Miller Electric MR-5 Owner's Manual
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Miller Electric MR-5 Owner's Manual

Miller Electric MR-5 Owner's Manual

Computer interface gas/current sensing contro
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IMPORTANT:
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 operation of welding equipment. Do not allow
untrained persons to install, operate, or maintain
this unit. Contact your distributor if you do not fully
understand these instructions.
OWN ER'S
MANUAL
MILLER ELECTRIC MFG. Co.
718 S BOUNDS ST, P 0 Box 1079
APPLETON, WI 54912 USA
ADDITIONAL COPY PRICE 95 CENTS
NWSA CODE NO. 4579
PRINTED IN U S A
Y8y7?~i
Effe~ti.
With SanE I Fic.
E
MODEL
MR-5/ARC PAK TM 350
COMPUTER INTERFACE
GAS/CURRENT SENSING
CONTROL
+5
millER
H1:33:~' I
..

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  • Page 1 718 S BOUNDS ST, P 0 Box 1079 APPLETON, WI 54912 USA ADDITIONAL COPY PRICE 95 CENTS NWSA CODE NO. 4579 PRINTED IN U S A Effe~ti. With SanE I Fic. H1:33:~’ I MODEL MR-5/ARC PAK TM 350 COMPUTER INTERFACE GAS/CURRENT SENSING CONTROL...

  • Page 2: Limited Warranty

    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 new and unused Equipment furnished by Miller is free from defect in workman- ship and material as of the time and place of delivery by Miller.
  • Page 3 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 A 25 ft. (8m) interconnecting cord with a five-pin Amphenoiplug is supplied with this unit but is not used IMPORTANT: in this installation.
  • Page 4 B. ARC FAILURE Light Connections (Figure 2-4) WARNING: Read and follow safety Information at beginning of Section 2-5 before proceeding. The ARC FAILURE lightorlthe 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 follows: For robot control units with no other connections at jig terminal strip 2: a.
  • Page 5 Add Figure 2-4. Arc Failure Light Connections Jig Terminal Strip 2 Common Robot control Unit weld Alarm To Voltage Source (115VAC, 24VAC, 24VDC) Robot Control Unit Weld Alarm AMENDMENT TO SECTION 5- MAINTENANCE & TROUBLESHOOTING Add the following Step to Section 5-1 Inspect motor control relay, CR2, and clean or replace as required.
  • Page 6 AMENDMENT TO SECTION 5 Amend Figure 5-3. Circuit Diagram For Computer Interface OM-882 Page 4 MAINTENANCE & TROUBLESHOOTING 000000 ~000 C0CWL.~CI~N =0CL,Lt,~tj7~~liU 00 0 0 0 0 0 ‘N S~~CNN N.FS SN-CCN( srNso~ JOG ~EV 9E’EC’ Ua’AGE...
  • Page 7 C.’J •~‘ — (3-, •0 OM-882 Page 5...
  • Page 8 4ELD START WELD CURRENT RELA’ JOG (RE. RE.. RE.A’ FIgure 5-6. CIrcuit Diagram For interface Board PC3 Effective With Serial No. JK588314 Thru KA819026 .24 C. ~ELC S’ART (L(~fl( — RELO CURRENT RELAY (RE6I C07R40N, REV. RELAX 1< Figure 5-6.Circuit Diagram For interface Board PC3 Effective With Serial No. KABi 9027 OM-882 Page 6 ,24V C ON-S...
  • Page 9 Add Figure 5-9. Wiring Diagram ‘N I”- c,,J Page 7 OM-882...
  • Page 10 OM-e82 Page 8...
  • Page 11 AMENDMENT TO PARTS LIST Amend Parts List as follows: Part Dia. Mkgs 111 992 117724 070 634 2-17 049 989 2-20 604 109 028 291 C2,3,6-10 2-39 090 890 2-48 iii 564 011 622 3-56 Added Ri-S 044 635 083 147 SR1,2 035 914 6-12...
  • Page 12 Parts Lists Continued C4,S Added Added ~First digit represents page no digits following BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. OM-882 Page 10 • CAPACITOR, eIctlt 220uf 35VDC 000 859 •RESISTOR,C2WlOKohm 601 394 BRACKET, mtg 136584 reed relay WASHER, flat nyl .265 ID x .437 OD...

  • Page 13: Table Of Contents

    TABLE OF CONTENTS Section No. SECTION 1 INTRODUCTION General Information And Safety 2. Receiving-Handling 3. Description SECTION 2 INSTALLATION 2-1. Location 2. Gas/Current Sensing Control Connections 3. Computer Interface Welding Power Source Connections 4. Computer Interface Welding Power Source Interface Connections. 5.
  • Page 14 Gas/Current Sensing + 16.5 in. (419 minI case only 2-7/8 in. (73.0 minI SECTION 1 INTRODUCTION Model Weight 31 lbs. (14 kg) MR-5AP Control 5 lbs. (2.3 kg) 16 in. (7.9 mm) Diameter 2 Holes Figure 1 1. Specifications TB-i 14346 TB-i 10320 OM-882 Page 1...

