Miller Travel Master Owner's manual

MILLER ELECT-RI

718 S. BOUNDS ST, P.O. Box 1079

APPLETON, WI 54912 USA

ADDITIONAL COPY PRICE $1.10

NWSA CODE NO. 4579

PRINTED IN U.S.A.

n

RAN

EFFECTIVE: JUNE 1, 1979

This warranty supersedes all prevtous MILLER warranties and is ex-

clusive with no other guarantees or warranties expressed or implied.

LIMITED WARRANTY-Subject to the terms and conditions

hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants

to its Distributor/Dealer that all new and unused Equipment

furnished by Miller is free from defect in workmanship and

material as of the time and place of delivery by Miller. No war-

ranty IS made by Miller with respect to engines, trade ac-

cessories or other items manufactured by others. Such

engines, trade accessories and other items are sold subject to

the warranties of their respective manufacturers, if any All

engrnes are warranted by therr manufaciurer for one year from

date of original purchase.

Except as specified below, Miller’s warranty does not apply

to components having normal useful lrfe of less than one (1)

year, such as spot welder tips, relay and contactor potnts.

MILLERMATIC parts that come in contact wrth the welding

wire rncluding nozzles and nozzle insulators where failure does

not result from defect in workmanshrp or material.

*.

Miller shall be required to honor warranty claims on war-

ranted Equipment in the event of failure resulting from a defect

wrthtn the following periods from the date of delivery of Equrp-

ment to the original user:

1. Arc welders, power sources and components 1 year

2. Original main power rectifiers 3 years

(labor 1 year only)

3. All welding guns and feeder/guns. SO days

4. All other Millermatic Feeders.. 1 year

5. Replacement or repair parts, exclusive of labor 60 days

6. Batteries................................ 6months

provrded that Miller is notified In writing withrn thirty (301 days

of the date of such failure.

As a matter of general policy only, Miller may honor claims

submitted by the original user within the foregoing periods.

In the case of Miller’s breach of warranty or any other duty

with respect to the quality of any goods, the exclusive remedies

therefore shall be, at Miller’s option (1) repair or (2) replacement

or, where authorized in writing by Miller in appropriate cases, (3)

the reasonable cost of repair or replacement at an authorized

Miller service station or (4) payment of or credit for the purchase

price (less reasonable depreciation based upon actual use) upon

return of the goods at Customer’s risk and expense. Upon receipt

of notice of apparent defect or failure, Miller shall instruct the clai-

mant on the warranty claim procedures to be followed.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND

ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA-

TION AS TO PERFORMANCE, AND ANY REMEDY FOR

BREACH OF CONTRACT WHICH, BUT FOR THIS PROVISION,

MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,

CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING

ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF

FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO

ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX-

CLUDED AND DISCLAIMED BY MILLER.

EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN

WRITING, MILLER PRODUCTS ARE INTENDED FOR

ULTIMATE PURCHASE BY COMMERCIAL/INDUSTRIAL

USERS AND FOR OPERATION BY PERSONS TRAINED AND

EXPERIENCED IN THE USE AND MAINTENANCE OF

WELDING EQUIPMENT AND NOT FOR CONSUMERS OR

CONSUMER USE. MILLER’ WARRANTIES DO NOT EXTEND

TO, AND NO RESELLER IS AUTHORIZED TO EXTEND

MILLER’S WARRANTIES TO, ANY CONSUMER.

TABLE OF CQ

Section No.

Page No.

SECTION 1 - INTRODUCTION

1 - 1. General Information And Safety

...............................

1 - 2. Receiving-Handling

.........................................

1 -3. Description

................................................

SECTION 2 - INSTALLATION

2 - 1. Loca~on ...................................................

2 -2. Assembly ..................................................

2 - 3. Electrical Connections

.......................................

2 - 4. Meter Display Selection Procedure.

............................

2 - 5. Digital Meter Travel Speed Calibration Procedure

................

SECTION 3 - OPERATOR CONTROLS

3 -1. PowerSwitch

..............................................

3 - 2. Reset Circuit Breaker

........................................

3 - 3. Digital Travel Speed Meter

...................................

3 -4. P~otLight ..................................................

3 - 5. Weld Travel Direction Switch

.................................

3 - 6. Travel Speed Control

........................................

3 - 7. JogSwitch

................................................

3 - 8. Start/Stop Push Buttons.

....................................

SECTlON 4 - SEQUENCE OF OPERATIO

4 - 1. Carriage Control Operation

...................................

