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Miller Electric MR-5 manual

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Table of contents for the manual

  • Page 1

    Y8y7?~i Read and understand the entire contents of both this manual and the power source manual used with this unit, with special eutiphasis on the safety material throughout both manuals, before installing, operating, or maintaining this equipment. This unit and these instructions are for use only by persons trained and experienced in the safe ope[...]

  • Page 2

    LIMITED WARRANTY 4; 4; 4; 4! 4; 4; ~Ji 4~ 1. 2. < 3. 4. ~ 7. This 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 condi - tions hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants to its Distributor/Dealer that all[...]

  • Page 3

    ERRATA SHEET AMENDMENT TO SECTION 2— INSTALLATION A WARNING: ELECTRIC SHOCK can kill. 0 Do not touch live electrical parts. A. CVICC Connections A 1. Locate terminal Strip 2T. May 31,1990 ~OM.882j After this manual was printed, refinements In equipment design occurred. This sheet lists exceptions to data appearing later in this manual. IMPORTANT:[...]

  • Page 4

    B. ARC FAILURE Light Connections (Figure 2-4) A WARNING: Read and follow safety Information at beginning of Section 2-5 before proceeding. The ARC FAILURE light orlthe computerinterface front panel is turnedon and off by a signalfromthe robot control unit. Locate supplied length of 18 gauge/2-conductor cord for this connection, and proceed as follo[...]

  • Page 5

    Add Figure 2-4. Arc Failure Light Connections Jig Terminal Strip 2 Common Robot control Unit weld Alarm Robot Control Unit Computer Interface 2TF +24VDC 2TG 2TL Arc Failure Indicator Light To Voltage Source (115VAC, 24VAC, 24VDC) -rj 2TF ~— Arc Failure Indicalor Light TA-il 5 648 Figure 2-4. Arc Failure Light Connections AMENDMENT TO SECTION 5- M[...]

  • Page 6

    AMENDMENT TO SECTION 5 - MAINTENANCE & TROUBLESHOOTING 000 0~ 000000 Amend Figure 5-3. Circuit Diagram For Computer Interface U K U k~, ~000 00 00000 - ~ -, C0CWL.~CI~N =0CL,Lt,~tj7~~liU C K -~ ~ N d z E Cu 0 (3 N.FS SN-CCN( srNso~ JOG ~EV ~ ~ cc to 0 C~J 6 z w U 0) 0) U 0) 0) 0. E 0 C.) I - 0 U - E I - 0) 0 I.. (3 0) 1~ ci ‘N S~~CNN 9E’EC?[...]

  • Page 7

    a I C.’J to C~4 1~ 6 6 z E Cu Cu •~‘ to o .~ — to U, o (3-, 6 z 1~ 0) C/) 0) 0 0) w 5 0. •0 I- Cu 0 3 0 C.) 0) C) Cu 3 I - 0 IL E Cu I- C) Cu 4 - U I- (3 0) C) OM-882 Page 5[...]

  • Page 8

    5V ,24V AR 4ELD START AL JOG F~C 2 WELD AL ~ CURRENT RELA’ AJ JOG (RE. A RE.. RE.A’ 4 06 CR CR5 C ON-S REF EE C ACTOR 6050’ CJRRE’.’ CE C XC T CR4 CON’N-C’CR AC Circuit Diagram No. B-128 016-A FIgure 5-6. CIrcuit Diagram For interface Board PC3 Effective With Serial No. JK588314 Thru KA819026 ‘LO A ‘24 Circuit Diagram C SE L FE C [...]

  • Page 9

    Add Figure 5-9. Wiring Diagram cc r-. I” - 1~ ‘N 0 6 z E Cu C) 0 C) cc U, to to 1.. I - cc to 0 c,,J 6 z h.. 0) U) 0) C.) 0) w E Cu I.. C) Cu 0 C) C U, 0) C) ir OM-882 Page 7[...]

  • Page 10

    to U, to to 6 2 I- 0) U) 0) 0) w E Cu C) 0 C 0) L.. c~J 1~ 6 z E Cu I- C) 0 C OM-e82 Page 8[...]

