Download Miller Electric MTXC 3501M Robot Gun Specifications

Millerfi
August 1990
FORM: OM-1556A
MODEL: MTXC 3501M
MTX 3502
MTXW 5001
ROBOT GUNS
OWNERS
MANUAL
IMPORTANT: Read and understand the entire contents of both this manual
emphasis on
operating, or
for use only
Instructions
and
these
are
unit
this
This
maintaining
equipment.
of
trained
In
and
the
safe
equip
welding
by persons
operation
experienced
and the power source manual used with this unit, with special
the safety material throughout both manuals, before installing,
MILLER ELECTRIC Mfg. Co.
ANtHer
Gr~ip Ltd.. Con~any
P.O. Box 1079
Appleton, WI 54912 USA
Tel. 414-734-9821
ment. Do not allow untrained persons to install, operate, or maintain this unit.
Contact your distributor If you do not fully understand these Instructions.
TB-114 276
PRINTED
N U S.A
:1~!
UI
MILLERS
TRUE BLUETM LIMITED WARRANTY
(Equipment
with
Effective January 1, 1992
serial number preface of KC
This limited warranty supersedes all previous MILLER warranties and is exclusive with
Subject
LIMITED WARRANTY
to the terms
or
a
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
workmanship at the time it is shipped by MILLER. THIS WAR
no
other guarantees
*
Accessory Kits
*
Replacement Parfa
feds in material and
MILLERS
RANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING TNE WARRANTIES OF MERCHANTABILITY AND FIT
True
Bluen
Umited
or
warranties expressed
Warranty shall
trade accessories. These items
Within the warranty periods
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
provide instruct ions
on
apply
imptied.
to:
are
covered
by
as
the manufacturers
engines
or
warranty, if
any.
listed below. MILLER will
which time MILLER will
not
or
Items furnished by MILLER, but manufactured by others, such
1.
NESS.
newer)
Consumable components; such
2.
and
the warranty claim procedures lobe
aa contact
lips. cutting nozzles, conlactora
relays.
followed.
Equipment
3.
and
main power rectifiers
Original
2.
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.
3 Years Labor
5 Years Parts
Parts and Labor
3 Years
In the event of a
Transformer/Rectifier Power Sources
*
Plasma Arc
Culling
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 customera risk and eapense. MILLERS option of repair or replacement
Robots
vice
Engine Driven Welding Generators
(NOTE. Engines are warranted separately by
4.
1 Year
ment for transportation costa of any kind wilt be allowed.
the
engine manufacturer)
TO TNE EXTENT PERMITTED BY LAW, TNE REMEDIES PROVIDED HEREIN
ARE TNE SOLE AND EXCLUSIVE REMEDIES. IN NC EVENT SHALL MILLER BE
Parts and Labor
LIABLE FOR DIRECT, INDIRECt SPECtAL. INCIDENTAL OR CONSEQUENTIAL
DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CON
TRACT. TORT OR ANY OTHER LEGAL THEORY.
Motor Driven Guns
Process Controllers
Water Coolant
Syslems
HF Units
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WAR
Grids
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.
Spot Welders
*
Load Banks
SOX Transformers
Running Gear/Trailers
Field Options
*
(NOTE: Field options
are
covered under True
warranty period Of the product they
whichever is greater.)
one year
5.
B Months
6.
90
Days
F.O.B.,Factory at Appleton, Wiaconsin, or FOB. ate MtLLER authorized aer
facility as determined by MILLER. Therefore no compensation or reimburse
will be
Parts and Labor
2 Years
are
BluenM
installed in.
or
for the remaining
for a minimum of
Some states in the U.S.A. do not allow Ilmitefiona of how
Baneries
In
Parts and Labor
Cuning
en
implied warranty
or
Canada,
legislation
or remedies
Plasma
long
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.
laata.
