Miller 5 TURNTABLE User manual

FORM: OM-890
Miller®
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.
OWNER’S MANUAL
IMPORTANT: Read and understand the entire contents of this manual,
with special emphasis on 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 by persons trained and experienced in Appleton, WI 54912 USA
the safe operation of welding equipment. Do not allow untrained persons Tel. [phone]
to install, operate, or maintain this unit. Contact your distributor if you
do not fully understand these instructions.
July 1988
PRgNTED IN U.S.A. ADDITIONAL COPY PRICE $1.40

LIMITED WARRANTY
EFFECTIVE FEBRUARY 16, 1988
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- 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 therefore shall be, at Millers optIon (11 repair or (2) replacement
Equipment furnished by Miller is free from defect in workman- or, where authorited in writing by Miller in appropriate c, (3)
ship and material as of the time and place of delivery by Miller. the reasonable cost of repair or replacement at an authorized
No warranty is made by Miller with respect to engines, trade Miller seivtce station or (4) payment of or credit for the purchase
accessories or other items manufactured by others. Such price (less reasonable depreciation based upon actual use) upon
engines, trade accessories and other items are sold subject to retum of the goods at Customer’s risk and experue. MILLER~s
the warranties of their respective manufacturers, if any . All option of repair or replacement will be FOB., Factory, at
engines are warranted by their manufacturer for one year from Appleton, Wmconsin, or F.O.B., at a MILLER authorized senice
date of original purchase, except Tecumseh engines which facility, therefore, no compensation for transportation costs of
have a two year warranty. any kind will be allowed. Upon receipt of notice of apparent
defect or failure, Miller shall instiuct the claimant on the warranty
Except as specified below, Miller’s warranty does not apply claim procedures to be followed.
to components having normal useful life of less than one (1)
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
• wire including nozzles and nozzle insulators where failure does ANY IMPUED WARRANTY, GUARANTY OR REPRESENTA -
BREACH OF CONTRACT WHICH, BUT FOR THIS PROViSION,
• not result from defect in workmanship or material. TION AS TO PERFORMANCE, AND ANY REMEDY FOR
7~ Miller shall be required to honor warranty claims on war- MIGHT ARISE BY IMPLICATiON, OPERATION OF LAW,
ranted Equipment in the event of failure resulting from a defect CUSTOM OF TRADE OR COURSE OF DEAUNG, INCLUDING
within the following periods from the date of delivery of Equip- ANY IMPUED WARRANTY OF MERCHANTABIUTY OR OF
ment to the original user: FIThESS FOR PARTiCULAR PURPOSE, WiTH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX -
1. Aac welders, p~r sources, robots, and components . 1 ~er CLUDED AND DISCLAIMED BY MILLER.
2. Load banks . 1 year
3. Original main power rectifiers 3 years
(labor - 1 year onlyl EXCEPT AS EXPRESSLY PROViDED BY MILLER IN
• 4. All welding guns, feeder/guns and torches 90 days WRITING, MILLER PRODUCTS ARE INTENDED FOR
5. All other Millermatic Feeders 1 year ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL
6. Replacement or repair parts, exclusive of labor .. 60 days USERS AND FOR OPERATION BY PERSONS TRAINED AND
7. Batteries 6 months EXPERIENCED IN THE USE AND MAINTENANCE OF
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
• provided that Miller is notified in writing within thirty 130) days CONSUMER USE. MILLER’S WARRANTIES DO NOT EXTEND
of the date of such failure. TO, AND NO RESELLER IS AUTHORIZED TO EXTEND
As a matter of general policy only, Miller may honor clalew MILLER’S WARRANTIES TO, ANY CONSUMER.
submitted by the original user within the foregoing periods.

TABLE OF CONTENTS
Section No. Page No.
SECTION 1 - INTRODUCTION
1 - 1. General Information And Safety 2
1 - 2. Receiving-Handling 2
1 - 3. Description 2
SECTION 2 - INSTALLATION
2 - 1. Work Cable Connections 3
2 - 2. Operation Control Cord Connections 5
SECTION 3 - OPERATION
3 - 1. Program Example For Turntable Mounting Plate Rotation 6
3 - 2. Program Example For Side 001 Welding Operation 7
3 - 3. Prgoram Example For Side 000 Welding Operation 8
3 - 4. Job Example For Linking Programs 8
3 - 5. Setting Relay Time For High-Speed Valve 11
SECTION 4 - MAINTENANCE ft TROUBLESHOOTING
4 - 1. Cleaning And Inspection 12
4 - 2. Lubrication 13
4-3. QilFilter 13
4 - 4. Checking Reservoir Fluid Level 14
4 - 5. Adjustment Of Low-Speed Rotation Control 15
4 - 6. Adjustment Of Locking Pin Speed Control 16
4 -7. AdjustmentQf ShockAbsorbers 17
4-8. SettingHardStops 18
4 - 9. Adjustment Of Pressure Switch For Accumulator 19
4-10. Adjustment Of Drive Belt Tension 21
4-11. Drive Belt Replacement 22
4-12. Hydrqaulic Fittings 24
4-13. Releasing Pressurized Fluid From Accumulator 24
4-14. Replacement Of Pressure Switch 25
4-15. Replacement Of Directional Control Valve 26
4-16. Replacement Of Rotary Actuator 27
4-17. Replacement Of High-Speed Valve 30
4-18. Replacement Of Locking Pin Cylinder 31
4-19. Replacement Of Proximity Switch 32
4-20. Recharging The Accumulator 33
4-21. Replacement Of Motor/Pump And Reservoir Assembly 34
4-22. Fuses 36
4-23. Troubleshooting Charts 37