  • Page 11

    AMENDMENT TO PARTS LIST Amend Parts List as follows: Part Replaced No. With 2-1 2-1 2-4 2-17 2-20 2- 2-39 2-48 3-56 3- 4- 6-2 6-5 6-12 6-15 6-16 6-25 6-26 6-26 6-28 8- C2,3,6-10 PC4 51 Ri-S SR 1,2 CR1 PCi PC3 PC3 RC5 8- 8- R48,49 11— 11— 11- 11- 11— 13- 13-3 13-6 C3 C4 REED CR5 Ti 111 992 117 724 CONTROL PANEL, (Elf w/JH290689 thru JK636568) [...]

  • Page 12

    Parts Lists Continued 000 859 601 394 Added 136584 Added 007501 • CAPACITOR, eIctlt 220uf 35VDC 2 •RESISTOR,C2WlOKohm BRACKET, mtg reed relay 1 WASHER, flat nyl .265 ID x .437 OD 2 ~First digit represents page no - digits following dash represent item no. BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. C4,S R4 13- 13[...]

  • Page 13

    TABLE OF CONTENTS Section No. Page No. SECTION 1 - INTRODUCTION 1 - 1. General Information And Safety 2 1 - 2. Receiving-Handling 2 I - 3. Description 2 SECTION 2 - INSTALLATION 2-1. Location 2 2 - 2. Gas/Current Sensing Control Connections 3 2 - 3. Computer Interface - Welding Power Source Connections 3 2 - 4. Computer Interface - Welding Power So[...]

  • Page 14

    SECTION 1 - INTRODUCTION Model I- MR-5AP I Gas/Current Sensing Weight 31 lbs. (14 kg) Control 5 lbs. (2.3 kg) + 16.5 in. (419 minI case only 2-7/8 in. (73.0 minI Figure 1 - 1. Specifications TB-i 14346 In. mm) 16 in. (7.9 mm) Diameter 2 Holes TB-i 10320 OM-882 Page 1[...]

  • Page 15

    1 - 1. GENERAL INFORMATION AND SAFETY A. General Information presented in this manual and on various labels, tags, and plates on the unit pertains to equip- ment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equip- ment. B. Safety The installat[...]

  • Page 16

    2 - 2. GAS/CURRENT SENSING CONTROL CON - NECTIONS (Figures 2-1 And 2-2) N-. ELECTRIC SHOCK can kill. • Do not touch live electrical parts. • Shut down unit, welding power source, and robot, and disconnect input power employing “lockout/tagging procedures” before making in - terconnections. Lockout/tagging procedures consist of padlocking li[...]

  • Page 17

    A. Wire Stick Sensing Connections 1. Align keyway, insert four-socket Amphenol plug into matching receptacle on computer interface, and rotate threaded collar fully clockwise. 2. Connect lead with ring terminal to welding power source positive output terminal. 3. Connect lead with clamp to welding power source negative output terminal. B. Voltage C[...]

  • Page 18

    3. Remove welding power source interface side panel. 4. Route remaining cord from computer interface through strain relief in bottom of welding power source interface, to 14-position terminal strip. 5. Connect leads as follows: a. Red lead to terminal 52. b. Blue lead to terminal 50. c. White lead to terminal 35. d. Green lead to terminal 36. e. Lo[...]

  • Page 19

    3 - 1. POWER SWITCH (Figure 3-1) 3 - 4. VOLTMETER (Figure 3-1) Placing the POWER switch in the ON position applies input power to the interface. The interface must be on for the robot to weld. Placing the POWER switch in the OFF position shuts down the interface. 3 -2. INDUCTANCE CONTROL (Figure 2-1) The INDUCTANCE control is a digital pushbutton c[...]

  • Page 20

    4 - 2. OUTPUT SIGNALS FROM COMPUTER IN - TERFACE (Figure 4-2) - The interface interprets the input signals from the welding power source, wire drive motor, robot, and wire stick check circuit. The output of the computer interface regulates the welding power source and wire feed functions while welding. Wire Start Relay Arc Initiation Open Close I I[...]

  • Page 21

    CAUTION: IMPROPER FUSES can damage this If replacement becomes necessary, use only fuses of the proper size, type, and rating (see Parts List). To replace the fuse, proceed as follows: 1. Depress and rotate fuse holder cover counterclockwise. 2. Pull out fuse with cover when fuse holder cover is free. 3. Insert new fuse into fuse holder cover. 4. I[...]

  • Page 22

    2. Remove screws securing board to stand-offs. Do not remove stand-offs. 3. Disconnect plugs PLG2O and PLG24 from mat - ching receptacles on PC4. 4. Gently pull board straight away from front panel. Do not pull up or down; otherwise, the meters and LED’s may be damaged. 5. To replace meter(s) proceed as follows: a. Remove nuts and lock washers fr[...]

