Miller 5 TURNTABLE User manual

FORM:

OM-890

Miller®

MODEL:

TURNTABLE

IMPORTANT:

Illustrations

and

text

this

manual

are

forthe

latest

Model

Turntable.

Ear-

lier

models may vary

slightly.

When

ordering

parts,

sure

identify

parts

name,

part

number

and

serial

number

the

machine

for

which

the

parts

are

being

ordered.

OWNER’S

MANUAL

IMPORTANT:

Read

and

understand

the entire contents of this

manual,

with

special emphasis

the safety

material

throughout

the

manual,

Mlflm

Electric

Mfg.

Co.

AMd~,

G,o,,~

Lid

Co~’,p,nv

before

installing,

operating, or

maintaining

this

equipment.

This

unit

and

P0. Box

1079

these

instructions

are

for

use

only

persons

trained

and

experienced

Appleton,

54912

USA

the

safe

operation

of welding

equipment.

not allow

untrained

persons

Tel.

414-734-9821

to install,

operate,

or maintain this unit. Contact your

distributor

you

not

fully

understand these

instructions.

July

1988

PRgNTED

U.S.A. ADDITIONAL COPY PRICE $1.40

LIMITED

WARRANTY

EFFECTIVE

FEBRUARY

16,

1988

This

warranty

supersedes

all

MILLER

warranties

and

exclusive

with

other

guarantees

warranties

expressed

implied.

LIMITED

WARRANTY

Subject

the

terms

and

condi-

the

case

Miter’s

breach

warranty

any other

duty

tions

hereof,

Miller

Electric

Mfg.

Co.,

Appleton,

Wisconsin

with

respect

the

quality

any

goods,

the

exclusive

remedies

warrants

its

Distributor/Dealer

that

all

new

and

unused

therefore

shall

be,

Millers

optIon

(11

repair

(2) replacement

Equipment

furnished

Miller

free

from

defect

workman-

or,

where authorited

writing

Miller

appropriate

(3)

ship

and

material

the

time

and

place

delivery

Miller.

the

reasonable

cost

repair

replacement

authorized

warranty

made

Miller

with

respect

engines,

trade

Miller

seivtce

station

(4)

payment

credit

for

the

purchase

accessories

other

items

manufactured

others.

Such

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

engines,

trade

accessories

and

other

items

are

sold

subject

retum

the

goods

Customer’s

risk

and experue.

MILLER~s

the

warranties

their

respective

manufacturers,

any

All

option

repair

replacement

will

FOB.,

Factory,

engines

are

warranted

their

manufacturer

for

one

year

from

Appleton,

Wmconsin,

F.O.B.,

MILLER

authorized

senice

date

original

purchase, except

Tecumseh

engines

which

facility,

therefore,

no compensation

for

transportation

costs

have

two

year

warranty.

any

kind

will

allowed.

Upon

receipt

notice

apparent

defect

failure,

Miller

shall

instiuct

the

claimant

the

warranty

Except

specified

below,

Miller’s

warranty

does

not

apply

claim

procedures

followed.

components

having normal

useful

life

less

than

one (1)

year,

such

spot welder tips,

relay

and

contactor

points,

MILLERMATIC

parts

that

come

contact

with

the

welding

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

•

wire

including

nozzles

and

nozzle

insulators

where failure

does

ANY

IMPUED

WARRANTY,

GUARANTY

REPRESENTA

BREACH

CONTRACT

WHICH,

BUT

FOR

THIS

PROViSION,

•

not

result

from

defect

workmanship

material.

TION

AS TO

PERFORMANCE,

AND ANY

REMEDY

FOR

Miller

shall

required

honor

warranty

claims

war-

MIGHT

ARISE

IMPLICATiON,

OPERATION

LAW,

ranted Equipment

the

event

failure

resulting

from

defect

CUSTOM

TRADE

COURSE

DEAUNG, INCLUDING

within

the

following

periods

from

the

date

delivery

Equip-

ANY

IMPUED

WARRANTY

MERCHANTABIUTY

ment

the

original

user:

FIThESS FOR

PARTiCULAR

PURPOSE,

WiTH

RESPECT

ANY

AND

ALL

EQUIPMENT

FURNISHED

MILLER

Aac welders,

p~r

sources,

robots,

and

components

~er

CLUDED

AND

DISCLAIMED

BY MILLER.