SECTION 1 - INTRODUCTION
Mounting
Plate
Diameter
Optional
Fixture
Plate
Diameter
Load
Capacity
Index
Speed*
Indexing
Repeatability
Weight
Net Ship
48 in.
(1219 mm)
60 in.
(1524 mm)
1000 lbs.
(454 kg)
5 Seconds
For 1800
Rotation
Either
Clockwise Or
Counterclockwise
At Load
Capacity
0.005 in.
(0.13 mm)
2000 lbs.
(907 kg)
2000 lbs.
(907 kg)
*Speed increases when operating with less weight.
Figure 1 - 1. Turntable Specifications
Input Power
Single-Phase
AC
Reservoir
Capacity
Hydraulic
Fluid
Pump
Flow
Rate
System
Relief
Pressure
Range Of
System
Operating
Pressure
115 Volts1
60Hz
Maximum:
8 qt.
(7.6 I)
Fill Quantity:
6 qt.
(5.7 I)
ISO 32
Antiwear
Hydraulic
Oil
0.5 gpm
(1.9 1/mm)
1500 psi
(10342 kPa)
950 psi
to
1250 psi
(6550 kPa
to 8618 kPa)
Figure 1 - 2. Hydraulic System Specifications
Dimensions
Inches Millimeters
A 32-1/4 819.2
B 48 1219.2
C 46 1158.4
D 35 989
E 24 609.6
F 13 330.2
G 2 50.9
H 1 25.4
I 47 1193.8
J 48 1219.2
Figure 1 - 3. Overall Dimensions And Base Mounting Hole Layout
OM-aSO Page 1
A
13/32 in.
(10.3 mm)
10 Holes
TC-120 288

00
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, and
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equip-
ment.
B. Safety
The installation, operation, maintenance, and
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others. Therefore, this equipment is to
be installed, operated, and maintained only by qualified
persons in accordance with this manual and all ap -
plicable codes and safety rules such as, but not limited
to, those listed in Section 1 - Safety of the robot
Owner’s Manual and in Section 1 - Safety Rules For
Operation of Arc Welding Power Source in the welding
power source Owner’s Manual.
Safety instructions specifically pertaining to this unit ap -
pear throughout this manual highlighted by the signal
words ~ and ~ which identify
different levels of hazard.
statements include installation, operation,
and maintenance procedures or practices which if not
carefully followed could result in serious personal injury
or loss of life.
CAUTION statements include installation, operation,
and maintenance procedures or practices which if not
carefully followed could result in minor personal injury
or damage to this equipment.
A third signal word, ~s•., highlights instruc -
tions which need special emphasis to obtain the most
efficient operation of this equipment.
1 - 2. 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 or
damage that may have occurred in transit must be filed
by the purchaser with the carrier. A copy of the bill
of lading will be furnished by the manufacturer on re -
quest if occasion to file claim arises.
When requesting information concerning this equip-
ment, it is essential that Model Description and Serial
Number of the equipment be supplied.
1 - 3. DESCRIPTION - The Model 5 Turntable is a
circular mounting plate and hydraulic drive system that
provides smooth, accurate rotation for deliverying parts
into a work envelope of an automated welding system.
The mounting plate operates in alternating clockwise
and counterclockwise rotations of 180 degrees. Index -
ing speed for a complete rotation at the 1000 pounds
(454 kg) load capacity is 5 seconds which includes lock -
ing the mounting plate in position. Control of the moun-
ting plate rotation and locking pin movement is provid-
ed by input/output signals through lead connections
from the Model 5 Turntable to the I/O ports on a pro -
grammable control unit.
A 60 in. (1524 mm) diameter optional fixture plate is
available for mounting weld fixtures and increasing the
working surface area. Additional fixture plates can be
used as fixturing requirements increase to provide fast
changeover of weld fixtures by only exchanging fixture
plates on the turntable.
All turntable control components are adjusted as part of
the original installation. If changes are made by the user
that affects load weight on the mounting plate, ad -
justments may then be required.
270~
•Weight of plate approximately
140 lbs. (63.5 kg)
Figure 1 - 4. DImensions And Hole Layout Of Optional Fixture Plate
1800
OM-590 Page 2

