Miller Electric MR-5, Millermatic 350 User Manual

Y8y7?~i

IMPORTANT:

contents manual on before equipment. This

use

safe

untrained this unit. understand these

of both this

used

with

the safety

installing,

only by

operation of welding

material

persons

personstoinstall,

Contact

Read

and

manual

this unit,

throughout

operating,

unit

and

trained

your

distributorifyoudonot

instructions.

understand

and

the

with

special

or maintaining this

these

instructions

and

experienced

equipment.Donot allow

operate,

the entire

power

eutiphasis

both

manuals,

or maintain

source

are

for

in the

fully

Effe~ti.EWith

MODEL

MR-5/ARC COMPUTER

GAS/CURRENT

CONTROL

SanEIFic...H1:33:~’

TM

PAK

350

INTERFACE

SENSING

I

OWN

ER’S

MANUAL

MILLER

ADDITIONAL

ELECTRIC

718SBOUNDS

APPLETON,WI54912

COPY

NWSA

CODE

PRINTEDINU S

ST,P0

PRICE95CENTS

NO.

A

MFG.

Box

USA

4579

+5

millER

Co.

1079

LIMITED

WARRANTY

This

warranty

4;

LIMITED

tions

warrants to

4;

Equipment

ship

and

No

warrantyismadebyMiller

accessories

engines,

4;

the

4!

4;

~Ji

4~

<

~

warrantiesoftheir

engines

date of

haveatwo

Exceptasspecified

to

components

year, suchasspot

MILLERMATIC

wire

including

not

result

Miller

ranted Equipmentinthe

within

ment to

1.

Arc

2.

Load

3.

Original

Ilabor-1

4.

All

All Replacementorrepair

7.

Batteries

provided of

the Asamatterofgeneral

submittedbythe

supersedes

WARRANTY

hereof,

Miller

its

furnishedbyMillerisfree

materialasof

or other

trade

accessories

are

warranted

original

year

nozzles

from defectinworkmanshipormaterial.

shallberequired

the

following

the

original

welders,

banks

main

year

welding guns,

other

Millermatic

that

Millerisnotifiedinwriting

date

of such

all

previous MILLER

Subjecttothe

Electric

Distributor/Dealer

purchase,

warranty.

having normal parts

periods

power

onlyl

failure.

original

Mfg.

the

time

items

manufacturedbyothers.

and

other

respective

bytheir

manufacturer

except

below,

Miller’s warranty

welder

that

and

user:

feeder/guns

useful

tips,

comeincontact with the

nozzle

to honor warranty

eventoffailure

from

sources,

robots,

rectifiers

Feeders

parts,

policy

user

within

Co.,

that

from defectinworkman

and

placeofdeliverybyMiller.

with

respecttoengines,

items

manufacturers,ifany . All

Tecumseh

lifeofless

relay

and

insulators

resulting

the

dateofdeliveryofEquip

and

plasma

exclusive

within

only,

Miller

the

EFFECTIVE:

warranties

terms

and

Appleton,

all

components.1

foregoing

Wisconsin

new

and unused

are

sold

subject

for

one

year

engines

does

not

than

contactor points,

where failure

torches...90days

oflabor..60days

may

one

welding

claimsonwar

fromadefect

3

6

months

thirty

1301

honor

periods.

OCTOBER1,1986

andisexclusive

condi

with

therefore

or,

the

Ill

Miller price

returnofthe

to

optionofrepairorreplacement Appleton,

facility, any defectorfailure, claim

ANY

•flONASTO BREACHOFCONTRACT MIGHT

CUSTOMOFTRADEORCOURSEOFDEALING, INCLUDING

ANY

FITNESS FOR

ANY CLUDED

WRITING,

ULTIMATE USERS

EXPERIENCEDINTHE USE

WELDING

CONSUMER USE. MILLER’S TO,

MILLER’S

trade Such

from

which

apply

does

year

1

year

years

1

year

days

claims

with no

other

guaranteesorwarranties

In

the

caseofMiller’s

respecttothe

shall

where

reasonable

(less

kind

ANY

EXCEPT

AND

be,atMiller’s

authorizedinwritingbyMillerinappropriate

service

procedures

IMPLIED

AND ALL

costofrepairorreplacementatan

stationor14)

reasonable

goodsatCustomer’s

Wisconsin,orFOB.,ata

therefore,nocompensation

willbeallowed.