  • Page 15: Section No

    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.

  • Page 16: Gas/Current Sensing Control Connections

    2. GAS/CURRENT SENSING CONTROL CON- NECTIONS (Figures 2-1 And 2-2) 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.

  • Page 17: Computer Interface Welding Power Source Interface Connections

    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.

  • Page 18: Computer Interface Terminal Strip Connections

    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: Red lead to terminal 52. b. Blue lead to terminal 50. White lead to terminal 35.

  • Page 19: Powerswitch

    1. POWER SWITCH (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.

  • Page 20: Output Signals From Computer Interface

    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. Arc Initiation Open Close...

  • Page 21: Display Board Meter Check

    CAUTION: IMPROPER FUSES can damage this unit. 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.
  • Page 22 2. Removescrews 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.

  • Page 23: Troubleshooting Chart

    c. Slide spacers onto new meter support. d. Push meter into socket with meter supports protruding through to rear of PC4. Reinstall lock washers and nuts to secure meter to board. Do not overtighten nuts or meter may be damaged. 6.
  • Page 24 TROUBLE PROBABLE CAUSE No wire feed. Robot signal. Relay CR1 not working. Motor board PC2 not work- ing. Wire feeds at maximum. Tach board PC5 at wire drive motor not working. No arc voltage control. Voltage control connec- tions. Wire stick sensing connec- tions.
  • Page 25 6. USE OF INDICATOR LIGHTS FOR TROUBLESHOOTING Gas does not flow: Gas flows: Check gas valve operation. System normal (on). Contactor open: Contactor closed: Check interconnecting System normal (on). cords. Check interface board PC3. Wire feeds: Wire does not feed: System normal (on).
  • Page 26 0000 0t00~N- 00000 A0UOUJL.0ZN-040 0 00 0 0 0 0 0 0 0 ~ t. ~ 0000 OcP~ 000000 ‘4.- I... RGTA~ OM-882 Page 13...
  • Page 27 & OM-882 Page 14 ‘I...
  • Page 28 4” I’) OM-882 Page 15...
  • Page 29 •24 V. START WELD (FAD) J .fl3 (REV) REV. RELAY Figure 5 OM-882 Page 16 6. Circuit Diagram For Interface Board PC3 •15 V. •24 V. ~F~-* ~CGAS R~UOT cGJTACT~ Circuit Diagram No. B-113 431...
  • Page 30 N-B V. AA co.~ 4 WS I~F~JT K V. C N-24 cOWTACTOW DETECT GAS F IFWO) .~G (REV) B N-12 V coeu~ 4 V~TS C i~eu•r c’J I~UUT Figure 5 7. Circuit Diagram For Display Board PC4 INHI IN LOW IN HI IN LOW IN HI...
  • Page 31 H-’ —~ PL Z~I IL IL IL ~ —~ RC2I Figure 5 OM-882 Page 18 —9 H- F— —-~ —~ —~ ~‘ ~‘ 8. Circuit Diagram For RF Filter Board PC6 N-~N- —i H- —9 H- ‘ Circuit Diagram No. B-ill 117 ~—9 —9 •...
  • Page 32 Effe~tiv With Serial Nc. ~H1 3 ?.~i1 PARTS LIST...
  • Page 33 Fig C TC-1 14 Figure A Control Box OM-882 Page 1...
  • Page 34 Part Item Dia. Mkgs. Control Box Figure A CONTROL PANEL (Fig C Pg 6) 111 992 010 855 RETAINER, screw No. 2 FASTENER, screw-hd No. 2 010 853 070 634 LABEL, warning electric shock can kill etc 109 026 COVER, top 079 683 HEAT SINK RESISTOR, WW fixed 100 wattS ohm...
  • Page 35 Part Item Dia. Mkgs. Figure A Control Box (Cont’d) LABEL, Miller robot computer interface 112 254 089 032 LENS, led 4341 046 432 HOLDER, fuse *012 655 FUSE, miniature glass 10 amp 250 volts 073 487 NUT, speed No. 2 011 622 SWITCH, toggle 3PDT 15 amp 125 volts CIRCUIT BREAKER, 1 pole 1 .5 amp 250 volts...
  • Page 36 Dia. Part Mkgs. 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...
  • Page 37 Figure C Control Panel OM-882 PageS...
