Miller 5 TURNTABLE Owner's Manual
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Miller 5 TURNTABLE Owner's Manual

Miller 5 TURNTABLE Owner's Manual

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Miller®
OWNER'S MANUAL
IMPORTANT: Read and understand the entire contents of this manual,
with special emphasis on the safety material throughout the manual,
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.
PRgNTED IN U.S.A.
July 1988
MODEL: 5 TURNTABLE
IMPORTANT:
Illustrations and text in this
manual are forthe latest Model 5 Turntable. Ear-
lier models may vary slightly. When ordering
parts, be sure to identify parts by name, part
number and serial number of the machine for
which the parts are being ordered.
Mlflm Electric Mfg. Co.
AMd~, G,o,,~ Li d Co~' , p,nv
P0. Box 1079
Appleton, WI 54912 USA
Tel. 414-734-9821
ADDITIONAL COPY PRICE $1.40
FORM: OM-890

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Summary of Contents for Miller 5 TURNTABLE

  • Page 1 MODEL: 5 TURNTABLE IMPORTANT: Illustrations and text in this Miller® manual are forthe latest Model 5 Turntable. Ear- lier models may vary slightly. When ordering parts, be sure to identify parts by name, part number and serial number of the machine for which the parts are being ordered.
  • Page 2 Subject to the terms and condi- In the case of Miter’s breach of warranty or any other duty tions hereof, Miller Electric Mfg. Co., Appleton, Wisconsin with respect to the quality of any goods, the exclusive remedies warrants to its Distributor/Dealer that all new and unused...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Section No. Page No. SECTION 1 INTRODUCTION General Information And Safety Receiving-Handling 3. Description SECTION 2 INSTALLATION 1. Work Cable Connections 2. Operation Control Cord Connections SECTION 3 OPERATION Program Example For Turntable Mounting Plate Rotation 2. Program Example For Side 001 Welding Operation 3.

  • Page 4: Introduction

    SECTION 1 INTRODUCTION Optional Mounting Fixture Plate Plate Load Index Indexing Weight Diameter Diameter Capacity Speed* Repeatability Ship 5 Seconds For 1800 Rotation 48 in. 60 in. 1000 lbs. Either 0.005 in. 2000 lbs. 2000 lbs. (1219 mm) (1524 mm) (454 kg) Clockwise Or (0.13 mm)

  • Page 5: General Information And Safety

    ~ which identify from the Model 5 Turntable to the I/O ports on a pro- different levels of hazard. grammable control unit. statements include installation, operation, A 60 in.

  • Page 6: Installation

    SECTION 2 INSTALLATION The Model 88 Gantry and Model 134 IMPORTANT: Gantry come with the Model 5 Turntable installed and connected for operation. If the turntable is to be used without a robot control, contactfactory Technical Sales department. TA-120 278 Figure 2 1.
  • Page 7 Mounting Rod (2) Mounting Plate Retainer. Bushing Cable Connects To This End Of Mounting Insulating Bushing Fits Against Retainer Bushing Inside Portion Of urntable Chassis Rof; TB-120 281 Tension Spring Figure 2 2. Contact Pad Assembly For Work Cable Connection Robot Control’...

  • Page 8: Operation Control Cord Connections

    ELECTROSTATIC DISCHARGE (ESD) can damage 2 -2. OPERATION CONTROL CORD CONNEC- TIONS circuit board components. • Put on propedy grounded wrist strap BEFORE handling circuit boards. ELECTRIC SHOCK can kill. • Transport all static-sensitive components in pro- • Do not touch live electrical parts. •...

  • Page 9: Program Example For Turntable Mounting Plate Rotation

    inside the Robot Control, match the numerical side 1. PROGRAM EXAMPLE FOR TURNTABLE designations. The edge of the mounting plate MOUNTING PLATE ROTATION To provide proper stamped with the numerical designations to identify the turntable operation, it is necessary to write and enter a two sides.

  • Page 10: Program Example For Side 001 Welding Operation

    PROGRAM NUMBER 999 Sequence No. Sequence Data Sequence Operation TOO.5 Robot Control timer set for 0.5 seconds to deenergize directional control valve solenoid. 5001 Turn on signal at Robot Control output port 001 that activates locking pin movement in the down direction. TOl .0 Robot Control timer set for 1 .0 second to allow time for locking pin move ment.

