Miller MTXC 3501M Robot Gun Manuel utilisateur

Millerﬁ

August

1990

FORM:

OM-1556A

MODEL:

MTXC

3501M

MTX

3502

MTXW

5001

ROBOT

GUNS

OWNERS

MANUAL

IMPORTANT:

Read

and

understand

the

entire

contents

both

this

manual

and

the

power

source

manual

used

with

this

unit,

with

special

emphasis

the

safety

material

throughout

both

manuals,

before

installing,

operating,

maintaining

this

equipment.

This

unit

and

these

Instructions

are

for

use

only

persons

trained

and

experienced

the

safe

operation

welding

equip

ment.

not

allow

untrained

persons

install,

operate,

maintain

this

unit.

Contact

your

distributor

you

not

fully

understand

these

Instructions.

MILLER

ELECTRIC

Mfg.

Co.

ANtHer

Gr~ip

Ltd..

Con~any

P.O.

Box

1079

Appleton,

54912

USA

Tel.

414-734-9821

TB-114

276

PRINTED

S.A

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1992

(Equipment

with

serial

number

preface

KC

newer)

This

limited

warranty

supersedes

all

MILLER

warranties

and

exclusive

with

other

guarantees

warranties

expressed

imptied.

:1~!

LIMITED

WARRANTY



Subject

the

terms

and

conditione

below.

MILLER

Electric

Mtg.

Co..

A~pleton.

Wisconsin,

warrants

its

original

retail

purchaser

that

new

MILLER

equipment

sold

aher

the

effective

date

this

limited

warranty

free

feds

material

and

workmanship

the

time

shipped

MILLER.

THIS

WAR

RANTY

EXPRESSLY

LIEU

ALL

OTHER

WARRANTIES,

EXPRESS

IMPLIED,

INCLUDING

TNE

WARRANTIES

MERCHANTABILITY

AND

FIT

NESS.

Within

the

warranty

periods

listed

below.

MILLER

will

repair

replace

any

war

ranted

parts

componenta

that

tail

due

such

detects

material

workmanship.

MILLER

must

notitied

writing

within

thirty

(30)

days

such

defector

failure,

which

time

MILLER

will

provide

instruct

ions

the

warranty

claim

procedures

lobe

followed.

MILLER

shall

honor

warranty

claims

warranted

equipment

listed

below

the

event

such

failure

within

the

warranty

lime

periods.

All

warranty

lime

periods

start

the

dale

that

the

equipment

was

delivered

the

original

retail

purchaser,

and

are

follows

Years

Parts



Years

Labor

Original

main

power

rectifiers

Years



Parts

and

Labor

Transformer/Rectifier

Power

Sources



Plasma

Arc

Culling

Power

Sources



Semi-Aatomalic

and

Automatic

Wire

Feeders



Robots

Years



Parts

and

Labor



Engine

Driven

Welding

Generators

(NOTE.

Engines

are

warranted

separately

the

engine

manufacturer)

Year



Parts

and

Labor



Motor

Driven

Guns



Process

Controllers



Water

Coolant

Syslems



Units



Grids

Spot

Welders

Load

Banks



SOX

Transformers

Running

Gear/Trailers



Field

Options

(NOTE:

Field

options

are

covered

under

True

BluenM

for

the

remaining

warranty

period

the

product

they

are

installed

in.

for

minimum

one

year



whichever

greater.)

Months



Baneries

Days



Parts

and

Labor

MIG

Guns/TIG

Torches



Plasma

Cuning

Torches



Remote

Controls

Accessory

Kits

Replacement

Parfa

MILLERS

True

Bluen

Umited

Warranty

shall

not

apply

to:

Items

furnished

MILLER,

but

manufactured

others,

such

engines

trade

accessories.

These

items

are

covered

the

manufacturers

warranty,

any.

Consumable

components;

such

contact

lips.

cutting

nozzles,

conlactora

and

relays.

Equipment

that

has

been

modified

any

party

other

than

MILLER.

equip

ment

that

has

been

improperly

installed,

improperly

operated

misused

based

upon

industry

standards.

equipment

which

has

not

had

reasonable

and

necessary

maintenance,

equipment

which

has

been

used

for

operation

outside

the

specifications

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCNASE

AND

USE

COMMER

CIAL/INDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

TNE USE

AND

MAINTENANCE

WELDING

EQUIPMENT.

the

event

warranty

claim

covered

this

warranty.

the

exclusive

remedies

shall

be,

MILLERS

option:

(1)

repair;

(2)

replacement;

or,

where

authorized

writing

MILLER

appropriate

cases.