MIG Guns/TIG Torches
*
warranty claim covered by this warranty. the exclusive remedies
shall be, at MILLERS
Power Sources
Semi-Aatomalic and Automatic Wire Feeders
3.
by any party other than MILLER. or equip
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.
follows
are as
1.
that has been modified
ment that has been
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,
in some
other than
as
provinces provides
for certain additional warranties
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
Torches
vary from
Remote Controls
province
to
province.
al
fi
RECEIVING-HANDLING
Before
unpacking equipment, check carton for any damage that may have occurred during shipment. File any claims for loss or damage
delivering carrier. Assistance for filing or settling claims may be obtained from distributor and/or equipment manufacturers
Transportation Department.
with the
When
requesting information about this equipment, always provide Model Designation and Serial
Use the
or
fol)ow)ng
spaces to record MDdel
Designation
and Serial
or
Style
or
Style Number,
Number of your unit, The information is located
on
the
rating label
nameplate.
Model
Serial
or
Style
No,
______________________________________________
Date of Purchase
___________
miller 5/93
ERRATA SHEET
After this manual
to data
appearing
was
printed, refinements
AMENDMENT TO SECTION 2
Amend MTXC 3501 M
in
equipment design
occurred. This sheet lists
exceptions
later in this manual.
welding
SPECIFICATIONS
gun view in
Figure
2-1. Dimension Information
SB-I 35 144-A
Figure
2-1. Dimension Information
AMENDMENT TO SECTION 3INSTALLATION
Amend
Figure
3-2. MTXC 3501M Gun Installation
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
Amend
PARTS LIST
5-2. MTXC 3501 M Air Cooled Gun
Figure
14
..-
>
13
12
I
I
SB-135 145-A
k
Figure
Amend Parts List
as
follows:
Part
Replaced
**
No.
With
143 697
143 693
10-
132 296
10-4
133 994
10-7
10-11
133997
133993
10-12
Added
10-13
Added
Added
10-14
5-2. MTXC 3501 M Air Cooled Gun
108776
143692
143 696
143694
143695
Description
MTXC-3501 M, air cooled gun
NOZZLE HOLDER ASSEMBLY
INSULATIONBUSHING
NOZZLEASSEMBLY
0-RING (used on nozzle assembly)
CLAMP,band
CLAMP,band
Quantity
1
1
1
1
1
1
*~First
digit represents page no digits following dash represent item no.
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
All
OM-1 556A
Page
2
identity of parts.
OM-1 556A
-
8i~
RECEIVING-HANDLING
Before unpacking equipment, check carton for any damage that may have occurred during shipment. File any
tion and Serial
claims for loss
mation is located
damage with the deliverIng carrIer.
filing or settling claims may be obtained
from the distributor and/or the equipment manufacturers Transportation Department.
or
Use the
following spaces to record the Model Designa
or Style Number of your unit. The infor
on
the data card
or
the
nameplate.
Assistance for
Model
________________________________
Serial
When requesting information about this equipment, al
ways provide the Model Description and Serial or Style
or
Style
No.
_____________________
Date of Purchase
______________________
Number.
TABLE OF CONTENTS
Page
Section No.
SECTION 1
1-1.
1-2.
SECTION 2
2-1.
2-2.
SAFETY PRECAUTIONS AND SIGNAL WORDS
General Information And
Safety
Alert
And
Symbol
1
Safety
Signal Words
1
SPECIFICATIONS
1
Duty Cycle
Description
1
SECTION 3INSTALLATION
2
3-1.
Gun
3-2.
Outlet Cable
2
3-3.
MTX 3502 And MTXW 5001 Gun Installation
3
3-4.
MTXC 3501M Gun Installation
4
3-5.
Water Connections
3-6.
Field Installation Of Water-Cooled Nozzle Onto Air-Cooled Gun
(MTX 3502 Models Only)
SECTION 4
Preparation
Preparation
Models
Only)
4
5
MAINTENANCE
And
4-1.
Inspection
4-2.
Contact Tube
4-3.
Changing
SECTION 5
(Water-Cooled
Upkeep
Replacement
Wire Size
6
7
7
PARTS LIST
Figure 5-1. MTX 3502 Air Cooled Gun
Figure 5-2. MTXC-3501 Air Cooled Gun
Figure 5-3. MTXW 5001 Water Cooled Gun
8
10
11
LIST OF CHARTS AND TABLES
Table 2-1.