  • Page 23

    c. Slide spacers onto new meter support. d. Push meter into socket with meter supports protruding through to rear of PC4. e. Reinstall lock washers and nuts to secure meter to board. Do not overtighten nuts or meter may be damaged. 6. To install replacement display board, carefully line board up with front panel openings for meters and LED’s. 7. [...]

  • Page 24

    TROUBLE PROBABLE CAUSE REMEDY No wire feed. Robot signal. Check input signal from robot to motor board PC2. Signal should be 0-10 vdc between pins K and B (common) on RC5. - Relay CR1 not working. Replace CR1. Motor board PC2 not work- ing. Replace PC2 (see Section 5-4). Wire feeds at maximum. Tach board PC5 at wire drive motor not working. Replace[...]

  • Page 25

    5 - 6. USE OF INDICATOR LIGHTS FOR TROUBLESHOOTING Ga~ Indicator Light I Gas does not flow: IF Gas flows: IF Gas dodes not flow: System normal (on). Check gas valve operation. Check gas valve operation and gas line for leaks. Check interface board PC3. System normal (off). -Contactor Indicator Light Contactor closed: System normal (on). I, IF Conta[...]

  • Page 26

    0000 0t00~N- 00000 A0UOUJL.0ZN-040 0 00 0000000 ~ t. ~ 0000 OcP~ 000000 -00 8 ~ ; ~i I - I - I - I- 6 6 2 E 0 L. U 0 4.. 0 C.) RGTA~ 0 U U ‘4.- 0 4- C 0 4- 0. E 0 C.) 0 U - E 0 I... 0 0 4- U (3 cy~ 10 0 I - OM-882 Page 13[...]

  • Page 27

    I & 1 N LI) I - I- 6 S 2 E C I - C a 4- 3 U (3 0. C 0 .3 4- C 0 C., 0 C 4- .5 ‘I 0 U - E C I - 0, C a 4- 3 U (3 LI) C 3 0, 041 U C OM-882 Page 14[...]

  • Page 28

    0 0 0) cv) 0 C Ca 0 z E U C 0 4” U I - G N C-) 0. -V h. C 0 0 0 S S 0. Co I - 0 4- 0 S 4- 0 U - S C I - C 4- U a In I’) S 3- it OM-882 Page 15[...]

  • Page 29

    •15 V. •24 V. 07 0 •24 V. F G A WELD START AS AS ~CGAS B ,.~ (FAD) J ~F~-* ~ .fl3 (REV) N R~UOT ~2 ~T c~ AX REV. RELAY K ~4 cGJTACT~ Circuit Diagram No. B-113 431 Figure 5 - 6. Circuit Diagram For Interface Board PC3 OM-882 Page 16[...]

  • Page 30

    I: N-B V. AA VR2 .1 1dj co.~ 4 AS -~ V. IN LOW 1ST INHI WS I~F~JT K N-24 V. C cOWTACTOW DETECT GAS F .~ IFWO) A .~G (REV) B L N-12 V H coeu~ 4 AD V~TS C i~eu•r I COW RFL ROW D3 V. IN LOW 191 IN HI V. IN LOW (ST IN HI ROW RFH RFL DOW Circuit Diagram No. B-ill 341 Figure 5 - 7. Circuit Diagram For Display Board PC4 04 c’J c~J U ~ 0. LL. M5 ~ I~UU[...]

  • Page 31

    AP AE A.A As AG AF AD AC AJ AN AL AM AN AN AR AS N-, N- A ,. A ~ ,~. ,, N-~N- A C32 C30 C25 C24 C22 C20 -~ H-’ —~ F— —-~ H- —9 H- -~ H- —i H- ~—9 H - PL Z~I IL IL IL ~ —~ H- —~ H- —~ H- -~ H- —9 H- —9 C33 C31 C29 C25 C23 CAR C21 RC2I ~‘ ~‘ V N ‘ N P 0 H L P4 D C ,J K F E S • A Circuit Diagram No. B-ill 117 Figure 5 -[...]

  • Page 32

    Yay - Effe~tiv With Serial Nc. ~H1 3 ?.~i1 K PARTS LIST[...]

  • Page 33

    Fig C 1 TC-1 14 345 Figure A - Control Box OM-882 Page 1[...]

