Miller JETLINE CWB LIGHT DUTY CIRCUM WELD FIXTURES Owner's manual

Miller
Brand
Miller
Model
JETLINE CWB LIGHT DUTY CIRCUM WELD FIXTURES
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Models CWB2 and CWB5
Serial Number 86472 and later
Revised March 1987
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
OPERATION MANUAL
For Lathe Control
Circumferential
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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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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
operation. 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.
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CONTENTS
Section I ............................................................................................................................................................................ 5
SAFETY PRECAUTIONS – READ BEFORE USING ....................................................................................................... 5
1.1 Symbol Usage......................................................................................................................................................... 5
1.2 Arc Welding Hazards ............................................................................................................................................ 5
1.3 Additional Symbols for Installation, Operation, And Maintenance ................................................................... 8
1.4 California Proposition 65 Warnings .................................................................................................................. 10
1.5 Principal Safety Standards ................................................................................................................................. 10
1.6 EMF Information ................................................................................................................................................. 10
Section II ........................................................................................................................................................................ 11
General Description ...................................................................................................................................................... 11
Section III ....................................................................................................................................................................... 12
Physical Characteristics ................................................................................................................................................ 12
Section IV ....................................................................................................................................................................... 13
Description of Each Major Component ........................................................................................................................ 13
A. Headstock ........................................................................................................................................................... 13
B. Bed and Track Assembly ..................................................................................................................................... 13
C. Tailstock .............................................................................................................................................................. 13
D. Non-Powered Carriage ........................................................................................................................................ 13
Section V ......................................................................................................................................................................... 14
Installation ..................................................................................................................................................................... 14
Section VI ....................................................................................................................................................................... 15
Operation ....................................................................................................................................................................... 15
Section VII ...................................................................................................................................................................... 16
Maintenace ..................................................................................................................................................................... 16
Section VIII ..................................................................................................................................................................... 17
KBIC-120 Motor Control Adjustments ........................................................................................................................ 17
Section IX ....................................................................................................................................................................... 19
Parts List ........................................................................................................................................................................ 19
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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.
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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.
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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.
FIRE OR EXPLOSION hazard.
FALLING EQUIPMENT can injure.
OVERUSE can cause OVERHEATING
FLYING SPARKS can injure.
STATIC (ESD) can damage PC boards.
MOVING PARTS can injure.
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• 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.
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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
GENERAL DESCRIPTION
These circumferential machines are a standard design in which a part is centered be- tween a headstock
and a tailstock similar to a lathe. The part is rotated for circumferential welding and it will rotate any round
or conical shape within the machines stated capacity.
The CWB-2 headstock is an adapted ZB-200 positioner. The positioner is driven by a gearhead motor
mounted inside the housing. The CWB-5 headstock is an adapted ZB-500 positioner. This positioner is
driven by a motor and reducer mounted inside the housing. The tailstock on both machines is adjustable
along the v-way track up to the capacity of the machine.
Tooling may be mounted to the headstock and tailstock as desired.
Usually the welding apparatus is mounted to the mounting column, which in turn mounts on a non-
powered carriage. The non-powered carriage is adjustable along the v-way track and can be locked at the
desired welding position.
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SECTION III
PHYSICAL CHARACTERISTICS
CWB2
-36
-48
-60
-72
-84
-96
-120
Weight (lbs)
1750
1800
1850
1900
1950
2000
2100
Height (inches)
75
75
75
75
75
75
75
Width (inches)
32
32
32
32
32
32
32
Length (inches)
71
83
95
107
119
131
155
Maximum Piecepart Diameter (inches)
18
18
18
18
18
18
18
Maximum Piecepart Length
(inches)
36
48
60
72
84
96
120
Speed ranges CWB2: A- 0.2 to 10 RPM
Speed range CWB2: B- 0.07 to 3.3 RPM
Part weight capability: 400 lbs.
