Miller JJ503984 Owner's manual

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www.MillerWelds.com

Weld Oscillator

Processes

Description

Automatic Welding System

Automatic Welding

OM-1085 052 563E

January 1996

Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

products, contact your local Miller distributor

to receive the latest full line catalog or

individual catalog sheets. To locate your nearest

distributor call 1-800-4-A-Miller.

Thank you and congratulations on choosing Miller. Now

you can get the job done and get it done right. We know

you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc

welders in 1929, he made sure his products offered

long-lasting value and superior quality. Like you, his

customers couldn’t afford anything less. Miller products

had to be more than the best they could be. They had to

be the best you could buy.

Today, the people that build and sell Miller products continue the

tradition. They’re just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They will

help you protect yourself against potential hazards on the worksite. We’ve

made installation and operation quick and easy.

With Miller you can count on years of reliable

service with proper maintenance. And if for

some reason the unit needs repair, there’s a

Troubleshooting section that will help you

figure out what the problem is. The parts list

will then help you to decide which exact part

you may need to fix the problem. Warranty and

service information for your particular model

are also provided.

Miller is the first weld-

ing equipment

manufacturer in the

U.S.A. to be registered

to the ISO 9001 Quality

System Standard.

Working as hard as

you do − every power

source from Miller is

backed by the most

hassle-free warranty

in the business.

From Miller to You

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols for Installation, Operation, and Maintenance 3. . . . . . . . . . . . . . . . . . . . . .

1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − INSTALLATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Load Data 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Oscillating Slide Dimensions 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Oscillator Control Dimensions 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Installing Gun Onto Mounting Plate 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Installation Of Customer-Supplied Remote Controls 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. Interconnecting, Oscillator Control, and Power Cord Connections 14. . . . . . . . . . . . . . . . . . . . .

2-8. Travel Width And Center Position Internal Adjustment 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − OPERATION 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Controls 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − MAINTENANCE 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Routine Maintenance 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Overload Protection 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Slide Lubrication 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Drive Belt Adjustment 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Slide Potentiometer Replacement 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Troubleshooting 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − ELECTRICAL DIAGRAM 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − PARTS LIST 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

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OM-1085 Page 1

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_5/97

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

Y Marks a special safety message.

. Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see

the symbol, watch out, and follow the related instructions to

avoid the hazard. The safety information given below is only

a summary of the more complete safety information found in

the Safety Standards listed in Section 1-4. Read and follow all

Safety Standards.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks

or severe burns. The electrode and work circuit is

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. In semiautomatic or automatic wire welding, the

wire, wire reel, drive roll housing, and all metal parts touching the

welding wire are electrically live. Incorrectly installed or improperly

grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present on

unit.

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable − do not use work clamp or work cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes. Do not breathe the fumes.

D If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.

D Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings,

cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld

area, the area is well ventilated, and if necessary, while wearing an

air-supplied respirator. The coatings and any metals containing

these elements can give off toxic fumes if welded.

OM-1085 Page 2

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Sparks fly off from the

weld.

ARC RAYS can burn eyes and skin.

D Wear a welding helmet fitted with a proper shade of filter to protect

your face and eyes when welding or watching (see ANSI Z49.1

and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (leather and wool) and foot protection.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is

safe before doing any welding.

WELDING can cause fire or explosion.

D Protect yourself and others from flying sparks and hot metal.

D Do not weld where flying sparks can strike flammable material.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock and fire hazards.

D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.

D Wearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise level is

high.

Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since

gas cylinders are normally part of the welding

process, be sure to treat them carefully.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder − explosion will result.

D Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

OM-1085 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,

using line filters, or shielding the work area.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American

Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-

dent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, American

Welding Society Standard AWS F4.1, from American Welding Society,

550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face

Protection, ANSI Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-1085 Page 4

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera-

tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi-

ble.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,

then following the above procedures is recommended.

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OM-1085 Page 8

1-4. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-

ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent

of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practice for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, norme AWS

F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL

33126

National Electrical Code, NFPA Standard 70, de la National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

de la Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Règles de sécurité en soudage, coupage et procédés connexes, norme

CSA W117.2, de l’Association canadienne de normalisation, vente de

normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-

tion, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les effets, pour l’organisme,

des champs magnétiques basse fréquence

Le courant de soudage, pendant son passage dans les câbles de sou-

dage, causera des champs électromagnétiques. Il y a eu et il y a encore

un certain souci à propos de tels champs. Cependant, après avoir ex-

aminé plus de 500 études qui ont été faites pendant une période de

recherche de 17 ans, un comité spécial ruban bleu du National Re-

search Council a conclu: “L’accumulation de preuves, suivant le

jugement du comité, n’a pas démontré que l’exposition aux champs

magnétiques et champs électriques à haute fréquence représente un

risque à la santé humaine”. Toutefois, des études sont toujours en cours

et les preuves continuent à être examinées. En attendant que les con-

clusions finales de la recherche soient établies, il vous serait

souhaitable de réduire votre exposition aux champs électromagnéti-

ques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement

de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur.