4 - 2. Shutting Down

.............................................

SECTION 5 - MAI TENANCE Et TROUBLESHOOTING

5 - 1. InspectionAndUpkeep ......................................

5 - 2. FuseProtection .............................................

5 - 3. Carriage And Side Beam Maintenance.

.........................

5 -4. General ....................................................

5 - 5. Troubleshooting Chart

.......................................

3

10

11

12

SECTION 1 - INT

Electrical

qeauirements

115 Volts AC

50/60 Hz.

Beam

Length*

a ft.

(2.4 m)

Weight

I

*Maximum Fixture Travel Length Is 5 Feet 10 Inches (1.77

meters)

Figure 1 - 1. Specifications

I

Crosrarm

TAO92 556

3666 Ibs. (1360 kg)

2626 Iba. (1190 kg)

Maximum

Recommended

Loading

Condition

Safe

Operating

Zone

2260 Iba. I1020 kg)

1875 lbs. (860 kg)

1600 Ibs. 1680 kg)

1126 lbs. (510 kg)

375 Ibs. (170 kg)

(ZO

cml

0 Ibr. (0 kg)

2 ft.

Front

(61.0

Of

cm) cm)

cm)

Track

LOAD WEIGHT

CENTER OF MASS DISTANCE

FROM FRONT OF TRACK

TAQSZ 556

INCORRECT CARRIAGE

cause personal injury and equip-

ment damage.

e

Nat effective loading

mu

downward direction.

Total load weight must

operating zone c on

The carriage will not

t UP

LOADING SAFETY CHECK:

1.

Estimate combined weight of all act

ories and distancs of center

of mass from front of track.

2.

Check values against chart. Loading condition must fall within saf

operating zone curve.

3.

Adjust weight/distance if necessary.

Figure 1 - 2. Weight And Dist

When Carriege Is At Max-

imum Travel-To-Right Poei-

tion.

**Add 9-l/2 in. (241.3 mm)

For Spool Support Bracket.

n Additional 21 in.

mm) For Optional

Spool Support And Reel.

TD-092 554

ONi-970 Page 2

figure 1 - 3. Dimensional View

1 - 1. GENERAL INFORMATION AND SAFETY

A. General

information presented in this manual and on various

labels, tags, and plates provided on this unit pertains to

equipment design, installation, operation, maintenance,

and troubleshooting which should be read, understood,

and followed for the safe and effective use of this equip-

ment.

6. 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 such as, but not limited to, those listed at

the end of Section 1 - Safety Rules For Operation Of

Arc Welding Power Source in welding power source

Owner’s Manual.

Safety instructions specifically pertaining to this unit ap-

pear throughout this manual highlighted by the signal

words

m and

1 .

which identify

different levels of hazard.

m statements include installation, operating,

A l

and maintenance procedures or practices which if not

carefully followed could result in serious personal injury

or loss of life.

m statements include installation, operating,

.

a

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,

highlights instruc-

tions which need speciai emphasis to obtain the most

efficient operation of this equipment.

1 - 2. RECEIVI G - Prior to installing

this equipment,

g material from around

the unit and carefully inspect for any damage that may

have occurred during shipment. Any claims for loss or

damage that may have occurred in transit must be filed

by the purchaser ith the carrier. A copy of the bill

of lading will be furnished by the manufacturer on re-

quest if occasion to file ciaim arises.

When requesting information concerning this equip-

ment, it is essentiai that Model Description and Serial

Number of the equipment be supplied.

1 - 3. BESCRIPTIO

This unit is a heavy duty linear prime mover designed

and built for manufacturing applications requiring

straight horizontal movements at precisely controlled.

variable speeds. Positive linear drive occurs through a

worm reducer and rack and pinion with direct English or

metric speed displayed on a digital panel meter.

A simple lever is provided to disengage the drive pinion

from the carriage beam rack and thus allow manual

movement of the carriage. Equipment may be mounted

from the holes provided in the front face, the top sur-

face, the crossarm, or from all of these surfaces. Car-

riage loading must be in a downward direction and

within the safe operating zone curve for weight and

distance used according to Figure 1-2.

This unit is not recommended for ap-

plications requiring continuous High-Frequency power.

High frequency may be used for arc starting only.

SECTION 2 - INST

TION

2 - 1. LOCATION

The service life and efficiency of this unit and associated

components will be reduced if they are subjected to

high levels of dust, dirt, moisture, corrosive vapors, and

extreme heat.

