Miller KE555371 Owner's manual

Brand: Miller

Model: KE555371

Category: Welding System

Type: Owner's manual

This manual is also suitable for

Miller

October

1994

Form:

OM-156306A

Effective

With

Serial

No.

KE555371

OWNERS

MANUAL

RPT-1

-500,

RPT-2-500,

And

RPT-2-1

000

Positioner



Read

and

follow

these

instructions

and

all

U

Give

this

manual

to

the

operator.





safety

blocks

carefully.

Have

only

trained

and

qualified

persons

install,

operate,

or

service

this

unit.

Call

your

distributor

if

you

do

not

understand

the

directions.



11113



U

For

help,

call

your

distributor

or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

Appleton,

WI

54912

414-734-9821



1

Axis

And

2

Axes

Positioners

For

Robotic

Welding

Systems



Requires

C2

Robot

Control

Equipped

With

External

Axis

Kit



For

Positioning

Of

Fixtures

And

Parts

Within

The

Work

Envelope



Motion

Range

Set

By

Soft

Limit,

Limit

Switches,

And

Mechanical

Stops



Sequential

Or

Cooperative

Operation

Capability

cover

5/94



Ref.

ST-800 574

'

1994

MILLER

Electric

Mfg.

Co.

PRINTED

IN

USA

I

ta.

I..

MILLERS

TRUE

BLUEﬁ

LIMITED

WARRANTY

Effective

February

7,

1996

(Equipment

with

a

serial

number

preface

of

KD

or

newer)

This

limited

werrenty

supersedes

elI

previous

MILLER

wsrrenties

end

is

exclusive

with

no

other

guerentees

or

werrenties

expressed

or

implied.

LIMITED

WARRANTY



Subject

to

theterms

snd

conditions

below,

MILLER

Electric

Mtg.

Co.,

Appleton,

Wisconsin,

werrents

to

its

originet

reteil

purcheser

Ihet

new

MILLER

equipment

sold

efter

the

effective

dete

of

this

limited

werrenty

is

free

of

de

fects

in

meteriet

end

workmenship

xl

the

time

it

is

shipped

by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES,

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTABIUTY

AND

FIT

NESS.

Within

the

wsrrenty

periods

listed

below,

MILLER

will

repeir

or

replece

eny

wer

rented

perls

or

components

thel

Isil

due

to

such

defects

In

meterisi

or

workmenship.

MILLER

must

be

notified

in

writing

within

thirty

(30)

deys

of

such

defect

or

fellure,

et

which

time

MILLER

will

provide

instructions

on

the

werrenty

cleim

procedures

to

be

followed.

MILLER

shell

honor

werrenty

cleims

on

werrented

equipment

listed

below

in

the

event

ol

such

e

feilure

within

the

werrenty

time

periods.

All

werrenty

time

periods

stert

on

the

dete

thet

the

equipment

wee

delivered

to

the

originel

reteil

purcheser,

or

one

yeer

efter

the

equipment

is

sent

to

e

North

Americen

distributor

or

eighteen

months

effer

the

equipment

is

sent

to

en

Intemelionel

distributor.

1.

5

Yeers

Pens

3

Yeere

Lebor

*

Originel

mein

power

rectifiers



Invenere

(Input

end

output

rectifiers

only)

2.

3

Yeers



Pens

end

Labor



Trensformer/Rectifier

Power

Sources



Plesme

Arc

Culling

Power

Sources

*

Semi-Autometic

end

Automef

ic

Wire

Feeders

Invener

Power

Supplies



Intellitig

*

Robots

(1

yeer

lebor)

3.

2

Yeers



Pens

end

Lebor

*

Engine

Driven

Welding

Generetors

(NOTE:

Engines

ere

werrented

seperelely

by

the

engine

menufecturer.)



Air

Compressors

4.

1

Yeer



Pens

end

Lebor

*

Motor

Driven

Guns



Process

Controllers



IHPS

Power

Sources

*

Weter

Coolent

Systems



HF

Units

5.

6

Months



Belleries

6.

90

Deys



Pens

end

Lebor



MIG

Gune/TIG

Torches

*

APT,

ZIPCUT

&

PLAZCUT

Model

Ptesme

Cutting

Torches



Remote

Controls



Accessory

Kite



Replecement

Pens

MILLERS

True

Blues

Limited

Werrenty

shell

not

epply

to:

1.