  • Page 34

    Item Dia. No. Mkgs. Figure A Part No. Description Control Box 111 992 010 855 010 853 070 634 + 109 026 079 683 R2 030 941 010 193 010 199 030 949 056 170 109 041 PLG9 047 636 079 535 079 739 096 813 PLG16 048 598 079 534 049 989 PLG12 073 686 039 328 604 109 600 848 600 750 601 226 601 228 111 951 097 868 039 734 090 263 097 866 010 916 070 731 05[...]

  • Page 35

    Item Dia. No. Mkgs. Figure A 51 52 53 54 55 56 57 58 59 Part No. Description Control Box (Cont’d) 112 254 089 032 046 432 Fl *012 655 073 487 51 011 622 CB1 011 991 S2 112392 RC9 047 637 079 534 026 202 079 760 079 798 081 379 092 159 084 198 111 500 Dl PLG18 PLG19 PLG20,26 PLG22 PLG24 PLG27 LABEL, Miller robot computer interface LENS, led 4341 H[...]

  • Page 36

    Dia. Mkgs. Part No. Description Quantity 2 3 Figure B 111 564 Circuit Card, Meter (FIg A Pg 2 Item 48) Cl ,2 000 348 CAPACITOR, tantalum 0.47 uf 35 volts C3-5 073 739 CAPACITOR, ceramic 0.1 uf 50 volts dc Dl ,2 028 351 DIODE, signal 0.020 amp 75 volts SP LCDl-3 108 453 METER, DCO-200MV LEDl,2,4,5 089 028 LED,5330A1040MCD LED3 097 763 LED, 5330A1920[...]

  • Page 37

    11 19 Figure C - Control Panel OM-882 PageS[...]

  • Page 38

    Item Dia. No. Mkgs. Part No. Description Quantity Figure C 111 992 Control Panel (Fig A Pg 2 Item 1) 1 PC2 071 642 CIRCUITCARD,digitalmotorspeed(FigC2PglO) 1 2 083 147 GROMMET, screw8-10 push in 1 3 CR2 052 964 RELAY, enclosed 24 volts dc DPDT 1 4 5T 038 839 BLOCK,terminal20amp5 pole 1 5 SRi 035 914 RECTIFIER, integrated 30 amp 400 volts 1 6 T2 109[...]

  • Page 39

    OM-882 Page 7 COMPONENT TO BE REPLACED Ret: Dlii 410 BY QUALIFIED PERSONNEL ONLY Figure Cl - Circuit Card, Voltage[...]

  • Page 40

    Dia. Mkgs. Part No. Description Quantity Figure Cl 111 408 Circuit Card, Voltage (Fig C Pg 6 Item 25) A1-3 Cl ,2 C3 ,4 CS-i 5,17-24 Cl 6 D1-4,6 L1-4 Ql Rl R2,34,35,41 R3 R4,20,26,27,30, 38,40 R5,9,10,18,25,28, 29,37,39 R6,7,12-1 5,36 R8 R11,16 R17 R19,21 .43 R22,42 R23 R24 R3 1 R32 R33 R45 RC25 R C26 Ul U2,4 U3 VR 1 VR2 096 275 039 482 000 348 073 [...]

  • Page 41

    A50 ~ !rr~ G GATE ANODE D CATHODE (LARGE TERM) O5~ 000 LOLC) ~ C5O~ + 0 rn~ ~ft Ret: 0-093 449-G COMPONENTS TO BE REPLACED BY QUALIFIED PERSONNEL ONLY Figure C2 - Circuit Card, Digital Motor Speed 0z~ o,~ ~ ~“-‘-0 w — ft~ t N~ C%J — c~4 — 0 R90 TUVWXYZ OM-882 Page 9[...]

  • Page 42

    Dia. Mkgs. Part No. Description Quantity Figure C2 071 642 Circuit Card, Digital Motor Speed (Fig C Pg 6 Item 1) ASO-53 C50 CS 1 C52 ,6 1 C53,62 C54 C55,66-75,77 C56 C57 C60 C63,64 C65 CR50 D50-54,56-60 D55 1C50 QSO ,53 Q5 1 Q52 R50 R51 ,54,55,57,67, 68,74,75,82,89 R52,56,61 R53 R58,62,65,66,71 72,76,90 R59 R60,87,88 R63,79 R64 R70 R73,83 R77 R78 R[...]