Specifications
1
No.
SECTION 1
SAFETY PRECAUTIONS AND SIGNAL WORDS
GENERAL INFORMATION AND SAFETY
1-1.
1-2.
SAFETY
ALERT
SYMBOL
AND
SIGNAL
WORDS
A.
General
The
following safety alert symbol and signal words are
throughout this manual to call attention to and
identify different levels of hazard and special
Information
presented in this manual and on various
and
labels, tags,
plates on the unit pertainsto equipment
design, installation, operation, maintenance, and
used
instructions.
should be read, understood, and
followed for the safe and effective use of this equipment.
troubleshooting which
B.
a
Safety
equipment is to
maintained
and
only by qualified
operated,
accordance with this manual and all
codes such as, but not limited to, those listed
Safety Rules For Operation 01
at the end of Section 1
Arc
Welding
Owners
WARNING
welding power source
Manual.
Table 2-1.
Rating: 50%
Duty Cycle
Model
350
call
statements.
a
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
identify special instructions
efficient operation of this
SPECIFICATIONS
SpecIficatIons
Cooling
Capacity
Method
.030-1/16 in.
(0.8 -1 .6 mm)
Air
Amperes
MTXC 3501M
MTXW5001
500
Amperes
.045 and 1/16 in.
and 1.6 mm)
(1.1
DUTY CYCLE
2-2.
duty cycle
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
a
shielding
gas. This means that the gun can be
five consecutive minutes. The remaining
five minutes the gun should be idle to permit proper
operated for
Water
Weight
Net
Ship
2.3 lbs.
3.2 lbs.
(1kg)
(1.5 kg)
2.6 lbs.
3.5 lbs.
(1.2kg)
(1.6kg)
3.7 lbs.
4.6 lbs.
(1.7 kg)
(2.1 kg)
DESCRIPTION
These guns are
robotic welding.
specifically designed
for automatic
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.
cooling.
a
signal
to
a
MTX 3502
CO2
CAUTION
WARNING statements identify procedures or
practices which must be followed to avoid
serious personal injury or loss of life.
Wire Diameter
With C02
of
used with the
equipment.
SECTION 2
2-1.
safety
IMPORTANT statements
necessary for the most
-
Power Source in the
The
and
others. Therefore, this
safety of
be installed,
persons in
applicable
safety alert symbol is
attention to the
and
The
maintenance,
installation,
operation,
troubleshooting of arc welding equipment requires
practices and procedures which ensure personal safety
and the
This
words
CAUTION:
THE
EXCEEDING
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
C02.
Reduce
duty cycle
when
using
using
mixed
shielding gases.
OM-1556
Page
1
MTX 3502
TB-114 276
MTXC 3501M
TB-135 144
TB-114 276
MTXW 5001
Figure
2-1. DImension Information
SECTION 3- INSTALLATION
a
CAUTION: IMPROPER ROBOTTOOL POINT
ADJUSTMENT can damage welding gun and
robot.
After
see
welding gun installation is completed,
Set-Up
Procedure section of robot Owners
Manual for tool point
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 redtagging circuit breaker(s) or other disconnecting
device(s).
MOVING PARTS can
3-1.
GUN PREPARATION
Keep away
Select contact tube for wire size used, and proceed
as
a
Allow
can cause
Injury.
Shut down
welding power
source
and robot
control, and disconnect input power employing
lockout/tagging procedures.
OM-1556
Page
2
1.
injury.
moving parts.
2.
cooling period before touching gun.
Remove nozzle
Install desired contact tube and nozzle onto
gun.
Do not touch live electrical parts.
serious
HOT SURFACES can cause severe burns.
follows:
WARNING:
ELECTRIC SHOCK can kill;
ROBOT ARM MOVEMENT can cause serious
injury or death; INCORRECT PROCEDURES
from
cause
MOVING PARTS can
Keep away
from
cause
HOT SURFACES can
Allow
serious
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).
Injury.
moving parts.
cause severe
cooling period
before
burns.
touching gun.
MOVING PARTS
1.