Items

fumixhed

by

MILLER,

but

menufectured

by

others,

such

ee

engines

or

trede

ecceesoriee.

These

items

ere

covered

by

the

menufecturere

werrenty,

If

eny.

2.

Consumeble

components:

such

es

confect

tips,

cutting

nozzles,

contectors

end

releyx

or

pens

thet

fell

due

to

normel

weer.

3.

Equipment

thet

hex

been

modified

by

eny

peny

other

then

MILLER.

or

equip

ment

thet

hex

been

improperly

inetelled,

improperly

opereted

or

misused

besed

upon

industry

stenderds,

or

equlpmenf

which

hex

not

hed

reexoneble

end

necexeery

meintenence,

or

equipment

which

hex

been

used

for

operetlon

outside

of

the

epecificetlone

for

the

equipment.

MILLER

PRODUCTS

ARE

INTENDED

FOR

PURCHASE

AND

USE

BY

COMMER

CIALJ1NDUSTRIAL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EQUIPMENT.

In

the

event

of

e

werrenty

cleim

covered

by

this

werrenty.

the

exclusive

remedies

shell

be,

xl

MILLERS

option:

(1)

repeir:

or

(2)

replecement:

or,

where

euthorized

In

writing

by

MILLER

in

eppropriete

cesee,

(3)

the

reeeoneble

cost

of

repeir

or

replece

ment

xl

en

euthorized

MILLER

service

sletion:

or

(4)

peyment

of

or

credit

for

the

pur

chese

price

(less

reexoneble

deprecletlon

bexed

upon

ectuel

use)

upon

return

of

the

goods

xl

customers

risk

end

expense.

MILLERS

option

of

repeir

or

replecement

wilt

be

FOB.,

Fectory

xl

Appleton,

Wisconsin,

or

FOB.

et

e

MILLER

euthorized

ser

vice

fecility

xx

determined

by

MILLER.

Therefore

no

compeneetion

or

reimburse

ment

for

trensponetion

costs

of

eny

kind

will

be

showed.

TO

THE

EXTENT

PERMIITED

BY

LAW,

THE REMEDIES

PROVIDED

HEREIN

ARE

THE

SOLE

AND

EXCLUSIVE

REMEDIES.

IN

NO

EVENT

SHALL

MILLER

BE

LIABLE

FOR

DIRECT,

INDIRECT,

SPECIAL,

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

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

ALL

EQUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

xtetes

In

the

U.S.A.

do

not

ellow

IlmlIeIlone

of

how

long

en

Implied

werrenly

lests,

or

the

exclusion

of

incidenlel,

indirect,

epeciel

or

coneequentlel

demegee,

eo

the

ebove

limitetion

or

exclusion

mey

not

epply

to

you.

This

werrenty

provides

spe

cific

legel

rights,

end

other

rights

mey

be

eveilebte,

but

mey

very

from

stete

to

xtete.

In

Cenede,

legieletion

in

some

provinces

providee

for

cenein

edditionel

werrenlies

or

remedies

other

then

xx

sleted

herein,

end

to

the

exfent

thet

they

mey

not

be

weived,

the

limitetions

end

exclusions

set

out

ebove

mey

not

epply.

This

Limited

Werrenly

providee

specific

legel

rights,

end

other

rights

mey

be

evelleble,

but

mey

very

from

province

to

province.

WHO

DO

I

CONTACT?

For

help,

U

contact

your

distributor

For

additional

information,

such

as

Technical

Manuals

(Service

And

Parts)

Engine

Manuals

Circuit

And

Wiring

Diagrams

Process

Handbooks

To

file

a

claim

for

loss

or

damage

during

shipment,

U

contact

the

delivering

carrier

For

assistance

in

filing

or

settling

claims,



contact

your

distributor

and/or

equipment

manufacturers

Transportation

Department

~Tj

Miller

Electric

Mfg.

Co.



CALL:

414-735-4505



FAX:

800-637-2348

(in

USA),

or

414-735-4136

(outside

USA)

Users

Guides

Distributor

Directories



contact

your

distributor

=

a

I I

.

WRITE:

Miller

Electric

Mfg.

Co.

