Instruction/ maintenance manual of the product MR-5 Miller Electric
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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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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. 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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
•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.
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.
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.
Yay - Effe~tiv With Serial Nc. ~H1 3 ?.~i1 K PARTS LIST.
Fig C 1 TC-1 14 345 Figure A - Control Box OM-882 Page 1.
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 .
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.
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.
11 19 Figure C - Control Panel OM-882 PageS.
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 C.
OM-882 Page 7 COMPONENT TO BE REPLACED Ret: Dlii 410 BY QUALIFIED PERSONNEL ONLY Figure Cl - Circuit Card, Voltage.
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 .
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~.
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-.
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.
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.
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.
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.
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.
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-.
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.
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.
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 .
An important point after buying a device Miller Electric MR-5 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Miller Electric MR-5 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Miller Electric MR-5 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Miller Electric MR-5 you will learn all the available features of the product, as well as information on its operation. The information that you get Miller Electric MR-5 will certainly help you make a decision on the purchase.
If you already are a holder of Miller Electric MR-5, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Miller Electric MR-5.
However, one of the most important roles played by the user manual is to help in solving problems with Miller Electric MR-5. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Miller Electric MR-5 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
