Miller MTXC 3501M Robot Gun User manual

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
of both
this
manual
and
the
power
source
manual
used
with
this
unit,
with
special
emphasis
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
equip
ment.
Do
not
allow
untrained
persons
to
install,
operate,
or
maintain
this
unit.
Contact
your
distributor If
you
do
not
fully
understand
these Instructions.
MILLER
ELECTRIC
Mfg.
Co.
ANtHer
Gr~ip
Ltd..
Con~any
P.O.
Box
1079
Appleton,
WI 54912
USA
Tel.
414-734-9821
TB-114
276
PRINTED
NU
S.A

UI
MILLERS
TRUE
BLUETM
LIMITED
WARRANTY
Effective
January
1,
1992
(Equipment
with
a
serial
number
preface
of KC
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
imptied.
:1~!
LIMITED
WARRANTY

Subject
to
the
terms
and
conditione below.
MILLER
Electric
Mtg.
Co..
A~pleton.
Wisconsin,
warrants
to
its
original
retail
purchaser
that
new
MILLER
equipment
sold aher
the
effective date
ot
this
limited
warranty
is free
of
de
feds
in
material and
workmanship
at
the time it
is
shipped by
MILLER.
THIS
WAR
RANTY IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS OR
IMPLIED,
INCLUDING
TNE WARRANTIES OF
MERCHANTABILITY
AND
FIT
NESS.
al
Within
the
warranty
periods
listed
below.
MILLER
will
repair
or
replace
any
war
ranted
parts
or
componenta
that
tail
due
to
such
detects
in
material
or
workmanship.
MILLER must
be notitied
in
writing
within
thirty
(30)
days
of
such
defector
failure,
at
which
time
MILLER
will
provide
instruct
ions
on
the
warranty
claim
procedures
lobe
followed.
MILLER shall honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
such
a
failure
within
the
warranty
lime
periods.
All
warranty
lime
periods
start
on
the dale
that the
equipment
was
delivered
to
the
original
retail
purchaser,
and
are
as
follows
1.
5
Years Parts

3
Years Labor
Original
main
power
rectifiers
2.
3
Years

Parts
and Labor
*
Transformer/Rectifier Power
Sources

Plasma
Arc
Culling
Power
Sources

Semi-Aatomalic
and
Automatic Wire
Feeders

Robots
3. 2 Years

Parts
and
Labor

Engine
Driven
Welding
Generators
(NOTE.
Engines
are
warranted
separately by
the
engine
manufacturer)
4. 1
Year

Parts
and
Labor

Motor
Driven Guns

Process Controllers

Water
Coolant
Syslems

HF
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
Of
the
product
they
are
installed
in.
or
for
a
minimum
of
one
year

whichever is
greater.)
5. B
Months

Baneries
6.
90
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:
1.
Items furnished
by
MILLER,
but
manufactured
by
others,
such
as
engines
or
trade accessories.
These
items
are covered
by
the manufacturers
warranty,
if
any.
2.
Consumable
components;
such
aa
contact
lips.
cutting
nozzles,
conlactora
and
relays.
3.
Equipment
that has
been modified
by
any
party
other than
MILLER.
or
equip
ment
that
has
been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards.
or
equipment
which has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
has
been used for
operation
outside of
the
specifications
for
the
equipment.
MILLER PRODUCTS
ARE
INTENDED
FOR
PURCNASE
AND
USE BY
COMMER
CIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
TNE USE AND MAINTENANCE
OF
WELDING
EQUIPMENT.
In
the
event
of
a
warranty
claim covered
by
this
warranty.
the exclusive remedies
shall
be,
at
MILLERS
option:
(1) repair;
or
(2) replacement;
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases.
(31
the
reasonable
coal
of
repair
or
replace
ment
at
an
authorized
MILLER
service
station;
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customera
risk
and
eapense.
MILLERS
option
of
repair
or
replacement
will
be
F.O.B.,Factory
at
Appleton,
Wiaconsin,
or
FOB.
ate
MtLLER
authorized
aer
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costa
of
any
kind
wilt
be
allowed.
TO
TNE EXTENT
PERMITTED
BY
LAW,
TNE
REMEDIES PROVIDED
HEREIN
ARE
TNE
SOLE
AND
EXCLUSIVE REMEDIES.
IN
NC
EVENT SHALL
MILLER
BE
LIABLE FOR
DIRECT,
INDIRECt
SPECtAL.
INCIDENTAL OR
CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON CON
TRACT.
TORT
OR
ANY
OTHER LEGAL THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED HEREIN
AND
ANY
IMPLIED
WAR
RANTY. GUARANTY OR REPRESENTATION
AS
TO
PERFORMANCE,
AND ANY
REMEDY
FOR
BREACH OF
CONTRACT
TORT
OR
ANY
OTHER LEGAL
THEORY
WHICH.
BUT
FOR
THIS
PROVISION.
MIGHT
ARISE
BY
IMPLICATION,
OPERATION CF
LAW,
CUSTOM OF
TRADE
DR
COURSE OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY DR FITNESS
FOR
PARTICULAR PURPOSE.
WITH
RESPECT
TO
ANY
AND ALL
EOUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
in
the
U.S.A.
do
not
allow
Ilmitefiona of how
long
en
implied
warranty
laata.
or
the eaclualon
of
incidental, indirect.
special
or
conaequenlial
damages,
so
the above limifation
or
escluaion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal
rights,
and ofher
rights
may
be
available,
but
may vary
from
elate
to
elate.
In
Canada,
legislation
in
some
provinces provides for
certain
additional
warranties
or
remedies
other than
as
stated
herein.
and
to the
estent
that
they
may
not
be
waived. the
limitations and esdluaiOna
sat out
above
may
not
apply.
Thia
Limited
Warranty
provides specific
legal
rights.
and
other
righta
may
be available,
but
may
vary
from
province
to
province.
fi
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have occurred
during
shipment.
File
any
claims
for loss
or
damage
with
the
delivering
carrier. Assistance for
filing
or
settling
claims
may
be obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information about this
equipment,
always
provide
Model
Designation
and Serial
or
Style
Number,
Use
the
fol)ow)ng
spaces
to
record
MDdel
Designation
and
Serial
or
Style
Number
of
your
unit, The
information
is
located
on
the
rating
label
or
nameplate.
Model
Serial
or
Style
No,
______________________________________________
Date of Purchase
___________
miller
5/93