P0,

BOX

1079

Appleton,

WI

54912

USA

Always

provide

Model

Name

and

Serial

or

Style

Number

J

.1

-

Grids

-

spot

Welders



Loed

Benke

-

5DX

Treneformers



Miller

Cyclometic

Equipment



Running

Geer/Treilers

-

Pleeme

Cutting

Torchee

(except

APT,

ZIPCUT

&

PLAZCIJT

Models)

Tecumseh

Engines

Deutz

Engines

(outside

Nonh

Americe)

-

Field

Options

(NOTE:

Field

options

ere

covered

under

True

Blues

for

the

remeining

werrenty

period

of

the

product

they

ere

Inetelled

In,

or

for

e

minimum

of

one

yeer



whichever

is

greeter.)

1=

I

mIhler_werl

3196

SAFETY

GUIDELINES

A.

ROBOTIC

SAFETY

Read,

understand,

and

comply

with

all

safety

rules

at

the

beginning

of

robot

Owners

Manual

Section

1



Safety

in

addition

to

the

following

before

beginning

robotic

procedures

or

operations.

1.

KEEP

OUT

of

robot

work

envelope

when

main

power

is

on.

2.

STAY

ALERT

when

near

robot.

3.

KEEP

INFORMED

about

status

of

robot

and

general

working

conditions.

4.

HAVE

AN

EMERGENCY

STOP

BUTTON

IN

HAND

whenever

you

are

near

the

robot.

5.

UNDERSTAND

AND

BE

FAMILIAR

WITH

ROBOTIC

MOVEMENTS.

Robots

are

unique

industrial

de

vices

and

can

present

unexpected

hazards

to

personnel

because

of

their

movements.

6.

UNPREDICTABLE

ROBOT

MOTION

can

occur

in

even

the

best

designed

areas

of

operation.

7.

NEVER

stand

with

your

back

toward

the

robot.

8.

NEVER

place

yourself

between

robot

work

stations

if

more

than

one

work

station

is

used.

9.

THOROUGHLY

TRAIN

ALL

PERSONNEL

in

robot

operation

and

safety.

10.

TEST

AND

VERIFY

that

ALL

safety

devices

and

components

used

in

the

robotic

cell

are

working

properly.

11.

TURN

OFF

robot

and

welding

power

source

input

power

before

entering

work

envelope.

12.

Provide

proper

Electrostatic

Discharge

(ESD)

protection

for

circuit

boards

in

Robot

Control

and

Teach

Pendant.

B.

WELDING

SAFETY

Read,

understand,

and

comply

with

all

safety

rules

at

beginning

of

welding

power

source

manual

in

addition

to

the

following

before

beginning

arc

welding

operations.

1.

Prevent

electric

shock.

2.

Provide

proper

protection

from

fumes

and

gases.

3.

Protect

eyes

and

skin

from

arc

rays;

protect

ears

from

noise.

4.

Prevent

fire

and

burns

caused

by

hot

metal,

spatter,

slag,

and

arc

sparks.

5.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

and

electric

arcs.

6.

Provide

impact

protection

to

all

persons

in

the

cell.

7.

Since

magnetic

fields

from

high

currents

can

affect

pacemaker

operation,

have

wearers

consult

their

doc

tor

before

going

near

arc

welding

operations.

8.

Turn

off

robot

and

welding

power

source

input

power

before

entering

work

envelope

or

working

on

weld

ing

power

source.

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

.

1

SECTION

2

SPECIFICATIONS

1

2-1.

Load

Moment

Charts

3

2-2.

Calculating

Load

Moment

4

2-3.

Weld

Current

Capacity

5

SECTION

3INSTALLATION

6

3-1.

Selecting

A

Location

And

Moving

Positioner

6

3-2.

Positioner

Connections

12

3-3.

Absolute

Offset

Adjustment

Of

Positioner

Axes

13

3-4.

Setting

Soft

Limit

Range

27

SECTION

4-

OPERATION

31

4-1.

Positioner

Components

31

4-2.

Method

Of

Entering

Simultaneous

Or

Cooperative

Motion

Data

32

4-3.

Teaching

Simultaneous

Motion

Data

36

4-4.

Teaching

Cooperative

Motion

Data

63

SECTION

5-

MAINTENANCE

&

TROUBLESHOOTING

78

5-1.

Routine

Maintenance

78

5-2.

Overrun

Protection

79

5-3.

Positioner

Lubrication

79

5-4.

Carbon

Tip

Inspection

80

SECTION

6

ERROR

CODES

81

6-1.

Error

Codes

Information

81

SECTION

7-

ELECTRICAL

DIAGRAMS

90

SECTION

8-

PARTS

LIST

93

Figure

8-1.