Route cable
through supports
on
robot. The cable
connector end goes to the wire drive
remaining end goes to the gun.
Keep away
assembly while
HOT SURFACES
the
2.
Install cable connector into wire drive assembly (see
Motor/Drive Assembly Owners Manual).
3.
Slide
4.
Mark linerflush with gun
5.
Measure distance between mark made
gun onto liner
until liner seats inside gun.
Step
6.
welding
body
4 and brass nut on
protruding
from cable
and slide gun off liner.
on
liner in
IMPORTANT:
1.
2.
end of liner.
TION
(Figure 3-1)
4A
If
a
ELECTRIC SHOCK can kill;
WARNING:
ROBOT ARM MOVEMENT can cause serious
Injury or death; INCORRECT PROCEDURES
can cause
Injury.
Shut down
welding
power
source
mounting
bracket is used, the
to
Secure gun to Phi axis (or Axis 5) mount using
supplied socket head screws (see Figure 3-1).
mounting bracket
is used,
Phi axis mount
secure
bracket to
using supplied
socket
head screws.
3.
Slide liner from outlet cable into gun.
4.
Secure outlet cable to adapter by
cable onto adapter.
Connect touch
sensor
tightening
nut from
leads from gun to leads from
outlet cable. Connect leads from outlet cable to cord
and robot
at
gas/current sensing control or to matching
robot manipulator. Polarity is not
control, and disconnect input power employing
connector at
lockout/tagging procedures.
important.
Phi Axis
Gun
(Axis 5)
Phi Axis
3(1
touching gun.
mounting bracket is used, secure bracket
using supplied socket head screws.
manipulator
5.
Do not touch live electrical parts.
a
burns.
300
If a 30
MTX 3502 AND MTXW 5001 GUN INSTALLA
If
before
between gun and bracket.
gun
3-3.
can cause severe
bracket must be installed with offset to the right when
viewing the Phi axis mount. Be sure phenolic insulator is
cable.
The liner needs to be shortened by the length
measured in Step 5. Cut off measured length from
moving parts.
cooling period
Allow
serIous Injury.
can cause
from
Mounting
Plate
(Axis 5)
Plate)
Mount (Phenolic
Air-Cooled
Gun Shown
PhenoUc
Insulator
300
MountIng
Bracket
Gun
FIgure
3-1. MTX 3502 And MTXW 5001 Gun Installation
OM-1556 Page 3
Axis 6
Insulator
TB-135 146
3501 M Gun Installation
Figure 3-2. MTXC
MTXC 3501 M GUN INSTALLATION
3-4.
(Figure 3-2)
WATER
3-5.
Models
a
ELECTRIC SHOCK can kill;
WARNING:
ROBOT ARM MOVEMENT can cause serious
injury or death; INCORRECT PROCEDURES
can cause
4A
Injury.
Do not touch live electrical parts.
Shut down welding power
source
MOVING PARTS
Keep away
can cause
from
1.
A.
1.
cause severe burns.
Connections To Gun
Push
ring snaps
2.
To
release
locking
fitting.
ring
up
1.
Self-Contained, Recirculating Coolant System
cooling period before touching gun.
CAUTION:
until
Supply
INCORRECT
COOLANT
damage gun.
Use only coolant specified
in
will
recirculating
coolant system manual.
Do not use tap water, automotive antifreeze,
or
Secure 900 mounting bracket to gun using supplied
socket head screws.
3.
Secure 90
bracket to Axis 6 mount using
socket head screws.
supplied
4.
Secure outlet cable to
cable onto adapater.
nut from
5.
Connect touch sensor leads from gun to leads from
outlet cable. Connect leads from outlet cable to cord
adapter by tightening
gas/current sensing control
connector at
important.
Page
push
hose from
Connections To Coolant
screws.
OM-1556
hose,
B.
Instafl and secure insulatorto gun usingthe supplied
washers, lock washers, and socket head
at
down.
disengaged; pull
flat
2.
quick-disconnect fitting on water hose onto
titling at gun (see Figure 3-3) until locking
barbed
Injury.
moving parts.
HOT SURFACES can
Allow
serious
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.
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).