Load

banks

year

Original

main

power

rectifiers

years

(labor

year

onlyl

EXCEPT

EXPRESSLY

PROViDED

MILLER

•

All

welding

guns,

feeder/guns

and

torches

days

WRITING,

MILLER

PRODUCTS

ARE

INTENDED

FOR

All

other

Millermatic

Feeders

year

ULTIMATE PURCHASE

COMMERCIAL/INDUSTRIAL

Replacement

repair

parts,

exclusive

labor

days

USERS

AND

FOR

OPERATION

PERSONS

TRAINED

AND

Batteries

months

EXPERIENCED

IN THE USE

AND

MAINTENANCE

WELDING

EQUIPMENT

AND

NOT

FOR

CONSUMERS

•

provided

that

Miller

notified

writing

within

thirty

130)

days

CONSUMER

USE.

MILLER’S

WARRANTIES

NOT

EXTEND

the

date

such

failure.

TO,

AND

RESELLER

AUTHORIZED

EXTEND

matter

general

policy

only,

Miller

may

honor

clalew

MILLER’S

WARRANTIES

TO,

ANY

CONSUMER.

submitted

the

original

user

within

the

foregoing

periods.

TABLE

CONTENTS

Section

No.

Page

No.

SECTION

INTRODUCTION

General

Information

And

Safety

Receiving-Handling

Description

SECTION

INSTALLATION

Work

Cable

Connections

Operation

Control Cord

Connections

SECTION

OPERATION

Program Example

For

Turntable

Mounting

Plate

Rotation 6

Program

Example

For

Side

001

Welding

Operation

Prgoram Example

For

Side

000

Welding

Operation

Job

Example

For

Linking

Programs

Setting

Relay

Time

For

High-Speed Valve

SECTION

MAINTENANCE

TROUBLESHOOTING

Cleaning

And

Inspection

Lubrication

4-3.

QilFilter

Checking

Reservoir

Fluid

Level

Adjustment

Of Low-Speed

Rotation Control

Adjustment

Locking

Speed

Control

-7.

AdjustmentQf

ShockAbsorbers

4-8.

SettingHardStops

Adjustment

Pressure

Switch

For

Accumulator

4-10.

Adjustment

Drive

Belt

Tension

4-11.

Drive

Belt

Replacement

4-12.

Hydrqaulic

Fittings

4-13.

Releasing

Pressurized

Fluid

From

Accumulator

4-14.

Replacement

Pressure

Switch

4-15.

Replacement

Directional

Control

Valve

4-16.

Replacement

Rotary

Actuator

4-17.

Replacement

High-Speed

Valve

4-18.

Replacement

Locking

Cylinder

4-19.

Replacement

Proximity

Switch

4-20.

Recharging

The

Accumulator

4-21.

Replacement

Motor/Pump

And

Reservoir

Assembly

4-22.

Fuses 36

4-23.

Troubleshooting

Charts

SECTION

INTRODUCTION

Mounting

Plate

Diameter

Optional

Fixture

Plate

Diameter

Load

Capacity

Index

Speed*

Indexing

Repeatability

Weight

Net Ship

in.

(1219

mm)

in.

(1524

mm)

1000

lbs.

(454

kg)

Seconds

For

1800

Rotation

Either

Clockwise

Counterclockwise

Load

Capacity

0.005

in.

(0.13

mm)

2000

lbs.

(907

kg)

2000

lbs.

(907

kg)

*Speed

increases

when

operating

with

less

weight.

Figure

Turntable

Specifications

Input

Power

Single-Phase

Reservoir

Capacity

Hydraulic

Fluid

Pump

Flow

Rate

System

Relief

Pressure

Range

System

Operating

Pressure

115

Volts1

60Hz

Maximum:

8 qt.

(7.6

Fill

Quantity:

6 qt.