EXPRESS

WARRANTY,

PERFORMANCE,

ARISEBYIMPLICATION,

WARRANTYOFMERCHANTABILITYOROF

PARTICULAR

AND

DISCLAIMEDBYMILLER.

AS

MILLER

PURCHASE

AND

FOR

EQUIPMENT

NO

WARRANTIES

breachofwarrantyorany

qualityofany

depreciation

Miller

shall

to be

followed.

WARRANTY

EQUIPMENT

EXPRESSLY

PRODUCTS

OPERATIONBYPERSONS

RESELLERISAUTHORIZEDTOEXTEND

goods,

option

(11

paymentofor

based

risk

willbeFOB.,

Upon

receiptofnoticeofapparent

instruct

the

NOT

GUARANTYORREPRESENTA

WHICH,

AND NOT

AND ANY BUT FOR

PURPOSE,

FURNISHEDBYMILLERISEX

PROVIDED BY

BY

COMMERCIAL/INDUSTRIAL

AND

WARRANTIESDONOT

TO,

ANY

expressedorimplied

the exclusive remedies

repairor121

credit for

upon

and

MILLER authorized

for

transportation

claimantonthe

PROVIDED

OPERATIONOFLAW,

WITH

ARE

MAINTENANCE

FOR

CONSUMER.

other

replacement

cases,

authorized

the purchase

actual

expense.

usel

MILLER’s

Factory,

service

costs

warranty

HEREIN

REMEDY

THIS PROVISION,

RESPECT

MILLER

INTENDED

TRAINED

CONSUMERS

EXTEND

duty

(3)

upon

at

of

AND

-

FOR

TO

-

IN

FOR

AND

OF OR

May

~OM.882j

31,1990

ERRATA

After to

data

AMENDMENTTOSECTION2—INSTALLATION

IMPORTANT:

in

this

Add the SOURCE

IMPORTANT:

connectedtothe terminal.

Amend AC/Contactor Control

IMPORTANT:

computer

SHEET

this

manual

appearing

A25ft.

installation. Retain

foliowing

CONNECTIONS: Wire

Section

interface

was

laterinthis

(8m)

IMPORTANT

If dc

electrode

negative

2-3C.

COMPUTER

Connection

Cords

are

available.

printed,

interconnecting

cord

weld

supplied

refinementsInequipment

manual.

for

future

blocktothe

Stick Sensing

negative

output

weldingisdesired,

terminal

INTERFACE-WELDING

that

may

cord

withafive-pin

use.

end of Section

Connections

and

not

be used

the

design

Amphenoiplugissupplied

2-3A.

reverse connections so

lead

withaclampisconnectedtothe

in this

installation.

occurred.

COMPUTER

POWER

SOURCE

Match

This

INTERFACE-WELDING

cordtowelding

sheet

lists

exceptions

with

this

unit

butisnot

the

lead

with

ring

positive

CONNECTiONS:

power

weld

source

used

POWER

terminal

output

115

Volts

and

is

1.

Align

keyways,

collar

fully clockwise.

2.

Align

keyway,

threaded

3.

Place

appropriate

remote control

Amend

A

There screwsonstrain

screwsonstrain

A.

Section 2-5.

WARNING: ELECTRIC

0

Do

0

Shut

ging

Lockout/tagging

from

fuse box,orshutting

are

several

CVICC

Connections

WARNING:

A

insert

4-socket

insert

14-pin

collar fully

not

down unit,

procedures

terminal

reliefonunit reliefifnecessary,

clockwise.

remote control switch(es)onthe

device.