Table

Assembly

And

Stand

94

Figure

8-2.

Drive

Unit

96

Figure

8-3.

Air

Outlet

Shaft

Assembly

97

Figure

8-4.

Component

Layout,

Label

Location

97

Figure

8-5.

Frame

Assembly

98

Figure

8-6.

Air

Outlet

Shaft

Assembly

101

Figure

8-7.

Connecting

Shaft

102

Figure

8-8.

Component

Layout,

Label

Location

103

Figure

8-9.

Reduction

Gear

Unit

104

Figure

8-10.

Main

Assembly

106

OM-156

306A

10194

SECTION

1

-

SAFETY

INFORMATION

modl.1

2/93

6

AA

WARNING

AA

CAUTION



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Leam

the

meaning

of

WARNING

and

CAUTION.

1

2

~

tIiI~

:1~II~eU

3



Do

not

touch

live

electrical

parts.

L

ELECTRIC

SHOCK

can

kill





Disconnect

input

power

betoreJj_

4

installing

or

servicing.

5

2

\

~



Keep

away

from

moving

parts.

I

MOVING

PARTS

can

injure.

I

S

Keep

all

panels

and

covers

closed

I

when

operating.

I

1

Safety

Alert

Symbol

2

Signal

Word

WARNING

means

possible

death

or

serious

injury

can

happen.

CAUTION

means

possible

minor

happen.

injury

or

equipment

damage

can

3

Statement

Of

Hazard

And

Result

4

Safety

Instructions

To

Avoid

Hazard

5

Hazard

Symbol

(If

Available)

6

Safety

Banner

Read

safety

blocks

for

each

sym

bol

shown.

7

NOTE

Special

instructions

for

best

oper

ation



not

related

to

safety.

~EAD

SAFETY

BLOCKS

at start

of

I

3ection

3-1

before

proceeding.

7H

NOTE

~

Turn

Off

switch

wh

en

using

high

frequency.

Figure

1-1.

Safety

Information

SECTION

2-

SPECIFICATIONS

Table

2-1.

Positioners

Specification

Description

Maximum

Load

RPT-1

-500

And

RPT-2-500:

1102

lb

(500

kg);

RPT-2-1

000:

2205

lb

(1000kg)

Rotating

Speed

RPT-1-500

And

RPT-2-500:

8rpm

(48/sec);

RPT-2-1000:

2

rpm

(12/sec)

Rotation

Load

Moment

RPT-2-500:

17350

lb

ft2/s2

(735

Nm

75

kgfm]);

RPT-2-1

000:

69384

lb

ft2Is2

(2940

Nm

300

kgfm])

Tilting

Speed

RPT-2-500:

4

rpm

(24Isec);

RPT-2-1000:

1

rpm

(6/sec)

Tilt

Load

Moment

RPT-2-500:

33560

lb

ft2/s2

(1421

Nm

145

kgfm]);

RPT-2-1000:

101606

lb

ft2/s2

(4312

Nm

440

kgf.m])

Rotating

Repeatability

–0.008

in

(–0.2

mm)

At

19.7

in

(500

mm)

From

Center

Tilting

Repeatability

–0.008

in

(–0.2

mm)

At

19.7

in

(500

mm)

From

Center

(RPT-2-500

And

RPT-2-1000)

Center

Of

Gravity

Eccentric

RPT-2-500:

5.9

in

(150

mm);

RPT-2-1

000:

11.8

in

(300

mm)

Center

Of

Gravity

Height

RPT-2-500:

5.9

in

(150

mm);

RPT-2-1000:

11.8

in

(300

mm)

Maximum

Tilting

AngIe

135

(RpT-2-soo

And

RPT-2-1000)

Maximum

Rotation

–10

Tums

(3600)

Rotating

Motor

850

W

AC

Servomotor

Tilting

Motor

850

W

AC

Servomotor

OM-156

306

Page

1

Specification

Description

Stop

Position

Tilting

Or

Rotating

Any

Position

Position

Detection

Encoder

Welding

Power

Rating

500

Amperes

At

60%

Duty

Cycle

Ambient

Temperature

And

Humidity

32

To

122

F

(0

To

50

C);

20%

To

80%

RH

(Without

Condensation)

Overall

Dimensions

See

Figure

3-3,

Figure

3-4,

Or

Figure

3-5

Weight

RPT

-1-500:

573

lb

(260

kg);

RPT-2-500:

882

lb

(400

kg);

RPT-2-1000:

1874

lb

(850

kg)

*

Units

in

gravitational

system.