(5.7

ISO 32

Antiwear

Hydraulic

Oil

0.5

gpm

(1.9

1/mm)

1500

psi

(10342

kPa)

950

psi

1250

psi

(6550

kPa

8618

kPa)

Figure

Hydraulic

System

Specifications

Dimensions

Inches

Millimeters

32-1/4

819.2

1219.2

1158.4

35 989

609.6

330.2

50.9

25.4

1193.8

J 48

1219.2

Figure

Overall

Dimensions

And

Base

Mounting

Hole

Layout

OM-aSO

Page

13/32

in.

(10.3

mm)

Holes

TC-120

288

GENERAL

INFORMATION

AND

SAFETY

General

Information

presented

this

manual and

various

labels,

tags,

and plates on

the

unit

pertains

equip-

ment

design,

installation,

operation,

maintenance,

and

troubleshooting which

should

read,

understood,

and

followed

for

the

safe

and

effective

use

this

equip-

ment.

Safety

The

installation,

operation,

maintenance,

and

troubleshooting of

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

in accordance

with

this

manual and

all

plicable

codes and

safety

rules

such

as,

but

not limited

to,

those

listed

Section

Safety

the

robot

Owner’s

Manual

and

Section

Safety

Rules

For

Operation

Arc

Welding

Power

Source

the

welding

power

source

Owner’s

Manual.

Safety

instructions

specifically

pertaining

this

unit

pear

throughout

this

manual

highlighted

the

signal

words

and

which

identify

different

levels

hazard.

statements

include

installation,

operation,

and

maintenance

procedures

practices

which

not

carefully

followed

could result

serious

personal

injury

loss

life.

CAUTION

statements

include

installation,

operation,

and

maintenance

procedures

practices

which

not

carefully

followed

could

result

minor

personal

injury

damage

this

equipment.

third

signal

word,

~s•.,

highlights

instruc

tions

which

need

special

emphasis

obtain

the

most

efficient

operation of

this

equipment.

RECEIVING-HANDLING

Before

installing

this

equipment,

clean

all

packing

material

from

around

the

unit

and

carefully

inspect

for

any

damage

that

may

have

occurred

during shipment.

Any

claim

for

loss

damage

that

may

have

occurred in

transit

must

filed

the

purchaser

with

the

carrier.

copy

the

bill

lading

will

furnished

the

manufacturer

quest

occasion

file

claim

arises.

When

requesting

information concerning

this

equip-

ment,

essential

that

Model

Description

and

Serial

Number

the

equipment

supplied.

DESCRIPTION

The

Model

Turntable

circular mounting

plate

and

hydraulic

drive

system

that

provides

smooth,

accurate

rotation

for

deliverying

parts

into

work

envelope

automated

welding

system.

The

mounting

plate

operates

in alternating

clockwise

and

counterclockwise

rotations

180 degrees.

Index

ing

speed

for

complete rotation at

the

1000

pounds

(454

kg)

load

capacity

seconds

which

includes

lock

ing

the

mounting

plate

position.

Control of

the

moun-

ting

plate

rotation

and

locking

movement

provid-

input/output

signals

through

lead

connections

from

the

Model

Turntable to

the

I/O

ports

pro

grammable

control

unit.

in.

(1524

mm)

diameter

optional

fixture

plate

available

for

mounting

weld

fixtures

and

increasing

the

working

surface

area.

Additional

fixture

plates

can

used

fixturing

requirements

increase

provide

fast

changeover

weld

fixtures

only

exchanging

fixture

plates

the

turntable.

All

turntable

control components

are

adjusted

part of

the

original

installation.

changes

are

made

the

user

that

affects

load

weight

the

mounting

plate,

justments

may

then

required.

270~

•Weight

plate

approximately

140 lbs.

(63.5

kg)

Figure

4. DImensions

And

Hole

Layout

Optional

Fixture

Plate

1800

OM-590

Page

SECTION

INSTALLATION

IMPORTANT:

The

Model

Gantry

and

Model

134

Gantry

come

with

the

Model

Turntable

installed

and

connected

for

operation.

the

turntable

used

without

robot

control,

contact

factory

Technical

Sales

department.