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
SPECIFICATIONS
Amend
MTXC
3501
M
welding
gun
view
in
Figure
2-1.
Dimension
Information
AMENDMENT
TO
SECTION
3INSTALLATION
Amend
Figure
3-2.
MTXC
3501M
Gun
Installation
SB-I
35
144-A
Figure
2-1.
Dimension
Information
Axis
6
Axis
6
Mount
900
Mounting
Bracket
insulator
SB-135
148-A
Figure
3-2.
MTXC
3501
M
Gun
Installation

AMENDMENT
TO
SECTION
5
PARTS
LIST
Amend
Figure
5-2.
MTXC 3501
M Air
Cooled
Gun
Amend Parts
List
as
follows:
Figure
5-2.
MTXC
3501
M
Air
Cooled
Gun

14
13

..-

12
I

I
k
>
SB-135 145-A
Quantity
Replaced
With
**
Part
No.
Description
10-
10-4
132 296
133
994
143 697
143
693
MTXC-3501
M,
air
cooled
gun
NOZZLE HOLDER ASSEMBLY
1
10-7
133997 108776
INSULATIONBUSHING
1
10-11
133993
143692
NOZZLEASSEMBLY
1
10-12
10-13
Added
Added
143 696
143694
0-RING
(used
on
nozzle
assembly)
CLAMP,band
1
1
10-14
Added
143695
CLAMP,band
1
*~First
digit
represents
page
no

digits
following
dash
represent
item
no.
All
gun
parts
remain
the
same
with
listed
exceptions.
When
ordering
replacement
parts
refer
to
view
on
this
errata
sheet
and
Fig
5-2
in
manual
for
correct
identity
of
parts.
OM-1 556A
Page
2

OM-1
556A
-
8i~
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
dam- Use
the
following
spaces
to
record the
Model
Designa
age
that
may
have
occurred
during
shipment.
File
any
tion
and
Serial
or
Style
Number of
your
unit. The infor
claims for loss
or
damage
with
the
deliverIng
carrIer.
mation is
located
on
the
data card
or
the
nameplate.
Assistance
for
filing
or
settling
claims
may
be obtained
from the distributor
and/or the
equipment
manufactur-
Model
________________________________
ers
Transportation
Department.
Serial
or
Style
No.
_____________________
When
requesting
information about
this
equipment,
al
ways
provide
the Model
Description
and
Serial
or
Style
Date of
Purchase
______________________
Number.
TABLE
OF CONTENTS
Section
No.
Page
No.
SECTION
1

SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1. General
Information
And
Safety
1
1-2.
Safety
Alert
Symbol
And
Signal
Words
1
SECTION
2 SPECIFICATIONS
2-1.
Duty
Cycle
1
2-2.
Description
1
SECTION
3INSTALLATION
3-1.
Gun
Preparation
2
3-2.
Outlet Cable
Preparation
2
3-3.
MTX
3502
And
MTXW
5001
Gun
Installation
3
3-4.
MTXC
3501M
Gun
Installation
4
3-5. Water
Connections
(Water-Cooled
Models
Only)
4
3-6.
Field
Installation
Of
Water-Cooled
Nozzle
Onto
Air-Cooled Gun
(MTX
3502
Models
Only)
5
SECTION
4
MAINTENANCE
4-1.
Inspection
And
Upkeep
6
4-2. Contact
Tube
Replacement
7
4-3.
Changing
Wire
Size
7
SECTION
5
PARTS LIST
Figure
5-1.
MTX
3502
Air
Cooled Gun
8
Figure
5-2.
MTXC-3501
Air
Cooled Gun
10
Figure
5-3.
MTXW
5001
Water
Cooled Gun
11
LIST OF
CHARTS
AND
TABLES
Table
2-1.
Specifications
1

