Miller JETLINE ZB-75 BENCHMASTER POSITIONERS Owner's manual

Miller
Brand
Miller
Model
JETLINE ZB-75 BENCHMASTER POSITIONERS
Category
Welding System
Type
Owner's manual

This manual is also suitable for

OM-ZB-75-03-2014
Revised March 2014
IMPORTANT
Read this manual carefully before installing,
commissioning or operating this product.
Miller Welding Automation, 281 E. Lies Rd., Carol Stream
Il 60188 • Telephone: (949) 951-1515 • Fax: (949) 951-9237
Web Site: www.jetline.com • E-mail: [email protected]
OPERATION MANUAL
for
Model ZB-75
Benchmaster Positioner
ZB-75 Benchmaster Positioner
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LIMITED WARRANTY
Components or parts manufactured directly by Miller Electric Mfg. Co. are subject to Miller’s True Blue® Warranty set forth
at www.millerwelds.com/support/warranty. Seller does not make any warranties for components or parts not
manufactured directly by Jetline Engineering, Miller Welding Automation, and Panasonic Welding Systems Company; such
components or parts are subject to the warranty terms of the respective manufacturer. Components and parts
manufactured by Jetline Engineering, Miller Welding Automation, and Panasonic Welding Systems Company are subject to
the following warranty terms. Terms and Conditions of Sale Seller warrants to Purchaser that the components or parts
manufactured by Seller or Panasonic Welding Systems Company shall be free from defects in material and workmanship,
and shall conform to the Seller’s specifications for the following periods:
a. 12 months from the date of shipment of the Products for components and equipment manufactured by
Panasonic Welding Systems Company including robot manipulator, controller and connecting cables; external axis
components (external axis base unit, servo amplifiers, motors, connecting cables and pre-engineered positioners);
peripheral devices (high voltage touch sensors, thru arc seam trackers); welding power sources (internally built
into the robot controller cabinet); wire feeders (separated design or integrated design, i.e. Active Wire
Torch/Feeder); or
b. 12 months from date of shipment of the Products for equipment manufactured by Jetline Engineering or Miller
Welding Automation.
In the event of a breach of the warranties set forth above, Seller will, at Seller’s option and as Seller’s sole liability and
Purchaser’s sole remedy, repair, replace or credit Purchaser’s account for, any Product that fails to conform to the above
warranty, provided that (i) during the applicable warranty period Seller is promptly notified in writing upon discovery of
such failure with a detailed explanation of any alleged deficiencies; (ii) Seller is given a reasonable opportunity to
investigate all claims; and (iii) Seller’s examination of such Product confirms the alleged deficiencies and that the
deficiencies were not caused by accident, misuse, neglect, improper installment, unauthorized alteration or repair or
improper testing. No Products may be returned to Seller until inspection and approval by Seller. All warranty work
performed shall be FOB Seller’s facility (Incoterms 2010) and freight for returned Products shall be paid for by Purchaser.
The above warranty against defects does not apply to: (1) consumable components or ordinary wear items including but
not limited to torches; or (2) defects due to (i) failure to install and perform maintenance set forth in Product
documentation, (ii) the use of components, parts, peripherals, attachments, accessories, or perishable tooling not
approved by Seller, (iii) accident, misuse, neglect, abuse, mishandling, misapplication, modification, alteration, acts of God,
or (iv) improper installation, service or maintenance. Purchaser and/or the operator of the Products are in full control of
the weld process. Seller makes no warranty regarding the quality or the success of the welds on the Products due to
factors under Purchaser’s and/or operator’s control including but not limited to welding procedures, material types,
material coatings, joint/part fit, part geometry, metallurgy, welding gases, proper machine/process maintenance, and
operator skill. EXCEPT AS SET FORTH ABOVE, SELLER MAKES NO WARRANTY OR REPRESENTATION OF ANY KIND, EXPRESS
OR IMPLIED (INCLUDING NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE).
- See more at: https://www.millerwelds.com/automation-terms-of-sale#sthash.l5oRebWB.dpuf
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ZB-75 Benchmaster Positioner
NOTICE
The installation, operation and maintenance guidelines set out in this manual will enable you to
maintain the equipment in peak condition and achieve maximum efficiency with your welding
opera- tion. Please read these instructions carefully to become aware of every advantage.
CAUTION
Only experienced personnel familiar with
the operation and safe practice of welding
equipment should install and/or use
this equipment.