Figure

Connection

Diagram

For

Turntable

And

MR-5

Robot Control

WORK

CABLE

CONNECTIONS

(Figure

2-2)

ELECTRIC

SHOCK

can

kill.

•

not

touch

ilve

electrical

pafls.

•

Shut

down

turntable,

welding

power

source,

and

robot

control, and

disconnect

input

power

employing

“lockout!

tagging

procedures”

before

making or

checking

work

cable

connection or

contact

pad

assembly.

Lockout/tagging

procedures

consist

removing

plug

from

receptacle,

padlocking

line

disconnect

switch

open

position,

removing

fuses

from

fuse box,

shut

ting

off

and

red-tagging

circuit

breaker

other

discon-

necting

device.

MOVING

PARTS

can

cause

serious injury.

•

Keep

clear

moving

parts.

PRESSURIZED

HYDRAULIC

FLUID

can

cause

serious

Injury.

•

Release

hydraulic

fluid

pressure

according to

Sec-

tion

4-13

before

touching

any

hydraulic

com

ponents.

Hydraulic

fluid

pressure is

present

even

though

elec-

trical

power

disconnected.

The welding

power

source

work

cable

connects

contact

pad

assembly

mounting

rod

located above

the

spindle

pulley inside

the

turntable

chassis.

Spring

ten

sion holds

the

contact

pad

against

the

spindle

retainer

bushing

provide

continuity

between

the

work

cable

connection

and

the

mounting

plate.

sure

that

work

cable

routed

away

from

moving

parts

and

lug

connection

tight.

Check

for

adequate

spring

tension at mounting

rods

properly align

con

tact

pad

against

spindle

retainer

bushing,

but

not

overtighten

springs

this

will

cause

premature

wear

the

contact

pad.

TA-120

278

OM-890

Page

Mounting

Plate

Mounting

Rod

(2)

Figure

Contact

Pad

Assembly

For

Work

Cable Connection

Robot

Control’

with

Cabinet

Door

Open

Retainer.

Bushing

Nut

Cable

Connects

This

End

Mounting

Rod

Insulating

Bushing

Inside

,,~

Portion

urntable

Chassis

Tension

Spring

Pad

Fits

Against

Retainer

Bushing

Rof;

TB-120

281

Figure

Location

Of Terminal

Strips

TB3

And TB4

Inside

MR-5

Robot Control

OM-890

Page

-2.

OPERATION

CONTROL

CORD

CONNEC

TIONS

ELECTRIC

SHOCK

can

kill.

•

not

touch

live electrical

parts.

•

Shut

down

turntable,

welding

power

source,

and

robot

control,

and

disconnect

input

power

employing

“lockout!

tagging

procedures”

before

making

checking

operation

control

cord

con

nections.

Lockout/tagging

procedures

consist

removing

plug

from

receptacle,

padlocking

line

disconnect

switch

open

position,

removing

fuses

from

fuse box,

shut

ting

off

and

red-tagging

circuit

breaker

other

discon-

necting

device.

Output

Leads

31, 32, 33,

And

Connect

Terminals

175,

176,

177,

And

178

Respectively

F~L~1

ELECTROSTATIC

DISCHARGE

(ESD)

can

damage

circuit

board

components.

•

Put

propedy

grounded

wrist

strap

BEFORE

handling

circuit

boards.

•

Transport

all

static-sensitive

components

pro

per

static-shielding

carriers

packages.

•

Perform

work

only

static-safe

work

area.

Control

turntable

operation

for

mounting

plate

rota

tion,

locking

movement,

and

the

Emergency

Stop

function

is provided

lead

connections

from

the

turn

table

control

panel

Input/Output

and

Emergency

Stop

terminals

inside

the

MR-S

Robot

Control.

The

location of

the

Robot Control

terminal

strips

and

ter

minal

designations are shown

Figures

2-3

and

2-4.

sure

that

all

lead

connections

are

correct

and

secure

terminals

appropriate

Robot

Control

terminal

strips (refer

circuit

diagram

Figure

4-25

for

identifica

tion

leads

and

connection

points).