  • Page 38 Item Dia. Part No. Mkgs. Figure C 111 992 Control Panel (Fig A Pg 2 Item 1) 071 642 CIRCUITCARD,digitalmotorspeed(FigC2PglO) 083 147 GROMMET, screw8-10 push in 052 964 RELAY, enclosed 24 volts dc DPDT 038 839 BLOCK,terminal20amp5 pole 035 914 RECTIFIER, integrated 30 amp 400 volts 109 017 TRANSFORMER, control 605 741 CLIP, mtg-resistor 079 497 RESISTOR, WWfixed25 watt2K ohm...
  • Page 39 COMPONENT TO BE REPLACED Ret: Dlii 410 BY QUALIFIED PERSONNEL ONLY Figure Cl Circuit Card, Voltage OM-882 Page 7...
  • Page 40 Part Dia. Mkgs. Figure Cl 111 408 Circuit Card, Voltage (Fig C Pg 6 Item 25) IC, linear 324 A1-3 096 275 Cl ,2 039 482 CAPACITOR, electrolyte 100 C3 ,4 000 348 CAPACITOR, tantalum 0.47 uf 35 volts CAPACITOR, ceramic 0.1 uf 50 voltsdc CS-i 5,17-24 073 739 Cl 6...
  • Page 41 ~“-‘-0 BY QUALIFIED PERSONNEL ONLY Figure C2 OM-882 Page 9 COMPONENTS TO BE REPLACED Circuit Card, Digital Motor Speed !rr~ — GATE ANODE f t ~ CATHODE (LARGE TERM) LOLC) C5O~ — — TUVWXYZ 0-093 449-G Ret:...
  • Page 42 Dia. Part Mkgs. Figure C2 071 642 Circuit Card, Digital Motor Speed (Fig C Pg 6 Item 1) IC, linear 3S8 ASO-53 009 159 039 482 CAPACITOR, electrolyte 100 uf35voltsdc CAPACITOR, mylar 0.0022 uf 200 volts dc CS 1 031 699 073 739 CAPACITOR, ceramic 0.1 uf50voltsdc C52 ,6 1...
  • Page 43 Dia. Part Mkgs. Figure C3 113 221 Circuit Card, Interface (Fig C Pg 6 Item 26) 009 159 IC,linear358 039 482 CAPACITOR, electrolyte 100 uf 35 volts dc 000 348 CAPACITOR, tantalum 0.47 uf 35 volts C3,6,9,10 072 130 CAPACITOR,tantaluml uf35voltsdc 005 023 CAPACITOR,tantalum2.2uf20volts C5,11 073 739 CAPACITOR,ceramic0.1 uf50voltsdc...
  • Page 44 Part Dia. Mkgs. 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 L1-3,5-7,9 110190 CHOKE,1000UH RC21 089 347 TERMINAL, header 14 pin RC22 092 160 TERMINAL,headerl6pin QI~IDQI~ID •...
  • Page 45 Part Item Dia. Mkgs. Figure D 109 936 Control Box, Gas/Current Sensor LABEL, general precautionary 047 497 +079 682 WRAPPER 079 687 RELAY, current REED 109 021 CASE SECTION, bottom/front/sides 049 455 CORD, No. 182/c (order by ft) 010 610 CONNECTOR, clamp-cable 1/2 inch 010 494 BUSHING, snap 1-3/8 ID x 1-3/4 mtg hole...
  • 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) interconnectingcord with a five-pin Amphenoiplug issuppliedwith this unit but isnot used in this installation.
  • Page 47 c. Route customer supplied 18 gauge/2-conductor cord under cross member below door. Make cord connections to terminal strip common and the Weld Alarm terminal. e. Close robot control unit door, and route cord to jig interface. Connect cord to isolation relay coil and voltage source. terminals from one end contacts on isolation relay.
  • Page 48 AMENDMENT TO SECTION 5- MAINTENANCE & TROUBLESHOOTING Amend Figure 5-3. Circuit Diagram For Computer interface ~ 0j-~ < N- N - N - ~4~L— ‘—~ N-N-v N-N- •~»•~•0•~~•« N-N- a »...~ <lop, — N> N-N-N- a> v~.-’ N-N-j IN-’,.,’ DALE OOWA.SN-N- CSOO 000000...
  • Page 49 Amend Figure 5-6. Circuit Diagram For Interface Board PC3 N-24 WELD START JOG (FN-dD) WELD CURRENT RELAY (REV) COl.*40N REV. RELAY FIgure 5-6. CIrcuit Diagram For Interface Board PC3 Effective With Serial No. JK588314 OM-882Page4 ‘ISV *24 V L. . . 44....) . R ~.C2 WIREFEED MOTOR...
  • Page 50 Add Figure 5-9. Wiring Diagram C.,’ 1— (U a- C..’ •6~ OM-882 Page 5...
  • Page 51 AMENDMENT TO PARTS LIST Amend Parts List as follows: Dia. Part Mk~s 111 992 070 634 2-17 049 989 2-20 604 109 C2,3,6-1 028 291 2-48 111 564 011 622 3-56 Ri -5 044 635 083 147 035 914 SRl,2 6-15 110 375 6-16...

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