SECTION
1

SAFETY
PRECAUTIONS
AND
SIGNAL
WORDS
1-1.
GENERAL INFORMATION
AND
SAFETY
A.
General
Information
presented
in
this
manual and
on
various
labels,
tags,
and
plates
on
the
unit
pertainsto equipment
design,
installation,
operation,
maintenance,
and
troubleshooting
which should be
read,
understood,
and
followed
for the safe and
effective
use
of this
equipment.
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
applicable
codes
such
as,
but
not
limited
to,
those listed
at
the end of
Section
1
-
Safety
Rules For
Operation
01
Arc
Welding
Power
Source
in
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
to
call attention
to
and
identify
different
levels
of
hazard and
special
instructions.
a
a
a
This
safety
alert
symbol
is
used with
the
signal
words WARNING and
CAUTION
to
call
attention
to
the
safety
statements.
WARNING
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid
serious
personal
injury
or
loss of life.
CAUTION
statements
identify
procedures
or
practices
which
must
be
followed
to
avoid minor
personal
injury
or
damage
to
this
equipment.
IMPORTANT
statements
identify special
instructions
necessary
for the
most
efficient
operation
of
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
.6
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
of
a
welding
gun
is the
percentage
of
a
ten
minute
period
that
the
gun
can
safely
be
operated
at
a
give
output
without
causing
overheating
and
damage
to
the
gun.
These
guns
are
rated
at
50%
duty
cycle using
CO2
shielding
gas.
This
means
that the
gun
can
be
operated
for
five
consecutive minutes.
The
remaining
five
minutes
the
gun
should
be idle
to
permit
proper
cooling.
CAUTION:
EXCEEDING
THE
RATED
AMPERAGE
WITH
C02
OR
FAILING
TO
REDUCE
THE
WELDING
AMPERAGE OR
DUTY
CYCLE
WHEN
USING
MIXED
SHIELDING
GAS
can
damage
gun.

Do
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
is
used when
Gas
Metal
Arc
Welding
(GMAW)
is done.
The
guns
are
shipped
with
the
necessary
components
for
a
specific
wire
size;
however,
through
minor
parts
changes,
each
gun
can
be
used with
various
sizes of wire.
a
OM-1556
Page
1

MTX
3502
TB-114
276
SECTION
3-
INSTALLATION
a
CAUTION:
IMPROPER
ROBOTTOOL
POINT
ADJUSTMENT
can
damage welding
gun
and
robot.

After
welding
gun
installation
is
completed,
see
Set-Up
Procedure
section of robot
Owners
Manual for
tool
point procedures.
3-1.
GUN
PREPARATION
Select
contact
tube
for
wire size
used,
and
proceed
as
follows:
a
WARNING:
ELECTRIC
SHOCK
can
kill;
ROBOT
ARM
MOVEMENT
can
cause
serious
injury
or
death;
INCORRECT
PROCEDURES
can
cause
Injury.

Do
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
of
removing
input
power
plug
from
receptacle, padlocking
line
disconnect
switch(es)
in
open
position, removing
fuses
from
fuse
box(es),
or
shutting
off
and
red-
tagging
circuit
breaker(s)
or
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.
1.
Remove
nozzle
2.
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
2

MOVING PARTS
can
cause
serious
Injury.

Keep
away
from
moving parts.
HOT SURFACES
can
cause
severe
burns.

Allow
cooling
period
before
touching
gun.
1.
Route cable
through
supports
on
robot. The
cable
connector
end
goes
to
the
wire
drive
assembly
while
the
remaining
end
goes
to
the
gun.
2.
Install
cable
connector
into
wire drive
assembly
(see
Motor/Drive
Assembly
Owners
Manual).
3.
Slide
welding
gun
onto
liner
protruding
from
cable
until
liner
seats
inside
gun.
4.
Mark linerflush
with
gun
body
and
slide
gun
off
liner.
5.
Measure
distance
between mark
made
on
liner
in
Step
4
and brass
nut
on
cable.
6.
The liner needs
to
be
shortened
by
the
length
measured
in
Step
5.
Cut
off measured
length
from
end
of liner.
3-3. MTX 3502
AND
MTXW
5001
GUN
INSTALLA
TION
(Figure
3-1)
4A
WARNING:
ELECTRIC
SHOCK
can
kill;
ROBOT
ARM
MOVEMENT
can
cause
serious
Injury
or
death;
INCORRECT
PROCEDURES
can cause
Injury.