3 Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

4 Garder le poste de soudage et les câbles le plus loin possible de

vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout

consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est

alors recommandé de respecter les consignes ci−dessus.

OM-1085 Page 9

SECTION 2 − INSTALLATION

2-1. Specifications

Input

Speed

Dwell

Total Slide

Width

Center

Weight

Input

Power

pee

Total Slide

Travel

Wid

Center

Adjustment

Item Net Ship

115 Volts AC

Control 27 lb (12 kg) 32 lb (14.5 kg)

±10% Single

Phase

16 To 130

IPM

0.1 To 2

Seconds

5 in (127 mm)

1/8 To 1-1/2 in

(3 To 38 mm)

±1-1/2 in (38

mm)

Slide 28 lb (12.7 kg) 33 lb (15 kg)

Phase

IPM

Seconds

(3 To 38 mm)

mm)

Cables 5 lb (2.3 kg) 5-1/2 lb (2.5 kg)

2-2. Load Data

SA-052 831-A

2-3. Oscillating Slide Dimensions

Dimensions

A 5 in (127 mm)

B 14 in (356 mm)

C* 14-3/8 in (365 mm)

D 9-3/8 in (238 mm)

E 5/8 in (16 mm)

F 11-3/16 in (284 mm)

G 1 in (25 mm)

H 5-19/32 in (142 mm)

ST-091 229-A

J 17/32 in (13 mm) Dia

*To Bottom Of Mounting Feet.

OM-1085 Page 10

2-4. Oscillator Control Dimensions

Dimensions

A 11-1/4 in (285 mm)

B 11-1/4 in (285 mm)

C 9-1/2 in (241 mm)

D 3/4 in (19 mm)

E 9-1/2 in (241 mm)

F 9/32 in (7 mm) Dia

G 10 in (254 mm)

H 11 in (279 mm)

J 5/8 in (16 mm)

K 8-1/4 in (210 mm)

Ref. ST-052 314-A L 9-1/2 in (241 mm)

2-5. Installing Gun Onto Mounting Plate

Ref. ST-154 578

1 Gun Mounting Plate

2 4-1/4 in. (108 mm)

3 4-1/4 in. (108 mm)

4 3/8−16 UNC Tapped Holes

Do not use screws longer than 1/2

in. (13 mm) to secure gun to plate.

Tools Needed:

9/16

OM-1085 Page 11

2-6. Installation Of Customer-Supplied Remote Controls

ST-052 705-A

Remove oscillator control wrapper.

Loosen strain relief on lower right

side of front panel.

Use matching type controls for re-

mote control functions (see Parts

List).

1 Mounting Bracket

2 Terminal Strip 1T

3 Terminal Strip 2T

4 Plastic Clamp

Route leads from remote controls

through strain relief on front panel,

through plastic clamp on bracket, to

terminal strips.

When installation is complete, tight-

en strain relief and reinstall wrap-

per.

Tools Needed:

8 53 3 54 7 46 2 45 12 49 13 14 15 16

9 5047485556245126522122

1/4 in

OM-1085 Page 12

A. Remote Start/Stop Switch

For the remote start/stop switch to work, the Mode switch must be in the RUN

position.

NOTE

Connect leads from normally-closed switch to terminals 2T21 and 2T22.

B. Remote Dwell On Left Control

Remove jumper link between 2T24

and 2T51.

Connect leads from remote control

to 2T9 and 2T24.

Rear

C. Remote Dwell On Right Control

Remove jumper link between 2T26

and 2T52.

Connect leads from remote control

to 2T9 and 2T26.

Rear

D. Remote Travel Width Control

If multiple Travel Width remote controls are desired, they must be switched using

relays with gold alloy cross bar type contacts or equivalent.

NOTE

Remove jumper links between

1T13 and 1T14, and 1T12 and

1T49.

Connect leads from remote control

to 1T12, 1T13, and 2T9.

Rear

OM-1085 Page 13

E. Remote Center Position Control

If multiple Center Position remote controls are desired, they must be switched

using relays with gold alloy cross bar type contacts or equivalent.