(Water-Cooled
CONNECTIONS
Only)
4
robot
or to matching
manipulator. Polarity is not
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.
2.
Utility Or Building Coolant System
MOVING PARTS
Route hoses from gun to coolant
drain.
b.
Connect one hose to coolant supply. Both hoses
have 5/8-18 left-hand male fittings.
c.
Route
remaining
supply
Keep away
and
a.
Allow cooling
hose to a proper drain.
ELECTRIC SHOCK can kIll;
WARNING:
ROBOT ARM MOVEMENT can cause serious
Injury or death; INCORRECT PROCEDURES
can cause
Injury.
moving parts.
can cause severe
period before
WIRE
can
burns.
touching gun.
cause
puncture
The welding wire and all metalparts in contact
with it are electrically energized when the
welding power source contactor is energized.
Injury.
Changing
the air-cooled gun to a water-cooled gun can
removing the gun from the robot. To
the gun from air-cooled to water-cooled,
be done without
Do not touch live electrical parts.
Shut down
serious
wounds.
3-6. FIELD INSTALLATION OF WATER-COOLED
NOZZLE ONTO AIR-COOLED GUN (MIX 3502 Mod
els Only) (Figures 3-3 And 3-4)
a
from
HOT SURFACES
WELDING
can cause
welding power
source
and robot
change
proceed
as
follows:
control, and disconnect input power employing
lockout/tagging procedures.
1.
Lockout/tagging procedures consistof 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).
Remove parts indicated in 3-4. Retain these parts
for future use.
2.
Installed
supplied water-cooled
Figure 3-3.
nozzle parts in the
order shown in
3.
See Section 3-5 for water connections.
Barbed
FittIng
U8e Nut8 Retained
From Air-Cooled
Nozzle
Install These Parts
1.
TIp Adapter
2.
Nut
3.
BushIng
4.
Baffle
5.
Contact Tip
InsulatIon Sleeve
Nozzle Body
6.
7.
TB-i 14 230
FIgure 3-3.
installatIon Of Water-Cooled Nozzle
OM-1 556 Page 5
Contact
1.
Tip
Nuts
*2.
5.
lip Adapter
Bushing
0-RIng
6.
Ceramic insulator
7.
Nozzle
3.
4.
Retain Nuts For Installation
Of Water-Cooled Nozzle
*
Remove These Parts
18.114 229
FIgure
3-4. Removal Of Air-Cooled Nozzle
SECTION 4- MAINTENANCE
4-1.
INSPECTION AND UPKEEP
a
Usage
WARNING:
ELECTRIC SHOCK can kill;
ROBOT ARM MOVEMENT can cause serious
Injury or death; INCORRECT PROCEDURES
can cause
Injury.
1.
shop
Inspect gun
as
Shut down welding power source and robot
control, and disconnect input power employing
2.
lockouttagging procedures.
frequency
and
phenolic plates
for broken areas,
required.
Carefully
remove
the nozzle
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).
can cause
conditions determine the
cracks, and loose parts; tighten, repair, and replace
Do not touch live electrical parts.
MOVING PARTS
and
and type of maintenance required. At minimum, inspect
welding gun and outlet cable monthly as follows:
serIous
weld spatter
or
dirt from around
opening.
3.
Repair or replace as required all hoses and cables;
give particular attention to frayed and cracked
insulation and areas where cables enter equipment.
4.
Remove grease and dirt from components, and
moisture from electrical parts and cables.
5.
Clean outlet cable liner using compressed air
whenever the wire is removed.
Injury.
Keep away from moving parts.
HOT SURFACES can cause severe burns.
Allow
cooling period before touching gun.
WELDING
WIRE
can
cause
puncture
wounds.
The welding wire and all metal parts in contact
with it are electrically energized when the
welding power source contactor is energized.
OM-1556
Page
6
a
CAUTION:
PARTICLES
FLYING
can
DIRT
injure
AND
METAL
and
personnel
damage equIpment.
Point outlet cable liner only in a safe direction
away from personnel and equipment when
cleaning with compressed air.
CONTACT TUBE REPLACEMENT
4-2.