COMPUTER

touch

procedures

strips

Read

INTERFACE

live

electrical

welding

before

inside the

rear

and

follow

Amp

plug

into

matching

Amphenol

SHOCK

powersource, and

making

consistofpadlocking

off

panelifnecessary,

and reinstall

plug

into

TERMINAL

can

kill.

parts.

interconnections.

and

red-tagging

computer

safety

interface

top

informationatbeginning of Section

and

cover

receptacleoncomputer

matching

welding

robot,

circuit

locate when

receptacleonwelding

power

sourceinthe

STRIP

line

CONNECTIONS

and

disconnect

breakerorother

for

control procedureisfinished.

connections. Remove

appropriate terminal

interface,

proper

input

power

switchinopen

disconnecting

strip

2-5

and rotate

power

source,

position

employing

position, removing fuses

device.

unit

top

for

connections.

before

threaded

and

rotate

for

useofa

locko

ut/tag

cover,

loosen

Tighten

proceeding.

-

1.

Locate

2.

ForCCoperation,

IMPORTANT:

terminal

The

Strip

2T.

remove

Inductance controlisdisabled

jumper

link

between

terminalEandFon

when operatingintheCC(constant

2T.

current)

mode.

B.

ARC

FAILURE

Light

Connections

(Figure 2-4)

WARNING:

A

The ARC FAILURE

Locate

supplied

1.

For

a.

Open

b.

Route

c.

Make cord connectionstoterminal

d.

Close

e.

Connect

2.

For

a.

Obtaina115or24

b.

Open

c. Route d.

Make

e.

Close

f.

Connect

g.

Cut contactsonisolation

h.

Connect

i.

Route cord

j.

Connect

lengthof18

robot control

cord under

robot control

cordto2TF

robot control

customer supplied18gauge/2-conductor cord under

cord connectionstoterminal

robot control

cordtoisolation

off

terminals from

one end of

cordto2TF

Read

and

light

orlthe

computerinterface front panelisturnedon

gauge/2-conductor cord

units

withnoother

unit

door,

cross member

unit

door,

and

Units

when

vac,or24

unit

door,

unit

door,

one end of

relay.

cordtoa

through strain

and

follow safety Informationatbeginning

and

for

this

connectionsatjig

and

locate

jig

below

door.

strip

common and

and

route cord

2TG.

115or24 vac,or24

Vdc

isolation

and

locate

strip

and

route

relay

coil

and

supplied18gauge/2-conductor

setofnormally-open

relief on

2TG.

rear

relay,

jig

common cordtojig

voltage source.

panelofcomputer interface.

connection, terminal

terminal

through strain

terminal

strip

2.

the Weld Alarm

vdcisusedatjig terminal

and install

strip

2.

and

the

Weld Alarm

interface.

contactsonisolation

and

strip

relief on

into

jig

cross member

of Section

off

by a

proceedasfollows:

2:

terminal.

rear

panelofcomputer

interface.

terminal.

cord,

and relay.

2-5

signalfromthe

strip

2T:

below

door.

install terminalstoconnect

before

robot control

proceeding.

unit.

interface.

to

OM-882 Page

2

Add

Figure

2-4.

Arc

Failure Light

Robot

control

Unit

Connections

Jig

Terminal

Strip

2

Common

weld

Alarm

Computer

2TF

2TG

2TL

Interface

+24VDC

Arc

Failure

Indicator

Light

To Voltage

(115VAC, 24VAC,

Robot

Control

Unit

Weld

Alarm

Figure

Source

24VDC)

Jig

2-4. Arc

Interface

Failure

Light

Connections

AMENDMENTTOSECTION5-MAINTENANCE&TROUBLESHOOTING

Add the

Amend Amend

3.

following SteptoSection

Inspect

Figure

motor

5-3.

Circuit

5-4.

Circuit

control

Diagram

relay,

5-1-INSPECTION

CR2,

and

cleanorreplaceasrequired.

For

Computer

For

Voltage

AND

Interface

Control

UPKEEP

(see

Board

Page4on

PCi

(see

this

Page5on

-rj 2TF ~—

Errata)

this

Errata)

Arc

Failure

Indicalor

Light

TA-il5

648

Amend Add

Figure

5-9.

5-6.

Circuit Diagram

Wiring Diagram

For

Interface

(see

Pages7and8on

Board PC3 (see

this

Errata)

Page6on

this

Errata)

OM-882

Page

3

AMENDMENT

TO SECTION

5-MAINTENANCE&TROUBLESHOOTING

Amend

Figure

K

5-3.