ZB-75 Benchmaster Positioner
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CONTENTS
Section I ..................................................................................................................................................................... 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 ................................................................ 4
1.4 California Proposition 65 Warnings ................................................................................................................ 6
1.5 Principal Safety Standards .............................................................................................................................. 6
1.6 EMF Information ............................................................................................................................................. 6
Section II .................................................................................................................................................................... 7
Introduction .............................................................................................................................................................. 7
Section III ................................................................................................................................................................... 8
Specifications ............................................................................................................................................................ 8
Section IV ................................................................................................................................................................10
Operation ................................................................................................................................................................10
Section V .................................................................................................................................................................11
Maintenance ...........................................................................................................................................................11
Section VI ................................................................................................................................................................13
ZB-75ACA Adjustments ...........................................................................................................................................13
A. Motor ..........................................................................................................................................................13
B. Control ........................................................................................................................................................13
Section VII ...............................................................................................................................................................14
Motor Control Adjustment for KBIC-120 ................................................................................................................14
A. General ........................................................................................................................................................14
B. Current Limiting/Torque Adjustment .........................................................................................................14
C. IR Compensation Adjustment .....................................................................................................................14
D. Maximum Speed Adjustment .....................................................................................................................15
E. Minimum Speed Adjustment ......................................................................................................................15
Section VIII ..............................................................................................................................................................16
Parts List ..................................................................................................................................................................16
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SECTION I
SAFETY PRECAUTIONS – READ BEFORE USING
(som 2013-09)
1.1 Symbol Usage
DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the
adjoining symbols or explained in the text.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or
explained in the text.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means: Warning! Watch Out! 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
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 1-5. Read and follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this unit.
During operation, keep everybody, especially children, away.
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.
• Do not touch live electrical parts.
• Wear dry, hole-free insulating gloves and body protection.
• Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work
or ground.
• Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.
• Use AC output ONLY if required for the welding process.
• If AC output is required, use remote output control if present on unit.
• Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations
or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting,
kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the work piece or ground. For these
conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is
recommended. And, do not work alone!
• 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).
• Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes.
• 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.
• When making input connections, attach proper grounding conductor first − double-check connections.
• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
• Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
• Turn off all equipment when not in use.
• Do not use worn, damaged, undersized, or repaired cables.
• Do not drape cables over your body.
Protect yourself and others from injury – read, follow and save these important safety precautions and operating instructions.
ELECTRIC SHOCK can kill.
ZB-75 Benchmaster Positioner
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• If earth grounding of the workpiece is required, ground it directly with a separate cable.
• Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.
• Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
• Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.
• Wear a safety harness if working above floor level.
• Keep all panels and covers securely in place.
• Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
• Insulate work clamp when not connected to workpiece to prevent contact with any metal object.
• Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use.
• Use GFCI protection when operating auxiliary equipment in damp or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
• Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before
touching any parts.
• Do not touch hot parts bare handed.
• Allow cooling period before working on equipment.
• To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
• Keep your head out of the fumes. Do not breathe the fumes.
• If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are
exposed.
• If ventilation is poor, wear an approved air-supplied respirator.
• Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
• 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 breathing air is
safe.
• Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to
form highly toxic and irritating gases.
• 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 while wearing an air-supplied respirator. The coatings and any metals containing these elements can
give off toxic fumes if welded.
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.
• Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
• Wear approved safety glasses with side shields under your helmet.
• Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.
• Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
HOT PARTS can burn.
ARC RAYS can burn eyes and skin.
FUMES AND GASES can be hazardous.
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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.
• Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.
• Do not weld where flying sparks can strike flammable material.
• Protect yourself and others from flying sparks and hot metal.
• Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
• Watch for fire, and keep a fire extinguisher nearby.
• Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
• Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).
• Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline).
• 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, sparks, and fire hazards.
• Do not use welder to thaw frozen pipes.
• Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
• Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
• Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.
• After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.
• Use only correct fuses or circuit breakers. Do not oversize or bypass them.
• Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.
Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables,
coolants, degreasers, fluxes, and metals.
• Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.
• Wear approved safety glasses with side shields even under your welding helmet.
• Shut off compressed gas supply when not in use.
• Always ventilate confined spaces or use approved air-supplied respirator.
• Wearers of Pacemakers and other Implanted Medical Devices should keep away.
• Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
• Noise from some processes or equipment can damage hearing.
• Wear approved ear protection if noise level is high.
WELDING can cause fire or explosion.
FLYING METAL or DIRT can injure eyes.
BUILDUP OF GAS can injure or kill.
ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices.
NOISE can damage hearing.
ZB-75 Benchmaster Positioner
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Compressed 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.
• Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
• Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.
• Keep cylinders away from any welding or other electrical circuits.
• Never drape a welding torch over a gas cylinder.