4A
WARNING:
ELECTRIC SHOCK can kIll;
ROBOT ARM MOVEMENT can cause serious
Injury or death; INCORRECT PROCEDURES
ELECTRIC SHOCK can kill;
WARNING:
ROBOT ARM MOVEMENT can cause serious
Injury or death; INCORRECT PROCEDURES
can cause
can cause
Shut down
Injury.
welding power
source
lockout/tagging procedures.
Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
disconnect switch(es) in open position,
removingfusesfrom fuse box(es), or shutting off
and red-tagging circuit breaker(s) or other
disconnecting device(s).
MOVING PARTS can cause serious
MOVING PARTS
Keep away
injury.
burns.
WIRE
cause
can
puncture
Injury.
can cause severe
WIRE
before
can
burns.
touching
gun.
puncture
cause
The welding wire and all metalparts in contact
with it are electrically energized when the
welding power source contactor is energized.
wounds.
The welding wire and all metal parts in contact
with it are electrically energized when the
welding power source contactor is energized.
serious
moving parts.
cooling period
WELDING
wounds.
cooling period before touching gun.
can cause
from
HOT SURFACES
Allow
WELDING
and robot
disconnecting device(s).
Keep away from moving parts.
Allow
source
line disconnect switch(es) in open position,
removingfusesfrom fuse box(es), or shutting off
and red-tagging circuit breaker(s) or other
line
can cause severe
power
lockout/tagging procedures.
Lockout/tagging procedures consist of removing
input power plug from receptacle, padlocking
and robot
control, and disconnect input power employing
HOT SURFACES
welding
control, and disconnect input power employing
Do not touch live electrical parts.
Shut down
injury.
Do not touch live electrical parts.
1.
Cut off
welding wire
at contact
tube, and
retract from
gun.
1.
Remove nozzle.
2.
Disconnect touch
leads, and
remove
outlet
Disconnect touch sensor leads, and
cable from wire drive assembly.
remove
outlet
sensor
cable from gun.
2.
Cut off any portion of welding wire which extends
beyond end
welding wire.
of
contact
tube.
Manually
3.
retract
4.
3.
Remove contact tube.
4.
Install new contact tube and reinstall nozzle.
5.
Manually
5.
6.
thread
welding wire
Prepare
and install
new
outlet cable
as
instructed in
Section 3-2.
out of
new
contact
Slide liner from outlet cable into gun.
Secure outlet cable to adapter by tightening nut from
cable onto
adapter.
tube.
7.
4-3.
CHANGING WIRE SIZE
8.
When
changing
wire size, it is necessary to change the
contact tube and wire drive rolls, and may be necessary
to change the outlet cable. Obtain parts for wire size
desired, and proceed as follows:
Connect
touch
sensor
leads.
Polarity
is
not
important.
9.
Remove nozzle and contact tube from gun.
Install
new
contact
tube, and reinstall nozzle onto
gun.
10. Thread
welding
wire.
OM-1556 Page 7
SECTION 5- PARTS LIST
1
6
7
8
11
9
5
1~
11
14
B114
Figure
OM-1556 Page 8
5-1. MTX 3502 AIr Cooled Gun
229
1
Part
No.
Item
No.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Description
5-1. MTX 3502 AIr Cooled gun
113 883
FIgure
115 527
115 526
SCREW, cap
SCREW, cap
108 780
114 249
115 524
108 772
0-RING
-
-
hex hd 8MM x 1.25 x 15MM
skt hd M5 x .8 x 14mm
(S-25)
1
ADAPTER, brs
SCREW, cap skt hd 4MM
-
1
x
.7
x
12MM
768
776
778
777
ADAPTER, tip
INSULATION, bush
1
0-RING
1
784
NOZZLE
775
779
766
INSULATOR,
.112 470
.112 469
16
.112 468
17
108 789
17
.108 788
17
.108 786
17
.108 790
CONTACT TIP
17
.129 886
108 767
CONTACT TIP, .023 wire..