\

Provide a suitable location that will allow sufficient

room for full carriage travel as well as room to open the

front panel (on control) and to remove wrapper(s) and

components for installation, inspection, maintenance,

and repair functions.

Mounting holes are provided on the carriage and

crossarm for installing desired equipment.

2 - 2. ASSEMBLY (Figure 2-l)

N IMPROPER LIFTING OR INSTALLING

0

OF’ EQUIPMENT can cause personal injury and

equipment damage.

l

Use equipment of adequate capacity to lift com-

ponents.

l

Use only bolts and fasteners of adequate capacitv

to assemble and install unit.

1.

2.

3.

4.

5.

Place track mount floor stands in approximate

mounting location.

Install cross bracing angles onto floor stands us-

ing the five supplied 1 /Z-13 x 1 -I /4 hex head

bolts and associated hardware (see Figure 2-I 1.

Install the two 3/4-16 x 2 in. leveling bolts and

associated hardware onto beam support pads

(see Figures 2-l and

Install beam onto suppocr pads (see Figures 2-l

and 2-2) using the eight supplied 1/2-l 3 x l-1 l4

in. socket head bolts and hardware: level beam.

Secure track mount floor stands to floor (hard-

ware not supplied) and level unit if desired.

FALLING BEAM ASSEMBLY can cause

serious personal injury and equipment damage.

Use 3/4 in. j19.05 mm) diameter SAE grade 5

noncorrosive steel bolts for securing track mount

floor stands to floor.

OM-870 Page 3

Track Mount

Clearance HOC For 314 in.

(19.1 mm) Dia. Bolt (4 Holw Total)

Thrmd&I Hole

For 112-13 Bolt

(4 Holes Total)

TD-092 557

Figure 2 - 1. Component Assembly

OM-870 Page 4

Seam

Safety

6.

7.

8.

Hex Head

support

Upright

TA-092 555

Figure 2 - 2. Beam Leveling

Push carriage locking lever (see Figure 2-3)

downward and in toward carriage until it locks in

place.

Install carriage on track by lowering it vertically

from above or by feeding it horizontally in from

either end of the beam (when end installing,

remove safety stop: reinstall safety stop after car-

riage is installed). Lower front portion of the car-

riage should be tipped upward slightly to facilitate

loading.

Manually move carriage from one end of track to

the other. Carriage travel should be smooth and

without scraping or obstruction.

9. Observe contact surfaces of front and rear rollers

at track running faces. Insert or remove 2C9G.4.

shims behind roller mounts until roller surfaces

are parallel with track and all rollers are in contact

(see Figure 2-3).

On non-machined’ track sections, it

will probably be necessary to check roller contact at

several positions along the track and then reach a com-

promise shim condition. Abays use a straight edge to

insure that the roller side faces are parallel to each other

after removal and reinstallation for shimming. (See fur-

ther discussion in TROUBLESNOOTING Section of this

manual under “CLIMBING” problems. I

10. Position carriage near center of track and engage

drive pinion by moving engagement lever to the

up position. Try to move carriage manually to be

sure pinion teeth are engaged in rack on carriage

track.

11. Adjust gear backlash between pinion and rack as

follows:

a.

Rotate adjustment nut (see Figure 2-3)

counterclockwise (outward) until washer

moves freely between nut and plate.

b . Rotate adjustment nut clockwise (inward)

until clearance at washer is removed -- then

rotate nut an additional l/4 to l/2 turn

clockwise.

Roller

Four Drilled And Tappod Wire Spool Support Bracket

Mounting Holes - Use l/4-20 x 314 in. Bolts And

Lock Washers

I

Shims

TAXIS2 874

orvl-870 Page 5

12.

c . Examine gear mesh between pinion and rack

from beneath carriage. A very slight amount

i.002 to .005 in.; .05 to .I3 mm) of gear

backlash is desirable and should be apparent

as carriage is moved left or right manually.

Adjust pinion gear vertically on gear box output

shaft to align with gear rack by loosening

setscrew and moving gear up or down as

necessary. Tighten setscrew when alignment is

complete.

The crossarm may be shortened (cut

off) if it extends beyond equipment and application

needs. If desired, cut off crossarm to desired length

before installing onto unit

13. Install crossarm onto carriage face as shown in

Figure 2-1 using the four supplied I/2-13 x

4-I /2 in. hex head bolts and hardware.

