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Manual

Manual Miller 350

Summary

Page 2 - LIMITED WARRANTY

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, Wisc...

Page 3 - ERRATA SHEET; AMENDMENT TO SECTION 2— INSTALLATION; Do not touch live electrical parts.; Connections; in this installation. Retain cord for future use.

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 exceptionsto ...

Page 5 - Add Figure 2-4. Arc Failure Light Connections; Figure 2-4. Arc Failure Light Connections; Add the following Step to Section 5-1

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 Fai...

Page 8 - Circuit Diagram

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 ...

Page 9 - ir

Add Figure 5-9. Wiring Diagram cc r-. I”- 1~ ‘N 0 6 z E Cu C) 0 C) cc U, toto 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 11 - AMENDMENT TO PARTS LIST; Amend Parts List as follows:; Ti; warning general precautionary; ii

AMENDMENT TO PARTS LIST Amend Parts List as follows: Part Replaced No. With 2-1 2-12-4 2-172-20 2- 2-39 2-48 3-56 3- 4- 6-2 6-5 6-126-156-16 6-25 6-26 6-266-28 8- C2,3,6-10 PC4 51 Ri-S SR1,2 CR1 PCiPC3PC3RC5 8- 8- R48,49 11— 11— 11- 11- 11— 13- 13-313-6 C3C4 REED CR5 Ti 111 992 117 724 CONTROL PANEL...

Page 12 - Parts Lists Continued; Added; reed relay; ~First digit represents page no; digits following; dash represent item no.

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 W...

Page 13 - TABLE OF CONTENTS; General Information And Safety

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 Connecti...

Page 14 - Model; Figure 1

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 - SECTION 2; The location should allow room to open and remove

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, andtroubleshooting which should be read, understood, and followed for the safe and effective ...

Page 16 - disconnect switch in open position, removing fuses; from fuse; Lockout/tagging procedures consist of padlocking line

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, androbot, and disconnect input power employing “lockout/tagging procedures” before making in-terconnections. Lockout/taggi...

Page 17 - four-socket Amphenol plug; into matching receptacle on computer interface,; Connect the twistlock receptacles to the mat-; from fuse box, or shutting off and red-tagging circuit; breaker or; other disconnecting device.

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 weldingpower source positive output terminal. 3. Connect lead with clamp to welding po...

Page 18 - Locate terminal strip 2T.; IMPORTANT: The Inductance control is disabled; SECTION 3; Figure 3

3. Remove welding power source interface side panel. 4. Route remaining cord from computer interfacethrough strain relief in bottom of welding powersource 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 ...

Page 19 - Fuse Protection; The interface is protected from damage due to an inter-; SECTION 4; Figure 4

3 - 1. POWER SWITCH (Figure 3-1) 3 - 4. VOLTMETER (Figure 3-1) Placing the POWER switch in the ON position appliesinput 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)...

Page 20 - weld is completed, the wire stick check is performed to; SECTION 5; INSPECTION AND UPKEEP

4 - 2. OUTPUT SIGNALS FROM COMPUTER IN- TERFACE (Figure 4-2) - The interface interprets the input signals from the welding power source, wire drivemotor, robot, and wire stick check circuit. The outputof the computer interface regulates the welding powersource and wire feed functions while welding. ...

Page 22 - Figure 5

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 ...

Page 25 - USE OF INDICATOR LIGHTS FOR TROUBLESHOOTING; IF; IF; IF; Arc Failure Indicator Ligl~; Check display board PC4.

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...

Page 32 - Yay; PARTS

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

Page 34 - Item; Figure A; Part; Description; Control Box; HEAT SINK; Quantity

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 193010 199 030 949056 170 109 041 PLG9 047 636 079 535 079 739096 813 PLG16 048 598 079 534 049 989 PLG12 073 686039 328604 109600 848 600 750 601 226 601 228 111 951 097 86...

Page 36 - II liD Ii LI; LID Ii II Dli; COMPONENTS TO BE REPLACED; Figure B

Dia. Mkgs. Part No. Description Quantity 23 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...

Page 39 - Figure Cl

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

Page 40 - BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN

Dia. Mkgs. Part No. Description Quantity Figure Cl 111 408 Circuit Card, Voltage (Fig C Pg 6 Item 25) A1-3 Cl ,2C3 ,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 R23R24 R3 1 R32R33R45 RC25 R C26 Ul...

Page 41 - Figure C2

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 43 - Al; Cl; III; Figure C3

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 CAPA...

Page 44 - ASSEMBLY; LU; COMPONENTS TO BE REPLACED BY; Figure C4

Dia. Mkgs. PartNo. 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 ...

Page 45 - mtg hole; Figure D

Part No. Description Quantity Figure D 109 936 Control Box, Gas/Current Sensor 047 497 +079 682 079 687 109 021 049 455010 610010 494057 358010 604602 934079 573 079 574047 637 079 534109 938 038 081 109 561 090 246 079 535 2 LABEL, general precautionary WRAPPER RELAY, currentCASE SECTION, bottom/fr...

Page 46 - appearing later in this manual.; WARNING: ELECTRIC SHOCK; ging procedures before making interconnections.; disconnecting device.; The Inductance control; is disabled when operating in the CC (constant current) mode.

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...

Page 47 - unit

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...

Page 48 - AMENDMENT TO SECTION 5- MAINTENANCE & TROUBLESHOOTING; Amend Figure 5-3. Circuit Diagram For Computer interface; DALE

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—))...

Page 49 - Amend Figure 5-6. Circuit Diagram For Interface Board PC3

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 CONTACT...

Page 50 - uu

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 - amp

AMENDMENT TO PARTS LIST Amend Parts List as follows: Part Replaced No. With C2,3,6-1 0 PC4 51 Ri -5 SRl,2 PC3RCS C3CS D9, 10,15,16 CR5 Ti 111 992 070 634 049 989 604 109 028 291111 564011 622044 635 083 147 035 914 110 375111 065113 221073 730072 130 073 739028 351 109 936 010 610 C4,5 R4 117 724 12...