(31

the

reasonable

coal

repair

replace

ment

authorized

MILLER

service

station;

(4)

payment

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

the

goods

customera

risk

and

eapense.

MILLERS

option

repair

replacement

will

F.O.B.,Factory

Appleton,

Wiaconsin,

FOB.

ate

MtLLER

authorized

aer

vice

facility

determined

MILLER.

Therefore

compensation

reimburse

ment

for

transportation

costa

any

kind

wilt

allowed.

TNE

EXTENT

PERMITTED

LAW,

TNE

REMEDIES

PROVIDED

HEREIN

ARE

TNE

SOLE

AND

EXCLUSIVE

REMEDIES.

EVENT

SHALL

MILLER

LIABLE

FOR

DIRECT,

INDIRECt

SPECtAL.

INCIDENTAL

CONSEQUENTIAL

DAMAGES

(INCLUDING

LOSS

PROFIT),

WHETHER

BASED

CON

TRACT.

TORT

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY.

GUARANTY OR

REPRESENTATION

PERFORMANCE,

AND

ANY

REMEDY

FOR

BREACH

CONTRACT

TORT

ANY

OTHER

LEGAL

THEORY

WHICH.

BUT

FOR

THIS

PROVISION.

MIGHT

ARISE

IMPLICATION,

OPERATION

LAW,

CUSTOM

TRADE

COURSE

DEALING,

CLUDING

ANY

IMPLIED

WARRANTY

MERCHANTABILITY

FITNESS

FOR

PARTICULAR

PURPOSE.

WITH

RESPECT

ANY

AND

ALL

EOUIPMENT

FURNISHED

MILLER

EXCLUDED

AND

DISCLAIMED

MILLER.

Some

states

the

U.S.A.

not

allow

Ilmitefiona

how

long

implied

warranty

laata.

the

eaclualon

incidental,

indirect.

special

conaequenlial

damages,

the

above

limifation

escluaion

may

not

apply

you.

This

warranty

provides

spe

cific

legal

rights,

and

ofher

rights

may

available,

but

may

vary

from

elate

elate.

Canada,

legislation

some

provinces

provides for

certain

additional

warranties

remedies

other

than

stated

herein.

and

the

estent

that

they

may

not

waived.

the

limitations

and

esdluaiOna

sat

out

above

may

not

apply.

Thia

Limited

Warranty

provides

specific

legal

rights.

and

other

righta

may

available,

but

may

vary

from

province

province.

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

for

loss

damage

with

the

delivering

carrier.

Assistance

for

filing

settling

claims

may

obtained

from

distributor

and/or

equipment

manufacturers

Transportation

Department.

When

requesting

information

about

this

equipment,

always

provide

Model

Designation

and

Serial

Style

Number,

Use

the

fol)ow)ng

spaces

record

MDdel

Designation

and

Serial

Style

Number

your

unit,

The

information

located

the

rating

label

nameplate.

Model

Serial

Style

No,

______________________________________________

Date

Purchase

___________

miller

5/93

ERRATA

SHEET

After

this

manual

was

printed,

refinements

equipment

design

occurred.

This

sheet

lists

exceptions

data

appearing

later

this

manual.

AMENDMENT

SECTION

2

SPECIFICATIONS

Amend

MTXC

3501

welding

gun

view

Figure

2-1.

Dimension

Information

AMENDMENT

SECTION

3INSTALLATION

Amend

Figure

3-2.

MTXC

3501M

Gun

Installation

SB-I

144-A

Figure

2-1.

Dimension

Information

Axis

Mount

900

Mounting

Bracket

insulator

SB-135

148-A

Figure

3-2.

MTXC

3501

Gun

Installation

AMENDMENT

SECTION

5

PARTS

LIST

Amend

Figure

5-2.

MTXC

3501

Air

Cooled

Gun

Amend

Parts

List

follows:

Figure

5-2.

MTXC

3501

Air

Cooled

Gun



..-



I

SB-135

145-A

Quantity

Replaced

With

Part

No.

Description

10-

10-4

132

296

133

994

143

697

143

693

MTXC-3501

air

cooled

gun

NOZZLE

HOLDER

ASSEMBLY

10-7

133997 108776

INSULATIONBUSHING

10-11

133993

143692

NOZZLEASSEMBLY

10-12

10-13

Added

143

696

143694

0-RING

(used

nozzle

assembly)

CLAMP,band

10-14

Added

143695

CLAMP,band

*~First

digit

represents

page



digits

following

dash

represent

item

no.