NOTE

Remove jumper links between

1T15 and 1T16, and 2T47 and

2T48.

Connect leads from remote control

to 1T15, 2T48, and 2T55.

Rear

F. Remote Speed To Left Control

If multiple remote speed controls (more than one of either left or right) are desired,

an optional multi-pass circuit board must be installed.

NOTE

Remove jumper link between 1T8

and 1T53.

Connect leads from remote control

to 1T46 and 1T53.

Rear

G. Remote Speed To Right Control

If multiple remote speed controls (more than one of either left or right) are desired,

an optional multi-pass circuit board must be installed.

NOTE

Remove jumper link between 1T3

and 1T54.

Connect leads from remote control

to 1T45 and 1T54.

Rear

OM-1085 Page 14

2-7. Interconnecting, Oscillator Control, and Power Cord Connections

ST-052 310-A

1 Oscillator Control

2 Oscillating Slider Assembly

3 Interconnecting Cord

Connect cord to matching recep-

tacles on control and slider.

4 Oscillator Control Cord

Connect cord to matching recep-

tacles on control and slider.

5 115 Volts AC Power Cord

Connect twistlock plug to recep-

tacle on control. Connect plug on

remaining end of cord to matching

grounded and protected (time delay

fuses or circuit breakers) 115 volts

ac receptacle.

2-8. Travel Width And Center Position Internal Adjustment

ST-052 705-A

. The unit is shipped from the

factory with the travel width set

for 1/8 to 1-1/2 in (3 to 38 mm).

Adjustments can be made for

total slide travel of 5 in (127

mm).

Remove oscillator control wrapper.

1 Mounting Bracket

2 Potentiometer R13 For Travel

Width

3 Dual Potentiometer R9 And

R11 For Center Position

. When travel width is increased,

the center position must be de-

creased or slide internal com-

ponents may hit the ends of the

housing.

Rotate R13 in a counterclockwise

direction to increase travel width.

Decrease center position by rota-

ting R9/R11 clockwise.

Reinstall unit wrapper.

Apply power and check adjust-

ments. Repeat procedure until ad-

justment is satisfactory.

Tools Needed:

1/4 in

OM-1085 Page 15

SECTION 3 − OPERATION

3-1. Controls

ST-052 315-A

1 Power Switch And Pilot Light

Use Power switch to turn unit and pilot light

On and Off.

2 Mode Switch

Set-Up position allows adjustment of the

Center Position control to position the weld-

ing gun over the weld joint before the welding

operation.

Y LEAVING UNIT IDLE IN STAND BY

can cause equipment damage. Shut

down unit when not being used in

Stand By mode.

Stand By position automatically centers and

locks the welding gun in place. The Center

Position control is the only functional control

in this mode. The Center Position control will

cause the gun to move in one direction only

without return capability.

Run position is used during welding. All front

panel controls are adjustable in Run mode.

3 Dwell Controls

Dwell On Left and Dwell On Right controls

set time that welding gun remains at either

end of its set travel width before reversing

direction. Control calibration is in percent

and provides 0.1 to 2 seconds of adjustment.

4 Travel Width Control

This control sets width of welding gun os-

cillation. Control calibration is in percent and

factory set width is 1/8 to 1-1/2 in (3 to 38

mm). Internal adjustment is provided ac-

cording to Section 2-8.

5 Center Position Control

. Center Position control is fully opera-

tional in Set-Up and Run modes.

This control adjusts the center of oscillation

to the right or left. Control adjustment pro-

vides a maximum of 1-1/2 in (38 mm) setting

from actual center of the slide.

6 Speed Controls

. If erratic motor operation occurs at mini-

mum speed setting, slightly increase the

speed setting.

Speed To Left and Speed To Right controls

set speed that welding gun travels from one

end of the set travel width to the other. Con-

trol calibration is in percent and provides 16

to 130 ipm of adjustment.

OM-1085 Page 16

SECTION 4 − MAINTENANCE

4-1. Routine Maintenance

Y Disconnect power before maintaining.

Every Month

Blow Off Neoprene

Seals On Slide.

3 Months

Replace

Unreadable

Labels

Cords

Replace

Cracked

Parts

6 Months

Blow Out Or

Vacuum Unit.

During Heavy

Service, Clean

Monthly.

4-2. Overload Protection

ST-052 315-A

Y Turn Off and unplug unit.

1 Fuse F1 (See Parts List For

Rating)

Fuse F1 protects oscillator control

from overload. If F1 opens, oscilla-

tor control shuts down, but pilot light

remains on. Replace F1.

OM-1085 Page 17

4-3. Slide Lubrication

ST-154 580

Y Turn Off and unplug unit.