• Never allow a welding electrode to touch any cylinder.
• Never weld on a pressurized cylinder − explosion will result.
• Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
• Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the
valve.
• Keep protective cap in place over valve except when cylinder is in use or connected for use.
• Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
• Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication
P-1 listed in Safety Standards.
1.3 Additional Symbols for Installation, Operation, And Maintenance
• Do not install or place unit on, over, or near combustible surfaces.
• Do not install unit near flammables.
• Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.
• Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
• Use equipment of adequate capacity to lift and support unit.
• If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.
• Keep equipment (cables and cords) away from moving vehicles when working from an aerial location.
• Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manually
lifting heavy parts or equipment.
• Allow cooling period; follow rated duty cycle.
• Reduce current or reduce duty cycle before starting to weld again.
• Do not block or filter airflow to unit.
• Wear a face shield to protect eyes and face.
• Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.
• Sparks can cause fires — keep flammables away.
• Put on grounded wrist strap BEFORE handling boards or parts.
• Use proper static-proof bags and boxes to store, move, or ship PC boards.
CYLINDERS can explode if damaged.
FALLING EQUIPMENT can injure.
FLYING SPARKS can injure.
STATIC (ESD) can damage PC boards.
- v -
• Keep away from moving parts.
• Keep away from pinch points such as drive rolls.
• Do not press gun trigger until instructed to do so.
• Do not point gun toward any part of the body, other people, or any metal when threading welding wire.
• Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
• Keep away from moving parts such as fans.
• Keep all doors, panels, covers, and guards closed and securely in place.
• Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary.
• Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.
• Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety
information at the beginning of the manual and in each section.
• Use only genuine replacement parts from the manufacturer.
• Perform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes.
• High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
• Have only qualified persons familiar with electronic equipment perform this installation.
• The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
• If notified by the FCC about interference, stop using the equipment at once.
• Have the installation regularly checked and maintained.
• 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.
• Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such
as robots.
• Be sure all equipment in the welding area is electromagnetically compatible.
• To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
• Locate welding operation 100 meters from any sensitive electronic equipment.
• Be sure this welding machine is installed and grounded according to this manual.
• 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.
WELDING WIRE can injure.
BATTERY EXPLOSION can injure.
MOVING PARTS can injure.
READ INSTRUCTIONS.
H.F. RADIATION can cause interference.
ARC WELDING can cause interference.
ZB-75 Benchmaster Positioner
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1.4 California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects
and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive
harm. Wash hands after use.
1.5 Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com
).
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com
).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
EngineeringDocuments (phone: 1-877-413-5184, website: www.global.ihs.com
).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way,
Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org
).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West
43rd Street, New York, NY 10036 (phone: 212-642-4900, web-site: www.ansi.org
).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy,
MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org
.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part
1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-
512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov
).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd,
Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH
).
1.6 EMF Information
Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes
including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields
may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For
example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a cable cover.
2. Do not place your body between welding cables. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recom-
mended.
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SECTION II
INTRODUCTION
The Benchmaster Positioner provides a
rotating faceplate eight inches in diameter
containing four slots for mounting a piecepart
or tooling. Optionally, a 4” 3-jaw chuck can be
installed in place of the faceplate. The
faceplate is mounted on the gear box spindle
which includes the motor and speed reducing
mechanism. A variable speed solid state
motor control is mounted in the housing.
The housing is supported by an arm which al-
lows it to pivot. The arm is fabricated to the
base containing two mounting holes (see
print ZB75ACA-Z for dimensions).
A hand knob is provided which allows the plane
of rotation of the faceplate to be adjusted 90
degrees from horizontal to the vertical.
The ZB-75ACA positioner is supplied with a
foot control and cable.
The ZB-75DCA and ZB-75DCB has a DC solid
state control with a dynamic brake for instant
starting and stopping. The DC models have dy-
namic braking and a speed holding accuracy
of 2% over the complete speed and torque
range. The FS-4 remote on-off foot control is
available as an option to the ZB-75DC models.
A rotary ground connection is provided for
use in welding applications.
CAUTION
It is important that a tight connection to the
welding power supply ground is maintained.
Otherwise, serious damage to the positioner
bearings can occur.
ZB-75 Benchmaster Positioner
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SECTION III
SPECIFICATIONS
Weight Capacity
Faceplate Vertical 75 lbs. (34 kg) with
center of gravity 2” (50
mm) from faceplate.
Faceplate Horizontal 100 lbs. (45 kg) with
center of gravity 2” (50
mm) from faceplate.
