Miller Weld Oscillator Owner's manual

Category
Welding System
Type
Owner's manual

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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 Owners 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
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
manufacturers 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.
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 cidessus.
OM-1085 Page 9
SECTION 2 INSTALLATION
2-1. Specifications
Input
Speed
Dwell
Total Slide
Width
Center
Weight
Input
Power
S
pee
d
D
we
ll
Total Slide
Travel
Wid
t
h
Center
Adjustment
Item Net Ship
115 Volts AC
Control 27 lb (12 kg) 32 lb (14.5 kg)
11
5
V
o
l
ts
AC
±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
A
Dimensions
A
A 5 in (127 mm)
H
J
B 14 in (356 mm)
C* 14-3/8 in (365 mm)
D 9-3/8 in (238 mm)
C
D
E 5/8 in (16 mm)
C
G
F 11-3/16 in (284 mm)
B
E
F
G
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
AB
A 11-1/4 in (285 mm)
B 11-1/4 in (285 mm)
C
C 9-1/2 in (241 mm)
C
D
D 3/4 in (19 mm)
D
E 9-1/2 in (241 mm)
E
F
F 9/32 in (7 mm) Dia
KL
F
G 10 in (254 mm)
H 11 in (279 mm)
G
H
J
J 5/8 in (16 mm)
J
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 3/816 UNC Tapped Holes
Do not use screws longer than 1/2
in. (13 mm) to secure gun to plate.
Tools Needed:
1
2
3
4
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
1T
2T
2
3
4
1/4 in
1
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
24
9
C. Remote Dwell On Right Control
Remove jumper link between 2T26
and 2T52.
Connect leads from remote control
to 2T9 and 2T26.
Rear
9
26
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
9
13
12
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
55
15
48
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
53
46
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
54
45
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.
1
2
3
4
5
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:
2
3
1/4 in
1
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.
1
2
3
4
5
6
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.
OR
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.
1
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.
1
2
3
4
5
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
3
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:
1
2
3
4
5
6
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.
OM-1085 Page 21
SECTION 6 PARTS LIST
1
2
4
5
Fig 6-3
Fig 6-2
3
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 Manufacturers Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1085 Page 22
1
2
345 6789
10
11
12
13
14
15
16
17
18
19
17
20
21
22
23
24
25
26
27
28
29
30
31
32
34
35
35
36
37
34
33
5
ST-052 312-C
. Hardware is common and
not available unless listed.
Figure 6-2. Slide, Oscillator
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Miller Weld Oscillator Owner's manual

Category
Welding System
Type
Owner's manual
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