14. Install control box bracket onto crossarm using

the two supplied 3i8-16 x 3/4 in. bolts and hard-

WX@.

15. Install control box onto crossarm bracket as

shown in Figure 2-l using the four supplied

f /4-20 x l/2 in. bolts and hardware.

1

6. As applicable, install cross slide(s), swivel

mount, and motor/drive assembly onto

orosaarm at desired location (mounting holes are

provided; use the four supplied 3/8-16 x 1 in.

bolts and hardware for mounting motor/drive

assembly). The welding gun mounts in the

motor/drive assembly.

Various wire spool support mounting

iocaaons afe provided. The spool support can be

mounted directly onto the carriage top or onto the sup-

plied spool support bracket. The spool support can also

be mounted inclining backward or forward. Be sure to

position components so that the wire feeds straight

down into the drive assembly. Choose the desired loca-

tion and mount applicable components according to the

following instructions.

i7. If desired, install supplied spool support bracket

onto carriage as shown in Figure 2-l using sup-

plied l/4-20 x 3/4 in. bolts and lock washers.

18. Install wire spool support onto support bracket

(or top of carriage) using the four supplied

t 14-20 x 1 in. bolts and hardware (use l/4-20 x

3i4 in. bolts and lock washers for installing onto

top of carriage).

lg. Install automatic weld control mounting bracket

onto carriage using the four supplied 3/8-16 x

3/4 in. bolts and lock washers (see Figures 2-l

and 2-3).

20. If applicable, install automatic weld control onto

bracket using the four supplied 5/16-18 x 1 in.

bolts and hardware.

21.

22.

If applicable, install gas control assembly onto

top of automatic weld control bracket using the

supplied l/4-20 x l/2 in. bolts and hardware

(see Figure 2-l ).

If applicable, install optional flux hopper onto

motor/drive assembly using the two supplied

3/8-16 x 3/4 in. bolts and lock washers (flux

hopper mounts onto right of drive assembly in

the two unused holes). Install any associated flux

hopper equipment.

2 - 3. ELECTRICAL CONNECTIONS (Figures 2-4,

2-6, and 2-6)

Side View

Of Unit

115 Volts AC Input

Power And Contector

Control Cord

Limit Switch And

Remote Start And

Stop Cords

Carriage Motor

Control Receptacl

TAG2 543

figure 2 - 4. Side View For Electrical Connections

ELECTRIC SHOCK can kill; MOVING

cause serious injury and equip-

ch live el&trical parts.

Shut down welding power source or disconnect

input power as applicable before making connec-

tions.

A. For Models With An Automatic Weld Con-

trol (Figures 2-4 And 2-5)

1.

2.

3.

4.

Connect 4-pin Amp plug on end of 115 volts

ac input power and contactor control cord

(see Figure 2-4) to corresponding receptacle

on supplied (loose) 115 vat and contactor

control interconnecting cord.

Connect remaining ends of interconnecting

cord from Step 1 to proper receptacles on

welding power source.

Route 115 volts ac output cord (see Figure

2-4) with 4-pin Amp plug attached to weld

control and connect plug to 115 vat and

contactor control receptacle on side of weld

control (see weld control Owner’s Manual

for location).

Route 2-conductor limit switch cord (see

Figure 2-4) to carriage limit switch and con-

nect white lead to tS common terminal and

black lead to LS normally-closed terminal.

OM-870 Page 6

5. Open weld control front panel and route

4-conductor remote start and stop cord (see

Figure 2-4) through side strain relief connec-

tor into unit,

6. Make remote start and stop connections as

follows:

For Automatic 1 D Models: Remove jumper

link between terminals F and E on terminal

strip 1T. Connect black lead to terminal F

and white lead to terminal H on terminal strip

1T.

For Automatic 1 Models: Remove jumper

link between terminals G and H on terminal

strip 1T. Connect black lead to terminal H

and white lead to terminal K on terminal strip

1T.

m

l ,* 1

These connections provide weld c ycie

remote start and stop con&o/ from the Travel Master

front pane/ push buttons (and carriage limit switch).

Start operation begins when the Travel Master START

button is depressed. Stop is accomplished by depress-

ing the Travel Master STOP button or having carriage

movement actuate the limit switch - whichever occurs

first.