NUT
POWER SUPPLY WIRE, (consisting
PROTECTION TUBE
16
.108 793
16
.108 785
16
.112 471
19
114 251
108 770
1
1
1
1
1
1
cer
16
.110 854
1
(P12)
16
16
18
6
1
(No. 8)
NOZZLE (No. 7 short)
NOZZLE (No. 8 long)
NOZZLE(No.10)
NOZZLE (No. 6 short)
NOZZLE (No. 6 long)
NOZZLE (No. 7 long)
NOZZLE (fine)
CONTACT TIP (Q0.9)
CONTACT TIP (Q0.8)
CONTACT TIP (01.2)
16
1
6
MICROSWITCH
PACKING
SWITCH COVER
SHIM
0-RING (S-32)
BOOT, rbbr
108 773
108 774
108
108
108
108
108
108
108
108
Quantity
1
1
1
1
1
1
1
1
1
1
1
1
(01.6)
1
2
of)
1
Optional Equipment
OM-1556
Page
9
Part
No.
Item
No.
133 992
WIRE ASSEMBLY, pwr supply........
0-RING
HOOD
NOZZLE HOLDER ASSEMBLY
5
133996
6
108 789
6
.108 788
6
108
792
6
108 786
6
.113 954
6
.108 790
7
133 997
8
9
108 778
108 777
10
108 784
10
.110 854
10
108
10
108 785
133 993
11
5-2. MTXC-3501M Air Cooled Gun
FIgure
4
3
Quantity
132 296
135 496
133 995
133 994
2
Description
793
1
2
1
1
TIPBODY
CONTACT TIP, (00.8)
CONTACT TIP, (00.8)
CONTACT TIP, (01.0)
1
CONTACT TIP, (01.2)
CONTACT TIP, .045 wire
1
CONTACT TIP, (01.6)
INSULATION BUSHING
1
0-RING, (P12)
INSULATOR, cer
NOZZLE, (No 8)
NOZZLE, (No 7 short)
NOZZLE, (No 8 long)
NOZZLE, (No 10)
1
1
1
1
1
1
1
1
1
1
1
NOZZLE ASSEMBLY
1
..-
.....
>
2
4
2
6
7
I
I
I
11
I
I
S.
SB-125 145
FIgure
Optionai Equipment
OM-1556
Page
10
5-2. MTXC-3501 M AIr Cooled Gun
Part
No.
Item
No.
Description
Quantity
5-3. MTXW 5001 Water Cooled Gun
113 882
FIgure
1
115 569
CONVERSION KIT, air to water cooled nozzle (consisting of)
1
2
~ADAPTER,tip
1
4
114250
114 255
114 252
5
NUT
1
INSULATION, bush
1
114 253
BAFFLE
1
6
129886
1
6
113 954
6
7
113 955
CONTACT TIP, .023 wire
CONTACT TIP, .045 wire
CONTACT TIP, .062 wire
POWER SUPPLY CABLE, (consisting of)
PROTECTION TUBE
INSULATION SLEEVE
3
114 251
108 770
114 254
114526
114 257
113 950
082 368
010 607
8
9
10
11
12
13
17
056851
115527
115 526
108 780
18
114 249
19
115 524
108 772
108 773
108 774
14
15
16
20
21
22
108 775
108 779
108 766
23
24
25
108 767
120 975
26
1
1
1
1
1
NOZZLE, water cooled
FITTING, water
WATER HOSE, (consisting of)
CLAMP, hose
FITTING, hose-brs nut 5/8-18 LH
FITTING, hose-brs barbed nipple 3/16 TBG
SCREW, cap hex hd 8MM x 1.25 x 15MM
SCREW, cap skt hd M5 x .8 x 14mm
1
0-RING
1
2
2
1
1
1
.
1
-
6
-
(S-25)
ADAPTER, brs
SCREW, cap skt hd 4MM
-
1
x
.7
x
6
12MM
MICROSWITCH
PACKING
SWITCH COVER
SHIM
0-RING (S-32)
1
1
1
1
I
BOOT, rbr
1
NUT
TIP GAUGE
2
1
1
.23
25
B.114 230
FIgure 5-3.
MTXW 5001 Water Cooled Gun
OM-1556
Page
11