Input

Leads

50, 51,

And

Connect

Terminals

101, 140,

And

141

Respectively

F-i--i

.±.

..L

.1.

.J..

.1..

.L.

‘

j6j6j6j6j~j~j6j~

~F ~T ~r ~T ~T ~T ~r~r ~f!T ~i ~

Input/Output

Terminal

Strip

TB3

Jumper

Lead

Connection

From

Terminal

195

For

Emergency

Stop

Lead

For

24VAC

Power

Supply

Connects

Terminal

194

Jumper

Lead

Connection

From

Terminal

174

For

Emergency

Stop

External

Control

Emergency

Stop

Terminals

•

‘I

I~L

uLN

(ii

•1

!1IjdI~al~aI\~A

•

-I--l--r--1----!--1-I

~ ~

——

~ Mli~

~4~

EUERGENC

STOP

Emergency

Stop

And

Function

Control

Terminal

Strip

TB4

Terminals

For

Additional

Start

Modules

Figure

Operation

Control

Cord

Lead

Connections

Terminal

Strips

TB3

And

TB4

Inside

MR-S

Robot

Control

SECTION

OPERATION

For

the

robot

system

to perform

operations

the

pro

per

sequence,

will

necessary

write

and

enter

programs

and

jobs

that

coordinate

turntable

functions

with

weld

programs.

This

Section

provides

program

and

job

examples

that

control

turntable

operation,

combine

the

turntable

operation

with

weld

programs,

and

links

the

individual

programs

together

into

job

for

total

robotic

system

operation.

IMPORTANT:

The

program

and

job

data

sequences

steps

shown

the

examples

can

used

for

actual

programs

jobs;

however,

some

modification

may

necessary

provide

different

functions

for

specific

system

applications

(see

Section

Teaching

the

robot

Owner’s

Manual

for

additional

data

information).

OM-890

Page

PROGRAM

EXAMPLE

FOR

TURNTABLE

MOUNTING

PLATE

ROTATION

provide

proper

turntable

operation,

necessary

write

and

enter a

program

that

controls

the

mounting

plate

rotation.

Since

full

rotation of

the

mounting

plate

180

degrees

either

clockwise

counterclockwise,

only

half

the

mounting

plate

surface

will

located

the

work

envelope.

dividing

the

mounting

plate

surface

into

halves,

and

assigning

numerical

side

designation

each

half, signals

from

the

turntable

allow

checking

for

appropriate

side

location

within

the

work

envelope.

put

ports

000 and

001,

located

the

I/O

terminal

strip

inside

the

Robot

Control,

match

the

numerical

side

designations.

The

edge

the

mounting

plate

stamped

with

the

numerical

designations

identify

the

two

sides.

IMPORTANT:

the

sequence

data

example

pro

gram

999

used

for

actual

program,

check

turntable

operation

for

the

program

sequences

BLOCK

FOR

WARD CONTINUOUS

mode

before

beginning welding

operations.

Mounting

plate

load

weight

may

require

justing

the

time-delay

relay

setting

(see

Section

3-5).

PROGRAM

NUMBER

999

Sequence

No.

Sequence

Data

Sequence

Operation

001

Position

(home)

move

manipulator

location

which

does

not

interfere

with

jigs,

fixtures,

weldments

on mounting

plate

turntable.

002

JNO

000

Jump

destination

PM0

side

000

work

envelope.

Jump

performed

signal

present

Robot

Control

input

port

000.

003

Position (home)

move

manipulator

(see

Sequence

Number

001).

004

ROOO

Turn

off

signal

Robot Control

output

port

000 that

activates

locking

movement in

the

direction.

005

TOO.5

Robot

Control

timer

set

for

0.5

seconds

deenergize

directional control

valve

solenoid.

006

SOOl

Turn

signal

Robot

Control

output

port

001

that

activates locking

movement in

the

down

direction.

007

TOl

Robot

Control

timer

set

for

second

allow

time

for

locking

move

ment.