OM-156

306

Page

2

2-1.

Load

Moment

Charts

.3

The

load

moment

charts

show

the

weight

and

location

of

a

load

on

the

positioners.

1

Eccentricity

Of

Height

Center

Of

Gravity

2

Eccentricity

Of

Radius

Center

Of

Gravity

3

Gravitational

Force

Height

Of

The

Center

Of

Gravity

And Mass

Of

Maximum

Load

5.9

in

(150

mm)l

1102

lb

(500

kg)

7.9

in

(200

mm)

939

lb

(426

kg)

9.8

in

(250

mm)

818

lb

(371

kg)

11.8

in

(300

mm)

725

lb

(329

kg)

13.8

in

(350

mm)

650

lb

(295

kg)

15.7

in

(400

mm)

591

lb

(268

kg)

Eccentricity

Of

Radius

Of

The

Center

Of

Gravity

And

Mass

Of

Maximum

Load

Height

Of

The

Center

Of

Gravity

And Mass

Of

Maximum

Load

1515

lb

(687

kg)

1310

lb

(594

kg)

1153

lb

(523

kg)

1032

lb

(468

kg)

Eccentricity

Of

Radius

Of

The

Center

Of

Gravity

And Mass

Of

Maximum

Load

Ref.

ST-800

565

Figure

2-1.

Load

Moment

Charts

RPT-2-500

Model

1102

lb

(500

kg)

661

lb

(300

kg)

551

lb

(250

kg)

472

lb

(214

kg)

412

lb

(187

kg)

RPT-2-1

000

Model

2205

lb

(1000

kg)

1653

lb

(750

kg)

1323

lb

(600

kg)

1102

lb

(500

kg)

944

lb

(428

kg)

827

lb

(375

kg)

OM-156

306

Page

3

2-2.

Calculating

Load

Moment

N

OlE

LI~i~

The

load

moment

of

each

axis

must

be

within

the

limit

of

the

mass

forthe

maximum

load.

The

equation

for

calculating

the

load

moment

is

as

follows:

(Load

moment

1)

=

(Mass

of

load)

x

(Gravitational

acceleration)

x

(Center

of

gravity

eccentricity)

Any

external

load

applied

to

the

original

load

must

be

calculated

for

each

axis

as

follows:

(Load

moment

2)

=

(External

force)

x

(External

force

eccentricity)

Total

axis

load

moment

=

Load

moment

1

+

Load

moment

2

For

example,

calculate

the

load

moment

for

the

RPT-2-500

using

the

conditions

as

follows:

Mass

of

load

=

661.4

lb

(300

kg)

Eccentricity

of

height

center

of

gravity

7.9

in

(200mm)

Eccentricity

of

radius

center

of

gravity

=

3.9

in

(100

mm)

No

external

force

NOTE

~

When

calculating

Axisi

load

moment,

(0.46

ft

0.14

mJ)

must

be

added

in

for

the

table

surface

height

of

5.5

in

(140

mm)

the

eccentricity

of

height

center

of

gravity.

Axis

1

load

moment

Ml

=

661.4

lb

x

32

ft/s2

x

(.328

ft

+

0.46

ft)

(300

kg

x

9.8

rn/s2

x

0.14

m

+

0.2

ml)

Ml

=

16678

lb

ft2/s2

(999.6

N.

m)

This

value

is

less

than

the

33560

lb

ft2/s2

(1421

N

m)

load

moment

limit

for

Axis

1.

Axis

2

load

moment

Ml

=

661.4

lb

x

32

ft/s2

x

.328

ft

(300

kg

x

9.8

m/s2

x

0.1)

Ml

=

6942

lb

ft2/s2

(294

N.

m)

This

value

is

less

than

the

17350

lb

ft2/s2

(735

N

.

m)

load

moment

limit

for

Axis

2.

1

Eccentricity

Of

Radius

Center

Of

Gravity

2

Eccentricity

Of

Height

Center

Of

Gravity

3

Height

Of

External

Force

Contact

Point

4

Eccentricity

Of

Height

For

Contact

Point

Of

External

Force

ST-800

566

2

Figure

2-2.

Example

Of

External

Force

Applied

To

Load

OM-156

306

Page

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Miller KE555371 Owner's manual

Brand: Miller

Model: KE555371

Category: Welding System

Type: Owner's manual

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