1 Gun Mounting Plate

2 Slide Cover With Seal

3 Shaft

4 Screw Lead

5 Pillow Block Oil Hole

Disassemble as shown. Wipe all

surfaces clean. Lubricate pillow

block with No. 20 oil. Lubricate

screw lead with No. 90 oil.

Reinstall cover and plate.

Tools Needed:

3/16 in.

4-4. Drive Belt Adjustment

ST-154 579

Y Turn Off and unplug unit.

Remove screws securing cover

over belt housing and remove cov-

er. Clean pulleys. Adjust belt as fol-

lows:

1 Motor Pulley

2 Toothed Drive Belt

3 Bolt

4 Belt Housing

5 Drive Pulley

Loosen four bolts and slide belt

housing towards motor to tighten

belt. Do not overtighten belt.

Clean and inspect drive gear and

potentiometer gear.

Tighten bolts. Install and secure

cover over belt housing.

Tools Needed:

12345

Motor

7/16 in

OM-1085 Page 18

4-5. Slide Potentiometer Replacement

1 Potentiometer Gear

Loosen setscrews, and remove

gear from potentiometer shaft.

2 Mounting Plate Screws

Remove two screws securing po-

tentiometer mounting plate.

3 Shaft Nut

Remove shaft nut securing poten-

tiometer to mounting plate. Slide

potentiometer out, and allow to

hang free.

Install new potentiometer into

mounting plate, and secure using

nut from old potentiometer.

4 White Lead

5 Red Lead

6 Black Lead

Y Do not allow solder to fall

into unit. Cover exposed

areas when soldering and

unsoldering. Remove cover

and clean unit when done.

Unsolder leads from old potentiom-

eter, and discard potentiometer.

Solder leads to new potentiometer.

Reinstall gear onto potentiometer

shaft. Hub of gear should be flush

with end of shaft. Tighten set-

screws.

Manually move gun mounting plate

to the center of slide.

Turn gear on slide potentiometer to

one extreme, and then back five

turns.

Align gear on slide potentiometer

with small gear on drive screw.

. Maintain a small amount of

backlash between gears.

Use screws removed previously to

secure potentiometer mounting

plate.

Tools Needed:

S CCW CW

5/64 in

4-6. Troubleshooting

Trouble Remedy

Unit completely inoperative. Check and replace line fuse(s), if necessary, or reset circuit breaker.

Unit inoperative, but pilot light is on. Check fuse F1 and replace if necessary (see Section 4-2).

Erratic operation

Speed set at minimum. Slightly increase speed setting (see Section 3-1).

Erratic operation.

Check and secure cord connections between oscillator control and slide (see Section 2-7).

Slide stalled and motor hums

Check slide area and remove any obstructions. Turn power off and back on to restart.

Slide stalled and motor hums.

Excessive load on slide. Reduce load (see Section 2-2). Turn power off and back on to restart.

Page is loading ...

OM-1085 Page 21

SECTION 6 − PARTS LIST

Fig 6-3

Fig 6-2

ST-052 310-A

. Hardware is common and

not available unless listed.

Figure 6-1. Main Assembly

Description

Part

No.

Item

No.

Figure 6-1. Main Assembly

Quantity

1 009 286 SLIDE, oscillator (Fig 6-2) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 075 044 CABLE, interconnecting (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 516 CONNECTOR, circ 11skt plug Amphenol MS-3106A-20-33S 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 734 CONNECTOR, circ clamp str rlf sz 20-22S Amphenol AN-3057-12 2. . . . . . . . . . . . . . . . . . . . . . . . . . .

073 139 CABLE, port No. 16 6/c (order by ft) 10ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 517 CONNECTOR, circ 11 pin plug Amphenol MS-3106A-20-33P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 009 285 CONTROL BOX, (Fig 6-3) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 052 723 CABLE, pwr (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

056 442 CONNECTOR BODY, twlk grd 2P3W 15A 277V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 341 CABLE, port No. 16 3/c (order by ft) 10ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 690 PLUG, str grd armd 2P3W 15A 125V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 009 266 CABLE, control weld oscillator (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

073 686 CONNECTOR, circ 4skt plug Amphenol MS-3106A-14S-2S 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

039 828 CONNECTOR, circ clamp str rlf sz 14-14S Amphenol AN-3057-6 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 469 CABLE, pwr shld 18ga 3/c (order by ft) 10ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

053 075 CONNECTOR, circ 4 pin plug Amphenol MS-3106A-14S-2P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested

Replacement Parts. Model and serial number required when ordering parts from your local distributor.