All

gun

parts

remain

the

same

with

listed

exceptions.

When

ordering

replacement

parts

refer

view

this

errata

sheet

and

Fig

5-2

manual

for

correct

identity

parts.

OM-1 556A

Page

OM-1

556A

8i~

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

dam-

Use

the

following

spaces

record

the

Model

Designa

age

that

may

have

occurred

during

shipment.

File

any

tion

and

Serial

Style

Number

your

unit.

The

infor

claims

for

loss

damage

with

the

deliverIng

carrIer.

mation

located

the

data card

the

nameplate.

Assistance

for

filing

settling

claims

may

obtained

from

the

distributor

and/or

the

equipment

manufactur-

Model

________________________________

ers

Transportation

Department.

Serial

Style

No.

_____________________

When

requesting

information

about

this

equipment,

ways

provide

the

Model

Description

and

Serial

Style

Date

Purchase

______________________

Number.

TABLE

CONTENTS

Section

No.

Page

No.

SECTION



SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

1-1.

General

Information

And

Safety

1-2.

Safety

Alert

Symbol

And

Signal

Words

SECTION

2

SPECIFICATIONS

2-1.

Duty

Cycle

2-2.

Description

SECTION

3INSTALLATION

3-1.

Gun

Preparation

3-2.

Outlet

Cable

Preparation

3-3.

MTX

3502

And

MTXW

5001

Gun

Installation

3-4.

MTXC

3501M

Gun

Installation

3-5.

Water

Connections

(Water-Cooled

Models

Only)

3-6.

Field

Installation

Water-Cooled

Nozzle

Onto

Air-Cooled

Gun

(MTX

3502

Models

Only)

SECTION

4

MAINTENANCE

4-1.

Inspection

And

Upkeep

4-2.

Contact

Tube

Replacement

4-3.

Changing

Wire

Size

SECTION

5

PARTS

LIST

Figure

5-1.

MTX

3502

Air

Cooled

Gun

Figure

5-2.

MTXC-3501

Air

Cooled

Gun

Figure

5-3.

MTXW

5001

Water

Cooled

Gun

LIST

CHARTS

AND

TABLES

Table

2-1.

Specifications

SECTION



SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

1-1.

GENERAL

INFORMATION

AND

SAFETY

General

Information

presented

this

manual

and

various

labels,

tags,

and

plates

the

unit

pertainsto

equipment

design,

installation,

operation,

maintenance,

and

troubleshooting

which

should

read,

understood,

and

followed

for

the

safe

and

effective

use

this

equipment.

Safety

The

installation,

operation,

maintenance,

and

troubleshooting

arc

welding

equipment

requires

practices

and

procedures

which

ensure

personal

safety

and

the

safety

others.

Therefore,

this

equipment

installed,

operated,

and

maintained

only

qualified

persons

accordance

with

this

manual

and

all

applicable

codes

such

as,

but

not

limited

to,

those

listed

the

end

Section

Safety

Rules

For

Operation

Arc

Welding

Power

Source

the

welding

power

source

Owners

Manual.

1-2.

SAFETY

ALERT

SYMBOL

AND

SIGNAL

WORDS

The

following

safety

alert

symbol

and

signal

words

are

used

throughout

this

manual

call

attention

and

identify

different

levels

hazard

and

special

instructions.

This

safety

alert

symbol

used

with

the

signal

words

WARNING

and

CAUTION

call

attention

the

safety

statements.

WARNING

statements

identify

procedures

practices

which

must

followed

avoid

serious

personal

injury

loss

life.

CAUTION

statements

identify

procedures

practices

which

must

followed

avoid

minor

personal

injury

damage

this

equipment.

IMPORTANT

statements

identify

special

instructions

necessary

for

the

most

efficient

operation

this

equipment.

SECTION

2

SPECIFICATIONS

Table

2-1.

SpecIficatIons

Model

Rating:

50%

Duty

Cycle

With

C02

Wire

Diameter

Capacity

Cooling

Method

Weight

Net

Ship

MTX

3502

MTXC

3501M

350

Amperes

.030-1/16

in.

(0.8

-1

mm)

Air

2.3

lbs.

(1kg)

3.2

lbs.

(1.5

kg)

2.6

lbs.

(1.2kg)

3.5

lbs.

(1.6kg)

MTXW5001

500

Amperes

.045

and

1/16

in.

(1.1

and

1.6

mm)

Water

3.7

lbs.