008

S002

Turn

signal

Robot Control

output

port

002 that

activates

mounting

plate

rotation

the clockwise

direction

and energize

time-delay

relay

(see

Section

3-5).

009

ROOl

Turn

off

signal at

Robot

Control

output

port

001

that

activates

locking

movement

the

down

direction.

010

NOQO

WDT

(infinite)

Check

for

signal at

Robot

Control

input

port

000

which

indicates

side

000

the

work

envelope.

011

TOl

Robot

Control timer

set for

second

allow

mounting

plate

position

stabilize

end

rotation.

012

SOQO

Turn

signal

Robot

Control

output

port

000 that

activates

locking

movement in

the

direction.

013

R002

Turn

off

signal

Robot

Control

output

port 002

that

activates

mounting

plate

rotation in the

clockwise

direction

and

reset

time-delay

relay.

014

Position (home)

move

manipulator

(see

Sequence

Number

001).

015 JP2 Unconditional

jump

to destination

PM2

after

mounting

plate

rotation to

side

000.

016

Position (home)

move

manipulator

(see

Sequence

Number

001).

017

PMO

Destination

point

for

jump

sequence

JNO

000

(see

Sequence

Number

002).

018

Position (home)

move

manipulator

(see

Sequence

Number

001).

019

ROOO

Turn

off

signal

Robot

Control

output

port

000

that

activates

locking

movement in

the

direction.

OM-890

Page

PROGRAM

NUMBER

999

Sequence

No.

Sequence

Data

Sequence

Operation

020

TOO.5

Robot

Control

timer

set

for

0.5

seconds

deenergize

directional

control

valve

solenoid.

021

5001

Turn

signal

Robot Control

output

port

001

that

activates

locking

movement in

the

down

direction.

022

TOl

Robot

Control

timer

set

for

second

allow

time

for

locking

move

ment.

023

S003

Turn

signal

Robot

Control

output

port

003

that

activates

mounting

plate

rotation

the

counterclockwise

direction

and energize

time-delay

relay

(see

Section_3-5).

024

ROOl

Turn

off

signal

Robot Control

output

port

001

that

activates

locking

movement in

the

down

direction.

025

NOOl

Check

for

signal

Robot

Control

input

port

001

which

indicates

side

001

WDT

work

envelope.

(infinite)

026

TOl

Robot

control

timer

set

for

second

allow

mounting

plate

position to

stabilize

end

rotation.

027

SOQO

Turn

signal

Robot

Control

output

port 000

that

activates

locking

movement in

the

direction.

028

R003

Turn

off

signal

Robot Control

output

port

003 that

activates

mounting

plate

rotation

the

counterclockwise

direction

and reset

time-delay

relay.

029

PM2

Destination

point

for

jump

sequence

JP2

(see

Sequence

Number

015).

030

Position (home)

move

manipulator

(see

Sequence

Number

001).

031 END

End

Program

Number

999.

OUTPUTS INPUTS

000:

Up 000:

Arrival

001:

Down 001:

CCW

Arrival

002:

Rotation

003:

CCW

Rotation

-2.

PROGRAM

EXAMPLE

FOR

SIDE

001

Data

example

Program

111

provides

the

necessary

WELDING OPERATION

Sequence data

that

mat-

check

for

the

location of

side

001

before beginning

any

ches

side

001

the

work

envelope

with

the appropriate

weld

sequence.

welding

operations

necessary

the

weld

program.

PROGRAM

NUMBER

111

(SIDE

001)

Sequence

No.

Sequence

Data

Sequence

Operation

001

Position

(home) move

manipulator to

location which

does

not

interfere

with

jigs, fixtures, or

weldments

mounting

plate

turntable.

002 JN4

000

Jump

destination

side

000

the

work

envelope.

Jump

is performed

signal is present

Robot

Control

input

port

000.

003

050

Enter sequence data

for

welding operation.

Total

number

sequences

and

specific

data

will

depend

the

desired

operation.

051

PM4

Destination

point

for

jump

sequence

(see

Sequence

Number

002).

052

Position (home)

move

manipulator

(see

Sequence

Number

001).

OM-890

Page

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