7. Connect red and green leads with female

friction connectors attached to terminals F

and H on receptacle RC4 (RC4 is located at

rear of timer panel at bottom of weld con-

trol - the receptacle and terminals are

labeled - the timer panel is connecting to

RC4).

m These connections will cause the car-

‘,’ A

riage to start moving at arc initiation and stop when the

limit switch is actuated or the Travel Master STOP but-

ton is pressed. if other conditions, such as carriage

movement start at run-in are desired, see the automatic

weld control Owner’s Manual for connection informa-

tion.

m Dclpressing the START button begins

9)’ L

the weld cycle but not necessarily carriage movement

unless the unit is so connected. Preflow (and run-in) will

occur first depending on connections. Carriage move-

ment does not begin until the automatic weld control

reaches the selected point in the weld cycle. When fix-

ture movement stops, crater, burnback, and postfiow

occur as governed by the weld control and connections.

8.

9.

10.

Close and secure automatic weld control

front panel door.

Connect one end of supplied (loose) inter-

connecting motor cord with amphenol plugs

attached to receptacle on carriage motor

cord.

Connect remaining end of interconnecting

motor cord to carriage motor control recep-

tacle (see Figure 2-4).

11. Affix supplied adhesive-backed cord retain-

ing tab onto left roller bracket under carriage

and route motor cord and limit switch cord

through retaining tab.

Four metal cushion clamps and sup-

plied or existing mounting hardware are provided to

secure the interconnecting cords. The clamp locations

will be determined by the specific application. Approx-

imate recommended locations follow.

12.

13.

14.

15.

Install two clamos onto left side of crossarm

with supplied 3j8-16 x 3/4 in. bolts and lock

washers.

Route cords from the control down the

crossarm to the carriage and secure cords in

clamps.

Route cords on and off carriage (the cords

that leave the carriage can be routed off the

back).

Install remaining two clamps onto carriage at

desired locations with existing hardware and

secure cords in clamps.

Five nylon cable ties are supplied to

secure cords together as necessary.

16. Using supplied cable ties, secure cords

together to maintain a proper cord dress

around components and to avoid contact

with moving parts.

.

For Models

n Automatic

d

Controi (Figures 2

-61

If applicable, terminal strips TS 7 and

TS2 are located inside control box. Remove wrapper

securing screws, pivot front panel/wrapper down, and

route leads through strain relief connectors to strips.

Close and secure front panel/wrapper when finished

connecting.

1. Connect input supply power to the 115 volts

ac and contactor control cord plug or

remove cord set and connect directly to in-

ternal terminal strips as follows:

Pin 1 - Black Lead - One Side Of 115 VAC

Supply - TSl Terminal 1

Pin 4 - Red Lead - Other Side Of 115 VAC

Supply - TS2 Frontmost Spare Terminal

Pin 3 - Green Lead - Chassis Ground - GRD

Terminal To Left Of TSl

Pin 2 - White Lead - Contactor Control - TSI

Terminal 2

(Pins 2 and 4 supply 115 vat output for con-

tactor control when using automatic weld

OM-870 Page 7

Power Source

Automatic

Weld Control

actor Control

Four-Conductor

Cord

T8-092 542

interconnection Diagram With Automatic Weld Control

controls. Pin 2 is connected directly to Pin 2

of cord set in Step 2 and serves no internal

function in this control.)

2. Connect control equipment to 115 vat out-

put and contactor control cord plug (see

Figures 2-4 and 2-6) or remove cord set and

connect directly to internal terminal strips as

follows:

Pin 1 - Black Lead - One Side Of 115 VAC

Supply - TSl Terminal 3

Pin 4 - White Lead - Other Side Of 115 VAC

Supply - TSl Terminal 2

Pin 3 - Green - Chassis Ground - GRD Ter-

minal To Left Of TS1

Pin 2 - Red - Contactor Control - TS2 Front-

most Spare Terminal

(Pins 2 and 4 supply 115 vat for contactor

control when using automatic weld controls.

Pin 2 is connected directly to Pin 2 of cord

set in Step 1 and serves no internal function

in this control.)

3. Route 2 - conductor limit switch cord (see

Figure 2-4) to carriage limit switch and con-

nect white lead to LS common terminal and

black lead to LS normally-closed terminal.

4. Route and connect 4-conductor cord (see

Figure 2-4) to desired equipment as follows:

The black and white leads provide a set of

normally-open maintained contacts that

close when the START button is pressed

and open when the STOP button is pressed

or the limit switch is actuated. Connect

equipment accordingly.

The red and green leads provide the equip-

ment signal for carriage movement control.