Circuit

U K U

-

~

Diagram

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For

k~,

-,

Computer

000

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OM-882 Page

Ua’AGE

4

a

I

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to

C~4

1~

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z

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Cu

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to

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E

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I-

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4

U

I-

(3

0)

C)

OM-882

-

Page

5

5V

,24V

4ELD

JOG

RE..

FIgure

START

F~C

WELD

CURRENT

RELA’

(RE.

RE.A’

5-6.

AR

AL

2

AL

~

AJ

A

4

CIrcuit

AC 6

Diagram

.24

C.

For

interface

Board

PC3

Effective

With

Serial

‘LO

Circuit

No.

JK588314

A

06

CR

Diagram

‘24

C ON-S

No.

REFEEC

ACTOR

6050’

CJRRE’.’

CECXC

T

CON’N-C’CR

AC

B-128

016-A

CR5

CR4

Thru KA819026

CC

~ELC

S’ART

UDO

(L(~fl(

RELO

CURRENT

RELAY A.

406

(RE6I

C07R40N,

REV. RELAX

AR AE

—

AL

A

ALA

1<

Figure 5-6.Circuit

Diagram

For

interface

Board

PC3

Effective

With

Circuit

Serial

06

CR

6

Diagram

No. KABi

045

C66

T

OR?

CR4

No.

B-i37905

9027

C

SELFEC AC’CR

6080’

CLPRE

N

CE

CEO

0C7,’4C’CR

AC

C

OM-882 Page

6

‘N

Add

Figure

5-9.

Wiring

Diagram

cc

r-.

I”

1~

0

6

z

E

Cu

C)

0

C)

-

cc

U,

to to

1..

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cc

to 0

c,,J

6

z

h..

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U)

0)

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0)

w

E

Cu

I..

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ir

OM-882

Page

7

c~J

1~

6

z

E

Cu

I-

C)

0

C

U)

w

0

to

U,

to to

6

2

I-

0)

E

Cu

C)

C

OM-e82 Page 8

0)

L..

AMENDMENTTOPARTS

LIST

Amend

Parts

2-1 2-1

2-4

2-17 2-20

2-

C2,3,6-10

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-

8- R48,49

11— 11—

11-

11—

13-

13-3

13-6

List

as follows:

Dia.

Mkgs

PC4

51

Ri-S

SR

1,2

CR1

PCi PC3 PC3 RC5

C3 C4

REED

CR5

Ti

Part

No.

111

992

117724

070 634

049 989 604

109

028

291

090 890

iii

564

011

622

Added

044

635

083

147

035 914 035 034

841

110375 111

065

111

408

113 221 128014 073

730

073 739 073

000 885 000

Added

072

130

072

130

005023 Deleted

073

739

028

3S1

109

936 079682 010

610

Replaced

With

117

724

129

952

123

154 LABEL,

118

676

604

109

028

291

135

304

117836 011

609

110

438

048 284 079 534

079

531

604

571

iii

122.HOUSING

109 770

030

028

083

147

704

109

006

110375

121

313

131

247

128 014 128014 CIRCUITCARD,interface,

073

730 739

88S

049

015

072

130

Deleted

073739 028351

117 617 136

59S

115

104

110386 RELAY,encI24VACDPDT 117725

117 726

Description

CONTROL

JK636568)

CONTROL CABLE,

WIRE, CAPACITOR, CABLE, CIRCUITOARD,

SWITCH,

CABLE, (consisting

HOUSING

.

TERMINAL, CLAMP, cable CABLE,

TERMINAL,

RESISTOR,C.5W GROMMET, RECTIFIER,

RELAY, STANDOFF,

PANEL, CIRCUIT

CIRCUIT TERMINAL,

CAPACITOR,

(EU

w/JK655454)

RESISTOR, (Elf

w/JK655454)

RESISTOR,CF.25W10meg ohm (Eff

w/JK655454) CAPACITOR, (Elf

w/JK588314

Elf

w/KA819027

Elf

w/KA819027

CAPACITOR (Elfw/JK5883

DIODE, (qty

CONTROL

RELAY,current

CONNECTOR TRANSFORMER,control

CAPACITOR/RESISTOR,

PANEL, PANEL,

warning general

volt

sensing

(qty

chg)

port

tgl

interconnecting

of)

PLUG&SOCKETS,

port

PLUG

(qty

end

24VAC

rntg-components

CARD, CARD, interface

hdr22pin

(qty

chg

BOX,

(Elf (Effw/JK636569)

(Eff

(qty

chg)

No.188/c

meter

SPDT

iSA

female

strain

reliefsz11

No.