CWB5
-24
-36
-48
-60
-72
-84
-96
-120
Weight (lbs)
2100
2150
2200
2250
2300
2350
2400
2500
Height (inches)
70
70
70
70
70
70
70
70
Width (inches)
30 ½
30 ½
30 ½
30 ½
30 ½
30 ½
30 ½
30 ½
Length (inches)
72
84
96
108
120
132
144
168
Maximum Piecepart Diameter (inches)
30
30
30
30
30
30
30
30
Maximum Piecepart Length (inches)
24
36
48
60
72
84
96
120
Speed ranges CWB2: A- 0.7 to 3.6 RPM
Speed range CWB2: B- 0.22 to 10.8 RPM
Part weight capability: 1000 lbs.
Service Requirements
115 volts, 1 phase, 60 Hz, 80 psi shop air.
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SECTION IV
DESCRIPTION OF EACH MAJOR COMPONENT
A. Headstock
The headstock on the CWB2 incorporates a 1Jil HP DC solid state drive system with dynamic braking and
reversing. The control is mounted on top of the positioner housing. The control has a "power off",
"forward" and "reverse" swit.ch, with a red pilot light indicating when the positioner is on. The
potentiometer is divided into increments from 0-100 indicating a percentage of the top speed. A
"manual", "remote" switch allows the positioner to be operated from the control or remotely started from
another source. The 3pin socket on the control panel is used for remote starting. The 3 pin plug is not
supplied, but may be ordered from the factory (part #M-1902).
B. Bed and Track Assembly
The bed and track assembly connects the headstock support to the leg assembly and incorporates a track
system the entire length. A non-powered carriage and mounting column is adjustable along the v-way
track.
C. Tailstock
The adjustable tailstock includes an air cylinder and hand valve mounted to the tailstock support plate.
The air cylinder has 6 inches of stroke and provides a horizontal force for weld shrinkage take-up and to
move tooling in or out, as required. The air cylin- der flow control valves are mounted to the air cylinder
and the air filter, lubricator and gage are mounted on the tail stock support plate. The tailstock assembly
is the v-way track and can be locked into position by tightening the set screws in the tailstock clamp
(page ??, item 4).
D. Non-Powered Carriage
The non-powered carriage travels along the v- way track on the side of the bed and track assembly,
positioned between the headstock and tailstock. The mounting column has two different positions to bolt
onto the carriage for positioning the welding apparatus at the desired position. The carriage has a locking
knob to secure the carriage at the welding position.
Lathe Type Circumferential
14
SECTION V
INSTALLATION
Uncrate the machine, remove the skid and set the equipment at the desired location. The machine can
be left unsecured or grouted to cement foundation, as desired.
Set up the machine by adjusting the leveling screws in the legs and checking with a machinist's level.
Tighten the jam nuts to lock.
All the electrical internal connections are complete.
Connect the shop air to the ¼ npt female pipe inlet on the side of the tailstock. Adjust the air pressure
regulator to zero until ready to use.
Set up the welding apparatus as described in the appropriate manuals included. Connect all hoses and
cables per instructions or per identification on the ends if mounted by Jetline.
CAUTION
Carefully follow all instructions in the appropriate manuals furnished from the welding apparatus
manufacturers for maximum safety and effectiveness.
Lathe Type Circumferential
15
SECTION VI
OPERATION
The headstock. control includes the following features: ''Forward", "Power Off'', ''Reverse", switch, this
switch supplies power to the headstock. motor for forward and reverse rotation.
"Manual" ''Remote" switch. When this switch is in the "Manual" position, operation of the headstock. is
from the control panel. When the switch is in the ''Remote" position, the headstock. can be activated from
an outside signal through the 3pin socket located on the control panel.
A one turn potentiometer allows the adjustment of the headstocks speed range.
A power indicating light will glow when the headstock. is in operation.
A fuse and fuseholder are mounted to the control panel which provides overload protection for the
control. Be sure to use proper protection 3 amp fast blo fuse.
The CWB5 headstock. includes an additional switch which reads "Tilt" "Rotation. With the switch in the
''Rotation" position the ''For- ward" "Reverse" switch will control rotation of the headstock. spindle. With
the switch in the "Tilt" position the "Forward" "Reverse" switch will tilt the headstock. position from
vertical to horizontal and back again.