Physical Characteristics
Length 11 7/16” (290 mm)
Height 7 3/8” (188 mm)
Faceplate Horizontal
Height 15¼” (387 mm)
Faceplate Vertical
Width 9 3/4” (248 mm)
Weight 28 lbs. (12.7 kg)
Speed Range
ZB-75ACA .5 to 7.5 RPM
ZB-75DCA .3 to 10 RPM
ZB-75DCB .1 to 3.2 RPM
Service Requirements
Electrical 115 VAC, 3 amp, single
phase, 50/60 Hz
Note: for 220VAC operation, a transformer is
required; 500VA is sufficient.
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Figure 1
ZB-75A-5 Faceplate, 8” (203 mm)
ZB-75 Benchmaster Positioner
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SECTION IV
OPERATION
The positioner is designed to be powered by
120 volts AC 50/60 Hz. We do not recommend
us- ing the 115 VAC receptacle, which is
provided with some TIG power supplies, to
power the positioner.
The controls on the positioner are the
Forward- Off-Reverse Switch, the Foot
Control On-Off Switch, and the one-turn
speed potentiometer.
Looking at the faceplate, select rotation “For-
ward” for clockwise movement, “Reverse” for
counterclockwise.
Put the foot control On-Off Switch in the “Off”
position and the positioner will run at a speed
which is set by the speed potentiometer.
When the foot control On-Off Switch is in the
“On” position, the speed of rotation is
controlled by the foot control on the AC
model. On the DC model, a remote start/stop
receptacle is provided.
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SECTION V
MAINTENANCE
(Refer to the drawings in the Parts List Section.)
To service the internal components of the
positioner, first remove the three ¼-20
flathead screws which mount the faceplate to
the rotary ground assembly, Item RGA-50 (see
drawing). Remove the ¼-20 set screw (RGA-
50, Item 8) from the rotary ground hub (RGA-
50, Item 2) and remove the rotary ground
assembly from the motor shaft. Remove the
four machine screws which fasten the
housing (Item 7, Positioner drawing) to the
base (Item 2, Positioner drawing). After
removing the housing, all components of the
positioner are accessible for service.
Backlash in the faceplate may increase as the
gears in the gear head set in or wear over
time. An adjustment can be made to minimize
the backlash. Locate the backlash adjusting
set screw and set screw lock nut to the rear
of the motor gear box, below the motor
housing (see figure 1). Loosen the lock nut and
gently turn the set screw clockwise to remove
the backlash and lock the set screw with its
locking nut.
CAUTION
The Miller Welding Automation Benchmaster
Positioner has been designed to give trouble
free operation under normal working
conditions and requires little maintenance.
The following items should be checked
periodically for optimum performance.
1.
Check interior box for foreign matter
which could interfere with efficient
operation.
2.
Check power supply for proper
grounding.
3.
Check rotary ground for wear and re-
place if necessary.
4.
Apply an electrical lube to the face of
the rotary ground strap, Item 3, where
it contacts the face of the hub, Item 2.
5.
Fuses - Check that proper overload
protection is being used; 3 amp fuse,
fastblow.
6.
Check connection to ground strap.
Tighten if necessary.
Over tightening of the set screw can cause
damage to the motor’s gear box.
ZB-75 Benchmaster Positioner
- 12 -
Figure 2
ZB-75ACA Adjustments
- 13 -
SECTION VI
ZB-75ACA ADJUSTMENTS
Remove cover as in Section V, Maintenance.
(See Figure 2)
CAUTION
Make this adjustment with power removed.
A. Motor
With ½” wrench, loosen lock nut on gearbox
and, with blade-type screwdriver, gently
rotate worm adjusting screw clockwise until
screw encounters resistance. While holding
screw in position, tighten lock nut. Check that
backlash as measured on the circumference
of the 8” diameter faceplate is 1/16” or less.
B. Control
Connect DC voltmeter (250 volt scale) to
KBDM control output (black and red wires-red
is positive). Switch foot control switch to “Off”
and forward/reverse switch to “Forward”.
Rotate main speed control fully clockwise to
maximum speed. With small blade-type
adjustment tool or screwdriver, adjust trimpot
to 90 VDC output. Rotate main speed control
fully counterclockwise. Adjust minimum
trimpot CCW so that motor armature starts
rotating within 10% rotation of main speed
control. Recheck maximum trimpot setting.
ZB-75 Benchmaster Positioner
- 14 -
SECTION VII
MOTOR CONTROL ADJUSTMENT FOR KBIC-120
A. General
The horsepower resistor value has been
selected and inserted by your distributor. The
current limited (CL or torque output)
adjustment is set at 1.2 times the motor rating.
