paint, rust, scale, or coatings from the clamping area.
   
3. Route the work cable so it does not create a trip hazard and is not in the path of the robot’s motion.

A poor work connection is one of the most common causes of erratic arc behavior and excessive spatter. If you’re experiencing weld quality issues, always check the work connection first.

3.7 Shielding Gas Setup

1. Secure the shielding gas cylinder to a wall, cart, or cylinder stand with a chain or strap. Never leave a gas cylinder freestanding.
   
2. Attach a regulator with a flowmeter to the cylinder.
   
3. Connect the gas hose from the regulator to the gas inlet on the rear of the DeltaWeld 350 power source.
   
4. Open the cylinder valve slowly and set the flow rate. A typical starting point for MIG welding mild steel with ER70S-6 wire and 75/25 Ar/CO₂ is 25–35 CFH (30-35 cfh). Adjust based on joint type, torch angle, and environmental conditions (increase flow in drafty areas).
   
5. Check all connections for leaks using a soapy water solution.

Gas Selection: The shielding gas depends on the welding process and base material. For general-purpose MIG welding of mild steel with ER70S-6 wire, 75% Argon / 25% CO₂ (C25) is the most common choice. 80% Argon / 20% CO₂ (C20) will allow use of the pulse process. Refer to the Miller process selection guide in Appendix B for recommendations by process type.

• 4 Connection Setup

  4.1 Overview

  The Auto DeltaWeld 350 and the RO2 communicate over Modbus TCP using a standard Ethernet connection. All Modbus register mapping between the two systems is preconfigured — you do not need to manually map any registers or configure data tables.

  The setup process is straightforward:

  1. Make the physical Ethernet connection.
     
  2. Set the IP addresses so both devices are on the same subnet.
     
  3. Activate the Modbus TCP connection on the RO2 side.

  4.2 Physical Ethernet Connection

  Connect an Ethernet cable between the Auto DeltaWeld 350 and the RO2 control box.

  The DeltaWeld 350 has an industrial M12 Ethernet connector on the rear panel. The system ships with a 6.7 ft (2 m) Ethernet cable with an M12 connector on one end and a standard RJ45 connector on the other. Plug the M12 end into the power source and the RJ45 end into the Ethernet port on the RO2 control box.

  If you need a longer cable, Miller offers industrial-grade shielded Ethernet cables in 9.8 ft (Part 300734) and 32.8 ft (Part 300736) lengths. These cables are rated for the electrical noise and environmental conditions typical of a welding cell. Standard office-grade Ethernet cables are not recommended.

  Note: Make sure the Ethernet cable is routed away from welding cables and power cables to minimize electromagnetic interference.

  4.3 Setting the IP Address on the DeltaWeld 350

  The DeltaWeld 350 has a built-in web interface that you access from a PC to configure network settings.

  1. Connect a PC directly to the DeltaWeld’s Ethernet port (Front port) using an Ethernet cable.
     
  2. Set the PC’s network adapter to a static IP on the same subnet as the DeltaWeld’s default address (255.255.0.0). Miller’s default Front Ethernet port IP address is 169.253.1.32. Refer to the Miller owner’s manual for additional details.
     
  3. Open a web browser on the PC and navigate to the DeltaWeld’s IP address.
     
  4. In the web interface, navigate to the network configuration page.
     
  5. Set a static IP address for the DeltaWeld on the same subnet you plan to use for the RO2. For example, if the RO2 is at 192.168.1.10, set the DeltaWeld to 192.168.1.20.
     
  6. Confirm that Modbus TCP is enabled.
     
  7. Save the settings.

  Record the IP address you’ve assigned — you’ll need it when configuring the RO2 in the next step.

  4.4 Setting the IP Address on the RO2

  1. On the Standard Bots tablet, navigate to Network.
     
  2. Verify the RO2’s IP address is on the same subnet as the DeltaWeld 350. If it isn’t, update the IP address so both devices share the same subnet (e.g., 192.168.1.X with a subnet mask of 255.255.0.0). Follow picture example for default settings
     
  3. Save the network settings if any changes were made.

  If the RO2 and DeltaWeld are on different subnets, they will not be able to communicate.

  [Ethernet Settings] (src/images/Robot_Select_Screen.PNG)

  [Ethernet Settings] (src/images/Ethernet_Settings.PNG)

  4.5 Verifying the Connection

  Once the connection is activated, verify that data is flowing between the two devices:

  • DeltaWeld Status LEDs: The communication status LED on the front of the power source should indicate an active connection. Refer to the Miller manual for the specific LED behavior.
    
  • RO2 Ethernet connection: The Ethernet port will have a checkmark next to the Ethernet setting.

  If the connection is not established, refer to Section 7.1 (Connection Issues) for troubleshooting steps. A power cycle of both may be needed to establish first connection.

  ---