SECTION 2 - INSTALLATION
IMPORTANT: The Model 88 Gantry and Model 134
Gantry come with the Model 5 Turntable installed and
connected for operation. If the turntable is to be used
without a robot control, contact factory Technical Sales
department.
Figure 2 - 1. Connection Diagram For Turntable And MR-5 Robot Control
2 - 1. WORK CABLE CONNECTIONS (Figure 2-2)
ELECTRIC SHOCK can kill.
• Do 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 of removing plug
from receptacle, padlocking line disconnect switch in
open position, removing fuses from fuse box, or shut -
ting off and red-tagging circuit breaker or other discon-
necting device.
MOVING PARTS can cause serious injury.
• Keep clear of 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 is disconnected.
The welding power source work cable connects to a
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 to provide continuity between the work cable
connection and the mounting plate.
Be sure that work cable is routed away from moving
parts and lug connection is tight. Check for adequate
spring tension at mounting rods to properly align con -
tact pad against spindle retainer bushing, but do not
overtighten springs as this will cause premature wear of
the contact pad.
TA-120 278
OM-890 Page 3

Mounting
Plate
Mounting
Rod (2)
Figure 2 - 2. Contact Pad Assembly For Work Cable Connection
Robot Control’
with Cabinet
Door Open
Retainer.
Bushing
Nut
Cable
Connects To
This End
Of Mounting
Rod
Insulating
Bushing ~ A
Inside
,,~ Portion Of
urntable Chassis
Tension Spring
Pad
Fits Against
Retainer Bushing
Rof; TB-120 281
Figure 2 - 3. Location Of Terminal Strips TB3 And TB4 Inside MR-5 Robot Control
OM-890 Page 4

2 -2. OPERATION CONTROL CORD CONNEC -
TIONS
~ ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down turntable, welding power source, and
robot control, and disconnect input power
employing “lockout! tagging procedures” before
making or checking operation control cord con -
nections.
Lockout/tagging procedures consist of removing plug
from receptacle, padlocking line disconnect switch in
open position, removing fuses from fuse box, or shut -
ting off and red-tagging circuit breaker or other discon-
necting device.
Output Leads 31, 32, 33,
And 34 Connect To Terminals 175,
176, 177, And 178 Respectively
F~L~1
ELECTROSTATIC DISCHARGE (ESD) can damage
circuit board components.
• Put on propedy grounded wrist strap BEFORE
handling circuit boards.
• Transport all static-sensitive components in pro -
per static-shielding carriers or packages.
• Perform work only at a static-safe work area.
Control of turntable operation for mounting plate rota -
tion, locking pin movement, and the Emergency Stop
function is provided by lead connections from the turn -
table control panel to 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 in Figures 2-3 and 2-4.
Be sure that all lead connections are correct and secure
to terminals on appropriate Robot Control terminal
strips (refer to circuit diagram Figure 4-25 for identifica -
tion of leads and connection points).
Input Leads 50, 51, And
52 Connect To Terminals
101, 140, And 141 Respectively
F-i--i
~
.±. ..L ~. .1. .J.. .L .1.. .L. ~ ‘ I 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 30 For
24VAC Power
Supply Connects
To Terminal 194
K
Jumper Lead
Connection From
Terminal 174
For Emergency Stop
External Control Emergency
Stop Terminals
• ~L ‘I I~L LL uLN (ii •1 !1IjdI~al~aI\~A
o
• -I--l--r--1----!--1-I ~
~ ~ 2 ~ -~
~ —— ~ Mli~
~4~ - EUERGENC STOP
Emergency Stop And Function
Control Terminal Strip TB4
Terminals For
Additional
Start Modules
Figure 2 - 4. Operation Control Cord Lead Connections To Terminal Strips TB3 And TB4 Inside MR-S
Robot Control
SECTION 3- OPERATION
For the robot system to perform operations in the pro -
per sequence, it will be necessary to 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 a job for total robotic system
operation.
IMPORTANT: The program and job data sequences
or steps shown in the examples can be used for actual
programs or jobs; however, some modification may be
necessary to provide different functions for specific
system applications (see Section 5 - Teaching in the
robot Owner’s Manual for additional data information).
OM-890 Page 5