  • Page 43

    Dia. Mkgs. Part No. Description Quantity Figure C3 113 221 Circuit Card, Interface (Fig C Pg 6 Item 26) Al 009 159 IC,linear358 1 Cl 039 482 CAPACITOR, electrolyte 100 uf 35 volts dc 1 C2 000 348 CAPACITOR, tantalum 0.47 uf 35 volts 1 C3,6,9,10 072 130 CAPACITOR,tantaluml uf35voltsdc C4 005 023 CAPACITOR,tantalum2.2uf20volts 1 1 C5,11 073 739 CAPAC[...]

  • Page 44

    Dia. Mkgs. Part No. Description Quantity 14 Figure C4 110 565 Circuit Card, Filter (Fig C Pg 6 Item 17) C1-6,9-14,46,47 028 292 CAPACITOR, ceramic0.OOSuflOOOvoltsdc C20-25,28-33,48,49 028 291 CAPACITOR, ceramic 0.1 uf500voltsdc 14 L1-3,5-7,9 110190 CHOKE,1000UH 7 RC21 089 347 TERMINAL, header 14 pin 1 RC22 092 160 TERMINAL,headerl6pin 1 ASSEMBLY I [...]

  • Page 45

    Part No. Description Quantity Figure D 109 936 Control Box, Gas/Current Sensor 047 497 +079 682 079 687 109 021 049 455 010 610 010 494 057 358 010 604 602 934 079 573 079 574 047 637 079 534 109 938 038 081 109 561 090 246 079 535 2 LABEL, general precautionary WRAPPER RELAY, current CASE SECTION, bottom/front/sides CORD, No. 182/c (order by ft) C[...]

  • Page 46

    ERRATA SHEET After this manual was prInted, refinements In equipment design occurred. This sheet lists exceptIons to data appearing later in this manual. AMENDMENT TO SECTION 2 - INSTALLATION IMPORTANT: A 25 ft. (8m) interconnecting cord with a five-pin Amphenoiplug is supplied with this unit but is not used in this installation. Retain cord for fu[...]

  • Page 47

    c. Route customer supplied 18 gauge/2-conductor cord under cross member below door. d. Make cord connections to terminal strip common and the Weld Alarm terminal. e. Close robot control unit door, and route cord to jig interface. f. Connect cord to isolation relay coil and voltage source. g. Cut off terminals from one end of supplied 18 gauge/2-con[...]

  • Page 48

    AMENDMENT TO SECTION 5- MAINTENANCE & TROUBLESHOOTING Amend Figure 5-3. Circuit Diagram For Computer interface 000 0~ 000000 a K ~ —000.000.00.0 ~ 0j-~ ; N-s -N- ~ I_ _9Z~L.~j e~7 A~AA < ~ - A N-N- S N-N-N- i~N-- ~ N-N- ~<o. ~ N-N- I N - ~<‘N- ~ Xx ! N N-N - ~N-~N- N-.N-j .1 EN-N - ~ 0—))~—-* N I K ~ I -0> 4> ~ ~ a.-> [...]

  • Page 49

    Amend Figure 5-6. Circuit Diagram For Interface Board PC3 ‘ISV *24 V N-24 ~.C2 Cit L... 44..................).R WELD START As 7 AS JOG (FN-dD) ,~ CR R 6 C GAS WIREFEED CR5 MOTOR WELD AL CURRENT RELAY A.J JOG (REV) P4 CR6 GAS WOBOT CR2 CURRENT COl.*40N AM L.............> AN REV. RELAY ~ CR4 CONTACTOR L~AC CIrcuit Diagram No. 5-128 016 FIgure 5-[...]

  • Page 50

    Add Figure 5-9. Wiring Diagram uu C.,’ 1— r-. 1~ 6 z E (U a- 0) 0 0) 0) 0) C..’ = 6 z a- a) U) •6~ a) 4- C.) a) E (U a- 0) (U 0 0) a) a - 0) U.. OM-882 Page 5[...]

  • Page 51

    AMENDMENT TO PARTS LIST Amend Parts List as follows: Part Replaced No. With C2,3,6-1 0 PC4 51 Ri -5 SRl,2 PC3 RCS C3 CS D9, 10,15,16 CR5 Ti 111 992 070 634 049 989 604 109 028 291 111 564 011 622 044 635 083 147 035 914 110 375 111 065 113 221 073 730 072 130 073 739 028 351 109 936 010 610 C4,5 R4 117 724 123 154 118 676 604 109 028 291 117836 011[...]