  • Page 11: Prgoram Example For Side 000 Welding Operation

    PROGRAM NUMBER 111 (SIDE 001) Sequence No. Sequence Data Sequence Operation End of Program Number 111. 3 - 3. PROGRAM EXAMPLE FOR SIDE Data in example Program 222 provides the necessary WELDING OPERATION - Sequence data that mat- check for location of side 000 before beginning any ches side 000 in the work envelope with the appropriate weld sequence.
  • Page 12 Parts Loading/unloading Side Weld Side TA-120 271 Figure 3 1. Example Job 100 Starting Position Of Turntable Parts Layout And Matching Program Numbers JOB NO. LINE NO. LINE DATA LINE OPERATION J100 P999 Run Program 999 to rotate mounting plate on turntable. CNOOO P300 Call and run Program 300 if side 000 is at weld side of turntable.
  • Page 13 Parts Loading/Unloading Side Weld Side TA-120 271 Figure 3 Turntable Parts Layout During First Run Of Job 100 2. Position Of While Job 100 runs the first time in Automatic mode Line 3: No input signal is present at control unit input and manipulator performs welding operations for Pro- port 000.

  • Page 14: Setting Relay Time For High-Speed Valve

    While Job 100 runs the second time in Automatic mode out which closes the high speed valve and the low- speed rotation control decreases mounting plate final and manipulator performs welding operations for Pro- rotating speed. grams 100 and 200, finished parts for Programs 300, 400, and 500 from first run of Job 100 are unloaded and new parts are loaded in side 000 fixtures.

  • Page 15: Maintenance Ft Troubleshooting

    SECTION 4 MAINTENANCE & TROUBLESHOOTING All directions, such as left or right, are IMPORTANT: Maintenance to be performed only by qualified persons. with respect to the operator facing the turntable (front) A schedule for cleaning and inspection should be set on the weld side of work envelope and with locking pin assembly located at opposite side (rear).

  • Page 16: Lubrication

    Lube fitting is located below mounting plate in the 2. LUBRICATION (Figure 4-1) cylinder pin guide bracket. A. Lubricating Ball Bearings Use a lithium-base grease for lubrica- tion. Sufficient lubrication is added when a slight ELECTRIC SHOCK can kill; MOVING WARNING: leakage of grease is present at the seals.

  • Page 17: Checking Reservoir Fluid Level

    The turntable is shipped with the proper amount of fluid The turntable is equipped with a spin-on type oil filter in in the hydraulic reservoir. A sight gauge, located on the the return line of the hydraulic system. Replace the filter end of the reservoir, is provided for ease of visually after every 350 hours of turntable operation as follows: checking the fluid level.

  • Page 18: Adjustment Of Low-Speed Rotation Control

    5. ADJUSTMENT OF LOW-SPEED ROTATION 1. Remove front, rear, and left side covers from CONTROL (Figure 4-4) The adjustable low-speed turntable chassis. rotation control reduces mounting plate speed during rotation after the high-speed valve deenergizes. The UJ~~~iU Check reservoir fluid level only when low-speed rotation control, located in the return line hydraulic system is at zero (0) pressure.

  • Page 19: Adjustment Of Locking Pin Speed Control

    4. Manually run the program for rotating the moun- To adjust mounting plate low speed rotation, proceed as follows: ting plate using the BLOCK FORWARD CON- TINUOUS mode to check the time-delay relay setting that keeps the high-speed valve open and low speed rotation after the relay times out WARNING: ELECTRIC SHOCK can kill;...

  • Page 20: Adjustmentqf Shockabsorbers

    7. ADJUSTMENT OF SHOCK ABSORBERS If pin speed is too slow, the locking cylinder stroke may (Figure 4-6 and 4-7) The two hard stops on the turn- not secure the mounting plate position after rotation. If table chassis are equipped with an adjustable shock ab- pin speed is too fast, the locking and unlocking cylinder sorber.

  • Page 21: Setting Hard Stops

    Mounting Plate Receiver Holes Knocker Block Stop Assembly Figure 4 Components For Index Stopping Of Mounting Plate Rotation 8. SETTING HARD STOPS (Figures 4-7 3. Manually run the program for rotating mounting 4-8) The two hard stops on the turntable chassis are plate using the BLOCK FORWARD CON- adjustable to align mounting plate receiver holes with TINUOUS mode.

  • Page 22: Adjustment Of Pressure Switch For Accumulator

    Block Adjustment Plate Securing Screw (4) Nuts TC-120 287 Figure 4 Components Of Hard Stop Assembly 6. Repeat steps 3, 4, and 5 to adjust remaining hard The lower and upper limits of the pressure range that the pressure switch energizes and stop at opposite side of turntable chassis.
  • Page 23 3. Adjust differential and maximum pressure con- The differential and maximum IMPORTANT: trols as necessary. Rotating upper control (max- pressure adjustment controls are located on the side of imum pressure adjustment) clockwise increases the pressure switch with the pressure gauge. Upperad- pressure and counterclockwise decreases justment control sets maximum pressure, and lowerad- pressure.