3 - 1. PROGRAM EXAMPLE FOR TURNTABLE
MOUNTING PLATE ROTATION - To provide proper
turntable operation, it is necessary to write and enter a
program that controls the mounting plate rotation.
Since a full rotation of the mounting plate is 180
degrees either clockwise or counterclockwise, only half
of the mounting plate surface will be located in the work
envelope. By dividing the mounting plate surface into
halves, and assigning a numerical side designation to
each half, signals from the turntable allow checking for
appropriate side location within the work envelope. In -
put ports 000 and 001, located on the I/O terminal strip
inside the Robot Control, match the numerical side
designations. The edge of the mounting plate is
stamped with the numerical designations to identify the
two sides.
IMPORTANT: If the sequence data in example pro -
gram 999 is used for an actual program, check turntable
operation for the program sequences in BLOCK FOR -
WARD CONTINUOUS mode before beginning welding
operations. Mounting plate load weight may require ad -
justing the time-delay relay setting (see Section 3-5).
PROGRAM NUMBER 999
Sequence No. Sequence Data Sequence Operation
001 P Position (home) move by manipulator to a location which does not interfere
with jigs, fixtures, or weldments on mounting plate of turntable.
002 JNO 000 Jump to destination PM0 if side 000 is in work envelope. Jump is performed
if signal is present at Robot Control input port 000.
003 P Position (home) move by manipulator (see Sequence Number 001).
004 ROOO Turn off signal at Robot Control output port 000 that activates locking pin
movement in the up direction.
005 TOO.5 Robot Control timer set for 0.5 seconds to deenergize directional control
valve solenoid.
006 SOOl Turn on signal at Robot Control output port 001 that activates locking pin
movement in the down direction.
007 TOl .0 Robot Control timer set for 1 .0 second to allow time for locking pin move
ment.
008 S002 Turn on signal at Robot Control output port 002 that activates mounting plate
rotation in 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 pin
movement in the down direction.
010 NOQO
WDT 00
(infinite)
Check for signal at Robot Control input port 000 which indicates side 000 is in
the work envelope.
011 TOl .0 Robot Control timer set for 1 .0 second to allow mounting plate position to
stabilize at end of rotation.
012 SOQO Turn on signal at Robot Control output port 000 that activates locking pin
movement in the up direction.
013 R002 Turn off signal at Robot Control output port 002 that activates mounting
plate rotation in the clockwise direction and reset time-delay relay.
014 P Position (home) move by manipulator (see Sequence Number 001).
015 JP2 Unconditional jump to destination PM2 after mounting plate rotation to side
000.
016 P Position (home) move by manipulator (see Sequence Number 001).
017 PMO Destination point 0 for jump sequence JNO 000 (see Sequence Number 002).
018 P Position (home) move by manipulator (see Sequence Number 001).
019 ROOO Turn off signal at Robot Control output port 000 that activates locking pin
movement in the up direction.
OM-890 Page 6

PROGRAM NUMBER 999
Sequence No. Sequence Data Sequence Operation
020 TOO.5 Robot Control timer set for 0.5 seconds to deenergize directional control
valve solenoid.
021 5001 Turn on signal at Robot Control output port 001 that activates locking pin
movement in the down direction.
022 TOl .0 Robot Control timer set for 1 .0 second to allow time for locking pin move
ment.
023 S003 Turn on signal at Robot Control output port 003 that activates mounting plate
rotation in the counterclockwise direction and energize time-delay relay (see
Section_3-5).
024 ROOl Turn off signal at Robot Control output port 001 that activates locking pin
movement in the down direction.
025 NOOl Check for signal at Robot Control input port 001 which indicates side 001 is in
WDT 00 work envelope.
(infinite)
026 TOl .0 Robot control timer set for 1 .0 second to allow mounting plate position to
stabilize at end of rotation.
027 SOQO Turn on signal at Robot Control output port 000 that activates locking pin
movement in the up direction.
028 R003 Turn off signal at Robot Control output port 003 that activates mounting
plate rotation in the counterclockwise direction and reset time-delay relay.
029 PM2 Destination point 2 for jump sequence JP2 (see Sequence Number 015).
030 P Position (home) move by manipulator (see Sequence Number 001).
031 END End of Program Number 999.
OUTPUTS INPUTS
000: Pin Up 000: CW Arrival
001: Pin Down 001: CCW Arrival
002: CW Rotation
003: CCW Rotation
3 -2. PROGRAM EXAMPLE FOR SIDE 001 Data in 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 in the work envelope with the appropriate weld sequence.
welding operations is necessary in the weld program.
PROGRAM NUMBER 111 (SIDE 001)
Sequence No. Sequence Data Sequence Operation
001 P Position (home) move by manipulator to a location which does not interfere
with jigs, fixtures, or weldments on mounting plate of turntable.
002 JN4 000 Jump to destination 4 if side 000 is in the work envelope. Jump is performed
if signal is present at Robot Control input port 000.
003
050
I Enter sequence data for welding operation. Total number of sequences and
specific data will depend on the desired operation.
051 PM4 Destination point 4 for jump sequence (see Sequence Number 002).
052 P Position (home) move by manipulator (see Sequence Number 001).
OM-890 Page 7