Connect a switch or set of relay contacts

between the red and green leads. A closure

starts carriage movement and an open stops

carriage movement (provided that the

START button on the carriage control was

depressed). Connect equipment according-

ly*

OM-a70 Page 8

115VAC And

Contactor Control

Input

Cord

Interconnectin .

Control Cord

Two-Conductor

Limit Switch

Cord

TN92 542

Figure 2 - 6. Interconnection Diagram Without Automatic

5. Connect one end of supplied (loose) inter-

connecting motor cord with amphenol plugs

attached to receptacle on carriage motor

cord.

6. Connect remaining end of interconnecting

motor cord to carriage motor control recep-

tacle (see Figure Z-4).

7. Affix supplied adhesive-backed cord retain-

ing tab onto left roller bracket under carriage

and route motor cord and limit switch cord

through retaining tab.

w Four metal cushion clamps and sup-

9,’ 1

plied or existing mounting hardware are provided to

secure the interconnecting cords. The clamp locations

will be determined by the specific application. Approx-

imate recommended locarions follow.

8.

9.

10.

11.

Install two clamps onto left side of crossarm

with supplied 3/8-16 x 3/4 in. bolts and lock

washers.

Route cords from the control down the

crossarm to the carriage and secure cords in

clamps. ;

Route cords on and off carriage (the cords

that leave the carriage can be routed off the

back).

Install remaining two clamps onto carriage at

desired locations with existing hardware and

secure cords in clamps.

m Five nylon cable ties are supplied to

.(’ L

secure cords together as necessary.

12.

Using supplied cable ties, secure cords

together to maintain a proper cord dress

around components and to avoid contact

with moving parts.

ELECTRIC SHOCK can kill.

uch live electrical parts.

Shut down unit and disconnect input power

before making internal adjustments.

The unit is shipped with the digital meter set to display

inches per minute (ipm). To select or change meler

display mode, proceed as follows:

1.

Remove the four control box wrapper securing

screws.

2.

Pivot front control panel with wrapper forward

and down to open it fully (the control

panel/wrapper is hinged on the bottom front

edge).

3.

Locate the two-position switch on rear of digital

meter.

4.

Place switch in desired position: IPM (inches per

minute) or CMM (centimeters per minute).

5.

Pivot control panel/wrapper closed and reinstall

securing screws.

6.

Reconnect power and resume operation.

The digital meter will require calibration if it is replaced

or if the speed range of the drive assembly is changed.

To calibrate the meter, proceed as follows:

SHOCK can kill.

Do not touch live

c tfical parts.

Calibration procedures must be performed by qualified

persons only. The unit will be electrically live during

these procedures.

OM-870 Page 9

1.

2.

3.

4.

5.

6.

Position the carriage near the left hand extreme

of its travel: be sure that the drive gear is still

Direction switch set

IN - CM/MIN switch

for desired units

(

Reference the carriage starting point with a

scribe line on the carriage track.

Rotate the TRAVEL SPEED control to its

midrange position. Do not readjust this setting

throughout the calibration.

Start carriage drive and a stopwatch or other ac-

Curate timing device simultaneously.

Stop carriage drive after exactly 30 seconds

elapsed time.

Measure the travel distance from the start point

(marked in Step 21 to the stop point. Multiply

this distance by two (2) and record the value.

7.

8.

9.

10.

11.

Remove the four control box wrapper securing

screws and pivot front control panel with wrap-

per forward and down to open it fully (the con-

trol panel/wrapper is hinged on the bottom front

edge).

Locate calibration trimmer potentiometers on

board PC2 behind digital speed meter.

Disengage the drive and press the START but-

ton. The motor will now run, but the carriage will

remain stationary.

Adjust calibration potentiometer VRl so that

reading on the digital speed meter matches the

value recorded in Step 6. Stop carriage drive.

Recheck travel speed (Step 6).

Calibration potentiometers VR2 and

VR3 are factory set and require no adjustment. The

IN/MN - CM/MIN conversion will automatically be

correct when the above procedures are performed as in-

structed.

12.

TiON 3 - 0 ATOR

Pivot control panel/wrapper closed and reinstall

securing screws.

CONTROLS

pilot

/Light

TA-092 873

Figure 3 - 1. Front

Placing the POWER switch in the ON position applies

115 voits ac to the unit and places it in an operational

condition. The pilot light will come on and the meter

display will illuminate. Placing the POWER switch in the

OFF position shuts the unit down.

overload condition, the breaker would trip and suspend

all output. Should this breaker trip, the RESET button

would have to be manually depressed to reset it.