  • Page 24: Adjustment Of Drive Belt Tension

    MOVING PARTS can cause serious injury. 4-10. ADJUSTMENT OF DRIVE BELT TENSION • Keep clear of pinch points. (Figure 4-10) PRESSURIZED HYDRAULIC FLUID can cause The initial break-in time for the drive serious injury. IMPORTANT: belt is one week of turntable operation which allows for •...

  • Page 25: Drive Belt Replacement

    7. Loosen the 4 nuts securing rotary actuator 4-11. DRIVE BELT REPLACEMENT (Figure 4-11) mounting plate to turntable base. Belt Removal SHOCK can kill. ELECTRIC The turntable spindle must be in a raised position to • Do not touch live electrical parts. allow replacement of the drive belt.
  • Page 26 crease belt tension. Belt should be snug, but not 11. Remove locknuts, flat washers, and springs that overtightened. secure contact pad against retainer bushing above spindle pulley. C. Adjusting Index Rotation Of Mounting Plate 12. Remove contact pad assembly from mounting Receiver holes in the mounting plate allow the locking position, and set assembly aside.

  • Page 27: Hydrqaulic Fittings

    care when retightening the connection. Compression e. Tighten tension adjustment bolt on left side fittings with free-turning nuts can crack or break if over- of rotary actuator mounting plate to increase tightened. belt tension (belt should be snug, but not overtightened).

  • Page 28: Replacement Of Pressure Switch

    4. Remove the 4 screws securing wiring cover to 2. Press the push button on top of the motor/pump switch box. adapter to release pressurized fluid from ac- cumulator and check for a zero (0) reading at pressure switch gauge. 5.

  • Page 29: Replacement Of Directional Control Valve

    MOVING PARTS can cause serious injury. 11. Secure wiring cover to switch box. • Keep clear of pinch points. PRESSURIZED HYDRAULIC FLUID can cause 12. Secure switch box to mounting base. serious injury. • Release hydraulic fluid pressure according to Sec- 13.

  • Page 30: Replacement Of Rotary Actuator

    10. Install and secure control valve to manifold block Be sure to remove white jumper lead IMPORTANT: with the 4 screws removed Step 4 (see Figure from terminal blocks for connection to replacement 4-15). valve terminal blocks. 11. Install and secure wiring cover on housing for 4.
  • Page 31 •Hydraulic Hose With Fitting Ret TB-120 281 Figure 4 16. Rotary Actuator Drive Components Removal Of Rotary Actuator 9. Remove hydraulic fittings from rotary actuator ports. 1. Remove front, rear, and left side covers from turntable chassis. 10. Remove the 3 bolts that secure the tapered bushing in the drive pulley.
  • Page 32 17. Remove rotary actuator from mounting plate. 10. Loosen the pusher bolts in drive pulley so that end of bolts are flush with bottom of pulley hub. B. Installation Of Rotary Actuator When installing pulley onto tapered IMPORTANT: 1. Install replacement rotary actuator onto moun- bushing, be sure to line up bolt holes in pulley hub and ting plate and secure bottom of actuator with the bushing.

  • Page 33: Replacement Of High-Speed Valve

    3. Loosen upper fitting, and disconnect valve from 17. REPLACEMENT OF HIGH-SPEED VALVE (Figure 4-17) manifold block. 4. Remove screw from rear of electrical plug, and WARNING: ELECTRIC SHOCK can kill. • Do not touch live electrical parts. disconnect plug from solenoid. •...

  • Page 34: Replacementof Locking Pin Cylinder

    4-18. REPLACEMENT OF LOCKING PIN CYLINDER 4-18 and 4-19) (Figures ELECTRIC SHOCK can kill; MOVING PARTS can cause serious injury. • Do not touch live electrical parts. • Keep clear of pinch points. Turntable operation is required to retract locking pin from securing mounting plate position.

  • Page 35: Replacement Of Proximity Switch

    Lockout/tagging procedures consist of removing plug 17. Clean threads on hydraulic fittings removed in Step 8, apply teflon tape to threads, and install from receptacle, padlocking line disconnect switch in fittings on replacement cylinder. open position, removing fuses from fuse box, or shut- ting off and red-tagging circuit breaker or other discon- 18.

  • Page 36: Recharging The Accumulator

    Remove replacement proximity IMPORTANT: WARNING: ELECTRIC SHOCK can kill. switch module from housing to allow lead connections • Do not touch live electrical parts. • Shut down turntable, welding power source, and to housing terminals. robot control, and disconnect input power 6.