(1.7

kg)

4.6

lbs.

(2.1

kg)

2-1.

DUTY

CYCLE

The

duty

cycle

welding

gun

the

percentage

ten

minute

period

that

the

gun

can

safely

operated

give

output

without

causing

overheating

and

damage

the

gun.

These

guns

are

rated

50%

duty

cycle

using

CO2

shielding

gas.

This

means

that

the

gun

can

operated

for

five

consecutive

minutes.

The

remaining

five

minutes

the

gun

should

idle

permit

proper

cooling.

CAUTION:

EXCEEDING

THE

RATED

AMPERAGE

WITH

C02

FAILING

REDUCE

THE

WELDING

AMPERAGE

DUTY

CYCLE

WHEN

USING

MIXED

SHIELDING

GAS

can

damage

gun.



not

exceed

rated

amperage

when

using

C02.



Reduce

duty

cycle

when

using

mixed

shielding

gases.

2-2.

DESCRIPTION

These

guns

are

specifically

designed

for

automatic

robotic

welding.

The

term

welding

gun

used

when

Gas

Metal

Arc

Welding

(GMAW)

done.

The

guns

are

shipped

with

the

necessary

components

for

specific

wire

size;

however,

through

minor

parts

changes,

each

gun

can

used

with

various

sizes

wire.

OM-1556

Page

MTX

3502

TB-114

276

SECTION

INSTALLATION

CAUTION:

IMPROPER

ROBOTTOOL

POINT

ADJUSTMENT

can

damage

welding

gun

and

robot.



After

welding

gun

installation

completed,

see

Set-Up

Procedure

section

robot

Owners

Manual

for

tool

point

procedures.

3-1.

GUN

PREPARATION

Select

contact

tube

for

wire

size

used,

and

proceed

follows:

WARNING:

ELECTRIC

SHOCK

can

kill;

ROBOT

ARM

MOVEMENT

can

cause

serious

injury

death;

INCORRECT

PROCEDURES

can

cause

Injury.



not

touch

live

electrical

parts.



Shut

down

welding

power

source

and

robot

control,

and

disconnect

input

power

employing

lockout/tagging

procedures.

Lockout/tagging

procedures

consist

removing

input

power

plug

from

receptacle,

padlocking

line

disconnect

switch(es)

open

position,

removing

fuses

from

fuse

box(es),

shutting

off

and

red-

tagging

circuit

breaker(s)

other

disconnecting

device(s).

MOVING

PARTS

can

cause

serious

injury.



Keep

away

from

moving

parts.

HOT

SURFACES

can

cause

severe

burns.



Allow

cooling

period

before

touching

gun.

Remove

nozzle

Install

desired

contact

tube

and

nozzle

onto

gun.

MTXC

3501M

TB-135

144

TB-114

276

MTXW

5001

Figure

2-1.

DImension

Information

OM-1556

Page

MOVING

PARTS

can

cause

serious

Injury.



Keep

away

from

moving

parts.

HOT

SURFACES

can

cause

severe

burns.



Allow

cooling

period

before

touching

gun.

Route

cable

through

supports

robot.

The

cable

connector

end

goes

the

wire

drive

assembly

while

the

remaining

end

goes

the

gun.

Install

cable

connector

into

wire

drive

assembly

(see

Motor/Drive

Assembly

Owners

Manual).

Slide

welding

gun

onto

liner

protruding

from

cable

until

liner

seats

inside

gun.

Mark

linerflush

with

gun

body

and

slide

gun

off

liner.

Measure

distance

between mark

made

liner

Step

and

brass

nut

cable.

The

liner

needs

shortened

the

length

measured

Step

Cut

off

measured

length

from

end

liner.

3-3.

MTX

3502

AND

MTXW

5001

GUN

INSTALLA

TION

(Figure

3-1)

WARNING:

ELECTRIC

SHOCK

can

kill;

ROBOT

ARM

MOVEMENT

can

cause

serious

Injury

death;

INCORRECT

PROCEDURES

can

cause

Injury.



not

touch

live

electrical

parts.



Shut

down

welding

power

source

and

robot

control,

and

disconnect

input

power

employing

lockout/tagging

procedures.

Lockout/tagging

procedures

consist

removing

input

power

plug

from

receptacle,

padlocking

line

disconnect

switch(es)

open

position,

removing

fuses

from

fuse

box(es),

shutting

oft

and

red-tagging

circuit

breaker(s)

other

disconnecting

device(s).

MOVING

PARTS

can

cause

serIous

Injury.