Do
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
of
removing
input
power
plug
from
receptacle,
padlocking
line
disconnect
switch(es)
in
open
position,
removing
fuses from fuse
box(es),
or
shutting
oft
and
red-tagging
circuit
breaker(s)
or
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:
If
a
3(1
mounting
bracket
is
used,
the
bracket
must
be
installed
with
offset
to
the
right
when
viewing
the
Phi
axis
mount.
Be
sure
phenolic
insulator is
between
gun
and bracket.
1.
If
a
300
mounting
bracket
is
used,
secure
bracket to
gun
using supplied
socket
head
screws.
2.
Secure
gun
to
Phi
axis
(or
Axis
5)
mount
using
supplied
socket head
screws
(see
Figure
3-1).
If
a
30
mounting
bracket
is
used,
secure
bracket
to
manipulator
Phi
axis
mount
using
supplied
socket
head
screws.
Slide
liner from outlet cable into
gun.
Secure
outlet cable
to
adapter by
tightening
nut
from
cable
onto
adapter.
5.
Connect
touch
sensor
leads from
gun
to
leads
from
outlet
cable. Connect leads
from
outlet cable
to
cord
at
gas/current
sensing
control
or
to
matching
connector
at
robot
manipulator.
Polarity
is
not
important.
Gun
Mounting
Plate
Air-Cooled
Gun
Shown
FIgure
3-1.
MTX
3502 And
MTXW
5001
Gun
Installation
3.
4.
Phi
Axis
(Axis
5)
Phi
Axis
(Axis
5)
Mount
(Phenolic
Plate)
PhenoUc
Insulator
300
MountIng
Bracket
Gun
OM-1556
Page
3

Axis
6
Figure
3-2. MTXC
3501
M
Gun
Installation
TB-135
146
3-4.
MTXC 3501
M
GUN
INSTALLATION
(Figure
3-2)
a
WARNING:
ELECTRIC
SHOCK
can
kill;
ROBOT
ARM
MOVEMENT
can
cause
serious
injury
or
death;
INCORRECT
PROCEDURES
can cause
Injury.

Do
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
of
removing
input
power
plug
from
receptacle,
padlocking
line disconnect
switch(es)
in
open
position,
removing
fuses from
fuse
box(es),
or
shutting
off
and
red-tagging
circuit
breaker(s)
or
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.
1.
Instafl and
secure
insulatorto
gun
usingthe supplied
flat
washers,
lock
washers,
and socket head
screws.
2. Secure
900
mounting
bracket
to
gun
using supplied
socket head
screws.
3.
Secure
90
bracket
to
Axis
6 mount
using
supplied
socket
head
screws.
4.
Secure
outlet cable
to
adapter by tightening
nut
from
cable
onto
adapater.
5. Connect
touch
sensor
leads
from
gun
to
leads from
outlet
cable.
Connect
leads
from
outlet cable
to cord
at
gas/current
sensing
control
or
to
matching
connector at
robot
manipulator.
Polarity
is
not
important.
3-5.
WATER
CONNECTIONS
(Water-Cooled
Models
Only)
4A
CAUTION: OVERHEATING
of
Gas
Metal
Arc
Welding
gun
can
damage
gun.

If
using
a
water
cooled
gun
and
recirculating
coolant
system,
make
connections
directly
from
the
coolant
system
to
gun
hoses.

Check
entire
cooling
system
periodically
for
proper
coolant
flow.
A.
Connections
To
Gun
1.
Push
quick-disconnect fitting
on
water
hose
onto
barbed
titling
at
gun
(see Figure
3-3)
until
locking
ring
snaps
down.
2.
To
release
hose,
push
locking
ring
up
until
disengaged;
pull
hose from
fitting.
B.
Connections
To
Coolant
Supply
1.
Self-Contained,
Recirculating
Coolant
System
CAUTION:
INCORRECT
COOLANT
will
damage
gun.

Use
only
coolant
specified
in
recirculating
coolant
system
manual.

Do
not
use
tap
water,
automotive
antifreeze,
or
plain
distilled
or
deionized
water.

Use
MILLER
Part No.
109
973
water
soluble
coolant
or a
mixture
of
pure
commercial
ethylene
or
propylene
glycol
and/or
water
soluble lubricants
in
distilled
or
deionized water.
Failure
to
comply
with
these instructions
may
void
the
warranty.
a.
Route
hoses
from
gun
to coolant
system.
b.
Connect
hoses
to
coolant
system
input
and
output
fittings.
The hoses
have 5/8-18
left-hand
male
fittings.
Insulator
OM-1556
Page
4