  • Page 37: Replacement Of Motor/Pump And Reservoir Assembly

    Accumulator~ Located Inside Rear Portion Of Turntable Chassis Ref: TD-120 290 Figure 4 -22. LocatIon Of Accumulator 4-21. REPLACEMENT OF MOTOR/PUMP AND 5. Have the accumulator recharged by a qualified RESERVOIR ASSEMBLY service station. 6. Reinstall and secure accumulator in mounting WARNING: ELECTRIC SHOCK can kill.
  • Page 38 Hydraulic Line To Base TD-120 Figure 4 And Reservoir Assembly 23. Location And Components Of Motor/Pump 12. Install replacement motor/pump and reservoir Release pressurized fluid from accumulator (see assembly on turntable base, and secure Section 4-13). assembly with the 4 bolts removed in Step 8. 3.

  • Page 39: Fuses

    4-22. FUSES (Figure 4-24) Fuses Fl and F2, rated at 15 amperes, protect the con- trol circuit and transformer against overload. Should Fl or F2 open, the turntable would be inoperative. WARNING: ELECTRIC SHOCK can kill. • Do not touch live electrical parts. •...

  • Page 40: Troubleshooting Charts

    Troubleshooting to be performed only by qualified per- Install replacement fuse into fuse block. sons. 5. Close and secure hinged cover. It is assumed that the unit was properly installed accor- 2 of this manual, the operator is familiar ding to Section 4-23.
  • Page 41 TROUBLE PROBABLE CAUSE REMEDY No locking pin movement. No output signal from con- Check program (see Section 3-1). Check opera trol unit. tion control cord lead connections (see Section 2-2). Check control unit output ports (see Robot Owner’s Manual). No high-speed cycle as Time-delay relay TDR set- Increase relay time setting (see Section 3-5).
  • Page 42 TROUBLE PROBABLE CAUSE REMEDY Locking pin cylinder not Locking pin cylinder. Replace cylinder (see Section 4-18). holding in up position. Mounting plate not holding Rotary actuator. Replace rotary actuator (see Section 4-16). position at end of rotation. Mounting plate Drive belt broken. Replace drive belt (see Section 4-11).
  • Page 43 l-~J F” N’ ‘C a.]— 4.’ 4.’ c’l OM-890 Page 40...
  • Page 44 —n Circuit Diagram No. A-120 980 Figure 4 26. Hydraulic Circuit Diagram OM-890 Page 41...
  • Page 45 July 1988 FORM: OM-890 PARTS LIST...
  • Page 46 9 10 Fig 0 — ‘27 FIg C TO-120 290 Main Assembly FIgure A OM-890 Page 1...
  • Page 47 Part Item Dia. Description Mkgs. Quantity Figure A Main Assembly 122 072 HARD STOP ASSEMBLY 122 087 MOUNTING TABLE 122 099 SPACER BAR 0.5x1.5x6 122 100 SHIM STOCK PIN CYLINDER MTG PLATE 122 101 122 102 PIN BLOCK 2.5 x 3 122 103 GREASE SEAL 122 125...
  • Page 48 TD-120 289 Figure B Control Panel OM-890 Page 3...
  • Page 49 Part Item Dia. Mkgs. Description Quantity Figure B Control Panel 122 122 ELECTRICAL WIREWAY 122 109 ELECTRICAL PANEL 122 121 ELECTRICAL WIREWAY RELAY, P&B 122123 122 108 ELECTRICAL ENCLOSURE 122117 TOGGLE SWITCH, ON/OFF 122112 CONTROL CIRCUIT TRANSFORMER 110/24 VOLTS 122 118 FUSE BLOCK TERMINAL STRIP 122111...
  • Page 50 ‘p. ‘U ‘p. OM-890 Page 5...
  • Page 51 Item Dia. Part Description Mkgs. Quantity Figure C Hydraulic Control Assembly (FIg A Pg 2 Item 31) 122 563 HOSE HYDRAULIC 122 566 FITTING HOSE 122 560 HOSE HYDRAULIC 122 550 FITTING HOSE 122 564 HOSE HYDRAULIC 122544 FITTING HOSE 122 546 FITTING HOSE 122 547...
  • Page 52 Item Dia. Part Description Mkgs. Quantity Item Figure D Drive Assembly (Fig D Pg 2 117192 TIMINGBELT 122084 PULLEY 122 156 DRIVEN PULLEY 122 157 TAPERED BUSHING 122 158 SHAFT KEY SHAFT SPACER 122 159 122 160 LOCK NUT 122 155 GROUNDING SHOE ASSEMBLY (consisting 123 223 GROUND PAD...
  • Page 53 Item Dia. Part Mkgs. Description Quantity Figure E Shock Absorber Assembly (FIg A Pg 2 Item 14) 122 077 SHOCK MTG NUT, LARGE 122 078 HYDRAULIC SHOCK ABSORBER SHOCK MTG NUT, SMALL 122 076 122 079 SHOCK MTG PLATE 122 080 SHOCK ASSEMBLY MTG PLATE BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

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