Do not tamper with these trimpots since they
are at the optimum setting. However, some
situations require customized settings. Please
follow the special instructions if the control is
to be readjusted.
B. Current Limiting/Torque
Adjustment
The current limiting (CL) circuitry is designed to
protect both the motor and control against
over- loads. Be sure the proper size fuse is
used. Many DC motors above ¼ HP have very
low armature resistance (½ OHM). This will
cause extremely high surge currents when the
control is set at maximum voltage during
starting. The CL will limit this current to a
safe level, preventing possible damage to
control power components and motor. CL can
also serve as torque limiter by reducing the
maximum horsepower output.
Adjust CL/Torque as follows:
1. Reduce IR comp trimpot to its minimum
level (maximum counterclockwise posi-
tion). Then set main speed
potentiometer so that motor is running
at approximately 1/3 to 1/2 speed.
Turn CL pot to counterclockwise
position.
2. Connect an AC ammeter in series with
AC input line or DC ammeter in series
with armature lead.
3. Lock shaft or motor (be sure CL pot is
counter clockwise position).
4. Apply AC power and rotate CL pot
clockwise slowly.
a. If AC ammeter is used, set CL at
.8 times motor rating.
b. If DC ammeter is used, set CL at
1.2 times motor rating.
C. IR Compensation Adjustment
IR compensation (IR comp) is provided to
substantially improve load regulation. If the
load presented to the motor does not vary
substantially, the IR comp may be set at a
minimum level (approximately ¼ of full
setting). If superior performance is desired
(less than 2% speed change of base speed from
zero to full load), then IR comp should be
adjusted as follows:
5. Set IR comp at approximately 50% of
travel. Run motor at approximately
1/3 speed and record RPM.
6. Run motor with maximum load and
ad- just IR comp trimpot so that the
motor speed under load equals the
unloaded speed per step 1.
7. Remove load and recheck unloaded
RPM. If unloaded RPM has shifted,
repeat step 2 for more exact
regulation.
- 15 -
The KBIC control is now compensated to pro-
vide minimal speed change under large varia-
tions to applied load.
NOTE
If IR comp is set too high, unstable motor
operation will result. Symptom is that motor
speed will increase and decrease in a cyclical
manner. To correct, rotate IR comp trimpot in
counterclockwise direction.
D. Maximum Speed Adjustment
Turn main speed potentiometer to full speed
(maximum clockwise direction). Adjust maxi-
mum speed trimpot to new desired setting.
NOTE
E. Minimum Speed Adjustment
If a higher than zero minimum speed is
desired, readjust the minimum speed by first
turning the main speed potentiometer to
minimum speed (full counterclockwise
direction). Then adjust the minimum speed
trimpot to the desired set- ting.
NOTE
The minimum speed adjustment will affect
the maximum speed setting. Therefore, it is
necessary to readjust the maximum speed
after the minimum speed, and it may be nec-
essary to repeat the operations until both the
minimum and maximum speeds are set to the
desired levels.
Some motors may become unstable if maxi-
mum speed is adjusted above motor’s rated
RPM.
For moderate changes in the maximum
speed, there will be a slight effect on the
minimum speed setting when the minimum
speed is set at zero. There will be significant
variation in the minimum speed setting if the
minimum speed is set at higher than zero
setting.
ZB-75 Benchmaster Positioner
- 16 -
SECTION VIII
PARTS LIST
The following pages provide a detailed parts
list of the Benchmaster Positioner. They are
arranged so that the assembly illustrated on
the left hand page is for the parts list on the
adjacent right hand page.
Item numbers shown in the parts list refer to
those items referenced by the balloon in the
drawing. All the quantities shown are the
quantities used to make the main assembly.
Two columns are included in the list to show
the spare parts which it is recommended
should be stocked by the user. The two levels
can be defined as follows:
Level 1
These are the spares recommended for US
domestic users whose use of the product
does not exceed 2000 hours per year.
Level 2
These are the spares recommended for
international users of the product or for US
domestic users who will use the product in
excess of 2000 hours per year.
The following parts lists are included in this
manual, their page numbers are:
ZB-75DCA/B Positioner......................... 18/19
ZB-75D-14 Control................................. 20/21
ZB-75ACA Positioner............................. 22/23
ZB-75A-14 Control................................. 24/25
RGA-50 Rotary Ground.......................... 26/27
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Miller JETLINE ZB-75 BENCHMASTER POSITIONERS Owner's manual

Miller
Brand
Miller
Model
JETLINE ZB-75 BENCHMASTER POSITIONERS
Category
Welding System
Type
Owner's manual
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