Set the air pressure on the tailstock to the minimum level consistent with the application. Too much
pressure will distort the part.
Set the headstock. travel speed to the appropriate speed for the welding application.
Determine the proper welding parameter per the manufacturer's instructions supplied with the welding
apparatus.
Lathe Type Circumferential
16
SECTION VII
MAINTENACE
Once a month check all the hoses and fittings for leaks or deterioration. Blow out water from the air filter
on the side of tailstock by pressing the needle valve at the bottom of the filter while the air is on.
Keep the tailstock spindle lubricated to allow easy rotation and linear movement.
Check the oil level of the air lubricator every day and add SAE 10 (non-detergent) oil if below ¼ full.
With the CWB6 periodically drain and replace oil in the headstock gearbox. Use a SAE 90W gear type oil.
Check ground strap tension regularly, located inside the headstock. Adjustment is achieved by passing a
standard screwdriver blade through the clearance hole in the rear cover and tightening the flathead
screw.
Lathe Type Circumferential
17
SECTION VIII
KBIC-120 MOTOR CONTROL ADJUSTMENTS
General
The horsepower resistor valve has been selected and inserted at the factory. 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.
Current Limiting/Torque Adjustment
The current limiting (CL) circuitry is designed to protect both the motor and control against overloads. Be
sure the proper size fuse is used. Many DC motors above 1/4 HP have very low armature resistance (1/2
to 4 OHMS). This will cause extremely high surge currents when the control is set at a maximum voltage
during starting. The CL will limit this cur- rent to a safe level, preventing possible dam- age 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 position). 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 in the counterclockwise 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.
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 1/4 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:
1. Set IR comp pot at approximately 50% of travel. Run motor at approximately 1/3 speed and record
RPM.
2. Run motor with maximum load and adjust IR comp trimpot so that the motor speed under load
equals the unloaded speed per step (1).
3. Remove load and recheck unloaded RPM. If unloaded RPM has shifted, repeat step (2) for more
exact regulation.
The KBIC control is now compensated to provide minimal speed change under large variation to applied
load.
Lathe Type Circumferential
18
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.
Maximum Speed Adjustment
Turn main speed potentiometer to full speed (maximum clockwise direction). Adjust maximum speed
trimpot to new desired setting.
NOTE
Some motors may become unstable if maximum 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 a higher than zero setting.
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 counter-clockwise direction}. Then adjust the minimum
speed trimpot to the desired setting.
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 necessary to repeat the
operations until both the minimum and maximum speeds are set to the desired levels.
Lathe Type Circumferential
19
SECTION IX
PARTS LIST
The following pages provide a detailed parts list of all elements of the circumferential system. They are
arranged so that the parts list on the left hand page is for the assembly illustrated on the right hand page.
Item numbers shown in the parts list refer to those numbers contained in the balloon in the drawing. On
each parts list, the first item is the assembly, the quantities shown are the number of items used in that
particular assembly.
The following parts lists are included in this manual, their appropriate page numbers are listed:
Circumferential Welder-Bench 10
Drive Housing 12
Control & Cover 14
Tailstock #3 Assembly 18
Tailstock #2 Assembly 20
500# Circumferential Welder 22
Drive Housing Standard Speeds 24
ZB500 Control 26
Carriage - Non Powered 28
Lathe Type Circumferential
20
Circumferential Welder-Bench
Item No.
Part No.
Description
Qty
CBW2-___
Circumferential Bench Welder
1
2
CWB2-L L/R
Leg
1L/1R
3
CWB2-B/T
Bed/Track
1
4
CWB2-H
Headstock
1
5
CWB2-T
Tailstock
1
6
CWB-C
Carriage
1
7
CWB-TMB1
Torch Mounting Bracket
1
8
CWB-TM1
Torch Mount
1
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Miller JETLINE CWB LIGHT DUTY CIRCUM WELD FIXTURES Owner's manual

Miller
Brand
Miller
Model
JETLINE CWB LIGHT DUTY CIRCUM WELD FIXTURES
Category
Welding System
Type
Owner's manual
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