3 - 3. DIGITAL TRAVEL SPEED METER (Figure

3-l)

3-2. R

AKER

(Figure 3-l) - A

circuit breaker provides protection to the carriage

motor. In the event the motor should be placed in an

This meter displays the carriage travel speed in either in-

ches per minute (ipm) or centimeters per minute (cmm)

depending on the display mode selected.

The meter will display 000 when the carriage is not

moving. To preset travel speed, disengage carriage

locking lever, depress JOG switch, and rotate TRAVEL

SPEED control until meter displays desired speed. Our-

ing operation the meter displays actual carriage travel

speed.

3 - 4. PILOT LIGHT (Figure 3-I)

The pilot light, when illuminated, indicates that the

POWER switch is in the ON position and that the unit is

in a ready-to-operate condition.

3 - 5. WELD TRAVEL DIRECTION SWITCH

(Figure 3-l 1

This switch is a three-position switch that selects the

direction of carriage travel. The travel directions (LEFT

or RIGHT) are indicated on the nameplate. In the OFF

(center) position, the carriage will not move either way

but rather remain stationary.

m CHANGING POSITION OF WELD

L

e

TRAVEL DIRECTION SWITCH while carriage is

moving can damage unit.

0

Allow carriage to stop completely before changing

direction of movement.

*

Do not change position of WELD TRAVEL

DIRECTION switch (except to OFF1 while carriage

is moving.

3 - 6. TRAVEL SPEED CONTROL (Figure 3-l)

This control is a ten-turn potentiometer which provides

a means of selecting the rate at which the carriage will

move on the side beam. Rotating the TRAVEL SPEED

control in a clockwise direction increases the rate of car-

riage travel speed. The selected speed will be displayed

on the digital meter.

This control can be adjusted while the

carriage is

in motion.

3 - 7. JDG SWITCH (Figure 3-l)

The JOG switch is a spring-loaded toggle switch. When

actuated, it completes the circuit to the carriage motor

without having to depress the START button. This

switch permits moving of the carriage in the selected

direction at whatever TRAVEL SPEED is selected

without depressing the START button. For this switch

to be functional, the POWER switch must be in the ON

position. When the JOG switch is released, the carriage

will stop. The JOG switch is not functional once car-

riage movement has staned.

3 - 8. START/STOP PUSH BUlT0 (Figure 3-l)

The START/STOP push buttons provide on/off control

of carriage movement. The POWER switch must be in

the ON position, the control must have power supplied,

and any external controls must be ON for these push

buttons to be functional. Depressing the START button

puts the unit in a ready state waiting for a command to

start moving from the automatic weld control or user

supplied equipment. Depressing the Stop button stops

the carriage and signals the automatic weld control or

user supplied equipment to finish the weld.

SECTION 4 - SEQUENC

OF OPERA-I-IQ

m ELECTRIC SHOCK can kill; MOVING

. l

PARTS can cause injury.

l

Do not touch live electrical parts.

l

Keep clear of pinch points.

4 - 1. CARRIAGE CONTROL OPERATION

5. Turn on all associated equipment and set

6.

welding parameters.

Depress the START push button (see Section

3-8) and begin operation.

1.

2.

3.

4.

4 - 2.

SHUlTlNG DO

Install the unit as instructed in Section 2.

i

Place WELD TRAVEL DIRECTION switch in

desired position (see Section 3-5).

1.

2.

Depress the STOP push button (see Section 3-8)

and wait for the operation to be completed.

Place the POWER switch in the OFF position.

Place POWER switch in the ON position (see

Section 3-l).

Rotate TRAVEL SPEED control to desired posi-

tion (see Section 3-6).

3.

Turn off all associated equipment.

SECTION 5 - MAINTENA

CE & TROUBLE

m Periodically inspect the labels on this

.,’ ‘

ELECTRIC SHOCK can kill; HOT

unit for feaibilitv. All orecautionarv labels must be main-

SURFACES can burn skin.

tained in “a cle’arly readable state and replaced when

necessary. See the Parts List for part number of precau-

tionary labels.

Disconnect unit from input power before internal-

iv inspecting or servicing.

Allow gun and unit to cool before touching.

5 - 1. INSPECTION AND UPKEEP - Usage

shop conditions will determine the frequency and

of maintenance. Inspect equipment as follows:

and

type

1. Repair or replace, as required, all cables; give

particular attention to frayed and cracked insula-

tion and areas where it enters equipment.