Keep

away

from

moving

parts.

HOT

SURFACES

can

cause

severe

burns.



Allow

cooling

period

before

touching

gun.

IMPORTANT:

3(1

mounting

bracket

used,

the

bracket

must

installed

with

offset

the

right

when

viewing

the

Phi

axis

mount.

sure

phenolic

insulator

between

gun

and

bracket.

300

mounting

bracket

used,

secure

bracket

gun

using

supplied

socket

head

screws.

Secure

gun

Phi

axis

(or

Axis

mount

using

supplied

socket

head

screws

(see

Figure

3-1).

30

mounting

bracket

used,

secure

bracket

manipulator

Phi

axis

mount

using

supplied

socket

head

screws.

Slide

liner

from

outlet

cable

into

gun.

Secure

outlet

cable

adapter

tightening

nut

from

cable

onto

adapter.

Connect

touch

sensor

leads

from

gun

leads

from

outlet

cable.

Connect

leads

from

outlet

cable

cord

gas/current

sensing

control

matching

connector

robot

manipulator.

Polarity

not

important.

Gun

Mounting

Plate

Air-Cooled

Gun

Shown

FIgure

3-1.

MTX

3502

And

MTXW

5001

Gun

Installation

Phi

Axis

(Axis

Phi

Axis

(Axis

Mount

(Phenolic

Plate)

PhenoUc

Insulator

300

MountIng

Bracket

Gun

OM-1556

Page

Axis

Figure

3-2.

MTXC

3501

Gun

Installation

TB-135

146

3-4.

MTXC

3501

GUN

INSTALLATION

(Figure

3-2)

WARNING:

ELECTRIC

SHOCK

can

kill;

ROBOT

ARM

MOVEMENT

can

cause

serious

injury

death;

INCORRECT

PROCEDURES

can

cause

Injury.



not

touch

live

electrical

parts.



Shut

down

welding

power

source

and

robot

control,

and

disconnect

input

power

employing

lockout/tagging

procedures.

Lockout/tagging

procedures

consist

removing

input

power

plug

from

receptacle,

padlocking

line

disconnect

switch(es)

open

position,

removing

fuses

from

fuse

box(es),

shutting

off

and

red-tagging

circuit

breaker(s)

other

disconnecting

device(s).

MOVING

PARTS

can

cause

serious

Injury.



Keep

away

from

moving

parts.

HOT

SURFACES

can

cause

severe

burns.



Allow

cooling

period

before

touching

gun.

Instafl

and

secure

insulatorto

gun

usingthe supplied

flat

washers,

lock

washers,

and

socket

head

screws.

Secure

900

mounting

bracket

gun

using

supplied

socket

head

screws.

Secure

90

bracket

Axis

mount

using

supplied

socket

head

screws.

Secure

outlet

cable

adapter

tightening

nut

from

cable

onto

adapater.

Connect

touch

sensor

leads

from

gun

leads

from

outlet

cable.

Connect

leads

from

outlet

cable

cord

gas/current

sensing

control

matching

connector

robot

manipulator.

Polarity

not

important.

3-5.

WATER

CONNECTIONS

(Water-Cooled

Models

Only)

CAUTION:

OVERHEATING

Gas

Metal

Arc

Welding

gun

can

damage

gun.



using

water

cooled

gun

and

recirculating

coolant

system,

make

connections

directly

from

the

coolant

system

gun

hoses.



Check

entire

cooling

system

periodically

for

proper

coolant

flow.

Connections

Gun

Push

quick-disconnect

fitting

water

hose

onto

barbed

titling

gun

(see Figure

3-3)

until

locking

ring

snaps

down.

release

hose,

push

locking

ring

until

disengaged;

pull

hose

from

fitting.

Connections

Coolant

Supply

Self-Contained,

Recirculating

Coolant

System

CAUTION:

INCORRECT

COOLANT

will

damage

gun.



Use

only

coolant

specified

recirculating

coolant

system

manual.



not

use

tap

water,

automotive

antifreeze,

plain

distilled

deionized

water.



Use

MILLER

Part

No.

109

973

water

soluble

coolant

mixture

pure

commercial

ethylene

propylene

glycol

and/or

water

soluble

lubricants

distilled

deionized

water.

Failure

comply

with

these

instructions

may

void

the

warranty.

Route

hoses

from

gun

coolant

system.

Connect

hoses

coolant

system

input

and

output

fittings.

The

hoses

have

5/8-18

left-hand

male

fittings.

Insulator

OM-1556

Page

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