184/c

&

PINS,

female1pinsz45

1.5K

chg)

(qty

chg)

integ

DPDT

(qtychg)

Voltage

(qty

chg

added

(qty

chg

thru KA819026)

(qty

chg

deleted

14) added D16)

gas/current

CLAMP, cable

w/JH290689

precautionary

w/HJ304076)

(orderbyft)

125V 25ft

(Eff

w/JK678982)

iskt

14-18w

(orderbyft)

(consisting

ohm

30A

600V

(Effw/JK636569)

(Elf

w/JJ377225)

control

added C25-30)

deleted

(Effw/JK655454)

(Effw/JK588314)

(Effw/KA819027)

R46,47)

C6,9,10)

Cli

(Elf

sensor

1/2

(consisting

thru

(consisting

16-22w

w/JK588314)

in

of)

Quantity

OM-582

1

1 1

2

6ft

7

61

t

1 1

1 1 4

1

25ft

1

14

1

2

1

7 1

1 1 1 1

25

ii

2

Page

9

Parts

Lists Continued

C4,S

R4

13-

~First

digit represents

BE

SURETOPROVIDE MODEL

page

Added Added

no

-

digits following

AND

000

859

601

394 136584 007501

SERIAL

•

CAPACITOR,

eIctlt

•RESISTOR,C2WlOKohm

BRACKET, WASHER,

dash

represent

NUMBER

mtg

flat

WHEN

reed

nyl

item

no.

ORDERING REPLACEMENT

220uf 35VDC

relay

.265

ID x

.437 OD

2

1

2

PARTS.

OM-882 Page

10

TABLE

OF

CONTENTS

Section

SECTION

1-1. 1-2.

I

-

SECTION

2-1.

2-2. 2-3. 2-4. 2-5.

SECTION

3-1. 3-2. 3-3.

3-4. 3-5. 3-6. 3

-

7.

SECTION

No.

1-INTRODUCTION

General

Receiving-Handling

3.

Description

2-INSTALLATION

Location Gas/Current

Computer Interface-Welding

Computer Interface Terminal

3-FUNCTIONOFCONTROLS

PowerSwitch Inductance Overload

Voltmeter

WireSpeedMeter

Ammeter

Indicator

4-SEQUENCEOFOPERATION

Information

Sensing

Control

Protection

Lights

And

Safety

Control

Connections

Power

Source

Power

Source Interface

Strip

Connections

Connections.

Page

2

2 2

2 3

3 4 5

6 6 6

6

No.

4-1.

4-2. 4-3.

SECTION

5-1.

5-2.

5-3.

5-4.

5-5.

input

Signal

From

Welding

Output

Wire

5-MAINTENANCE8TROUBLESHOOTING

Inspection Overload

Display Board

Troubleshooting

Signals

Stick

Board

Replacement

From

Check

And

Upkeep

Protection

Meter

Chart

Power

Source

Computer Interface

Check

Procedures

6 7

7

7 7

8 8

10

SECTION

1-INTRODUCTION

I-

I

Gas/Current

Model

MR-5AP

Sensing

Weight

31

lbs.

Control5lbs.

(14

(2.3

kg)

+

16.5

in.

(419

2-7/8

(73.0 minI

minI

in.

case only

Figure

16

in. (7.9

Diameter2Holes

1-1.

mm)

Specifications

TB-i

In.

mm)

TB-i

14346

10320

OM-882

Page

1

1-1.

GENERAL

A.

General

Information labels,

ment

tags,

design,

INFORMATION

presented in this

and

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The

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2-1.

The

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the

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end

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Welding

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Manual.

instructions

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Figure

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OM-882

Page

2

Wire

Receptacle

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GaslCurrent

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Control

Control-

Cord

Interconnection

Diagram

Sensor

TB-i14357

OM-882

Page

3