OM-870 Page 11

2. Remove grease and grime from components;

moisture from electrical parts and cables.

5-2. FU

TECTI

igure 3-I)

The control is protected from damage due to an internal

shofl or excessive overload by fuse F’l . Should Fl open,

the cantrol would be completely inoperative.

G&

D

SIDE

. BEA

A

Basic maintenance for this unit should include the

following procedures:

1. Keep all machinery clean. Blow dust, ac-

cumulated weld spatter, etc., from carriage, aux-

iliary equipment, and especially from running

ways and gear rack on

.

track. Do not

lubricate ways or gear ra

motes dirt accumulation.

lubrication pro-

2. Worm gear reducer has been filled with the pro-

per oil prior to shipment. After the first 100 hours

of operation and then every 2500 hours, oil

should be drained and replaced. Drive assembly

must be removed from the carriage to provide

access to fill and level plugs. Refill reducer to

level hole with AGMA No. 8EP or oil of equal

viscosity and composition. Be sure to check oil

level if leaks are noticed.

3. Inspect drive pinion and track monthly for signs

of abnormal alignment and wear. Reference the

TROUBLESHOOTING section in this manual if

problems occur.

No pilot light or meter

displav with POWER switch

ON.

Pilot light on but no meter

Carriage does not move

when JOG switch is ac-

tivated .

4.

5.

Inspect cables and hoses for tangling, kinks, or

damage. Replace cables or hoses found to be

defective.

Check carriage and auxiliary equipment every 3

to 6 months for loose or damaged components.

Repair or replace the components to insure safe,

efficient operation.

5 - 4. GENERAL - It is assumed that proper installa-

tion has been made, according to Section 2 of this

manual, and that the unit has been functioning properly

until this trouble developed.

5 - 5. TROUBLESHOOTING CHART

ELECTRIC SHOCK can kill.

o not

touch live electrical parts.

Disconnect unit from input power before internal-

ly inspecting or servicing.

Troubleshooting of internal parts to be performed only

by qualified persons.

The following chart is designed to diagnose and provide

remedies for some of the troubles that may develop in

this unit.

Use this chart in conjunction with the circuit diagram

and the instructions in this manual while performing

troubleshooting procedures. If the trouble is not

remedied after performing these procedures, the

nearest Factory Authorized Service Station should be

contacted. In all cases of equipment malfunction, the

manufacturer’s recommendations should be strictly

followed.

PROBABLE CAUS

No 115 vat input power.

Fuse Fl open.

Loose meter plug.

Defective meter.

Defective meter calibration

board PC3.

Drive assembly not engag-

ed.

WELD TRAVEL DIREC-

TION switch S2 in OFF

position.

Motor circuit breaker CBl

on front panel tripped.

Defective SCR control

board PC2.

Check fuse Fl on front panel: replace if open.*

Check and secure plug at meter base.

Replace meter.

Replace PC3.

Engage drive assembly.

Place direction switch S2 in RIGHT or LEFT posi-

tion.

Reset circuit breaker C81.

Replace PC2.

or+a70 Page 12

motor.

button is depressed.

Carriage speed erratic or

not controllable.

Digital meter display erratic

or not functioning.

Improper gear mesh (too

Check and correct gear mesh and/or binding con-

tight) or binding on track. dition (see Section 2-2).

motor: loose connections.

Be sure electrical connections are correct and

TRAVEL SPEED poten-

Check potentiometer R2 and replace if necessary.

tiometer R2 defective.

board PC2.

Loose plug connection at

Check and secure meter plug connection.

rear of meter.

I

Defective meter. Replace meter.

Defective tach-generator Replace motor assembly.

system on motor.

Digital speed display inac-

curate.

IPM/CMM switch S4 in

Place switch S4 in correct position (see Section

wrong position.

2-5).

Carriage “climbs” vertically

up track during horizontal

motion.

Excessive loading.

Reduce loading to safe operating range (see

Figure l-2).

Align roller assemblies by placing a straight edge

across roller side faces (see Section 2-2).

Excessive loading.

1 Reduce loading to safe

operating

range (see

OM-870 Page 13

Excessive prnlon wear.

Drive frequently jumps out

of gear or trips circuit

breaker.

defective units.

“Be sure replacement fuse is same size, type, and rating.

GOWER IT-4

Figure

- 1. Circuit Diagram

Circuit Diagram No.

B-092 872

OM-870 Paae 14

Oh%870 Page 1

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