Miller MH000000 Owner's manual

MH000000
Miller
Brand
Miller
Model
MH000000
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Effective with Serial Number 8640
IMPORTANT
Read this manual carefully before installing,
commissioning or operating this product.
Revised September 1996
Jetline Engineering, Inc., 281 E. Lies Rd., Carol Stream Il 60188 Telephone:(949)
951-1515 • Fax: (949) 951-9237
OPERATIONAL
MANUAL
for TD-1000A
Turning Roll Driver
TD-1000A Turning Roll Driver
2
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
TD-1000A Turning Roll Driver
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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.
TD-1000A Turning Roll Driver
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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
SPECIFICATION .......................................................................................................................................................................... 11
SECTION III .................................................................................................................................................................................. 12
OPERATION AND MAINTANACE ........................................................................................................................................... 12
A. Part Diameter Adjustments .............................................................................................................................. 12
B. Motor Control Adjustment KBIC-120-1/8....................................................................................................... 13
C. Reducing Turning Roll “Creep” ........................................................................................................................ 14
SECTION IV .................................................................................................................................................................................. 15
PARTS LIST .................................................................................................................................................................................. 15
TD-1000A Turning Roll Driver
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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.
Protect yourself and others from injury – read, follow and save these important safety precautions and operating instructions.
ELECTRIC SHOCK can kill.
TD-1000A Turning Roll Driver
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• Do not drape cables over your body.
• 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.
TD-1000A Turning Roll Driver
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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.
TD-1000A Turning Roll Driver
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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
SPECIFICATION
Weight Capacity:
TD-1000A Turning Roll Driver 1000 lbs (455 kg)
TD-1000A Turning Roll Idler 1000 lbs (455 kg)
TD-1000A & TI-1000A combined Maximum capacity 2000 lbs (910 kg)
Diameter Capacity:
Complete Range ½″ to 32″ (12 mm to 815 mm)
Wheels in lower position 3″ to 32″ (75 mm to 815 mm)
(as shipped from factory)
Wheels in upper position ½″ to 10″ (12 mm to 255 mm)
Speed Range: 1.5 to 60 IPM (38 to 1525 mm/min)
Power Input:
Voltage 110-120 VAC, 1 Phase, 50/60 Hz
Amperage 3 amps (Higher voltage need step-down transformer – Part No. HVC-1-240)
Wheels: Polyurethane covers (“melting” point approximately 315° F)
Outer diameter is 8″ (203 mm)
Motor: DC Permanent Magnet, 1/8 hp (90 watt)
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SECTION III
OPERATION AND MAINTANACE
The Benchmaster Turning Rolls provide a rotating surface that can turn round parts with diameters from
a minimum of ½″ (12 mm) to a maximum of 32″ (815 mm). It incorporates a DC motor with a solid state
motor control. The speed range is from 1.5 to 60 IPM. The weight capacity of the TD-1000A driver is 1,000
lbs (455 kg). The turning capacity of the TD-l000A driver when coupled with the TI-l000A idler is 2,000 lbs
(910 kg). Additional TI-l000A idlers can be added for support purposes, but total weight capacity is not
enhanced.
The solid state incorporates the following features:
The increments on the speed potentiometer 0-100 represent a percentage of the unit's speed from 1.5 to
60 IPM (38 to 1524 mm/min). The "Forward/Off/Reverse" switch controls the direction the turning rolls
travel and turns off the 115 volts AC to the entire control. A 3Amp fuse protects the entire unit. A
“Remote/Manual” switch selects the mode in which to control the unit. In “Remote” FS-4 foot switch is
typically used. When ready to weld, the switch is pressed (or remote signal activated) and the rolls will
rotate based on how “Forward/Reverse” switch is set. In the “Manual” position the unit is controlled by
the “Forward/Off/Reverse" switch.
The motor is of the DC permanent magnet design with a permanently sealed lubricated gear box.
Both the TD-1000A and TI-1000A driver rolls have roller bearings that need to be lubricated every 500
hours with an automotive type grease. A zerk fitting is provided for lubrication.
The motor brushes should be checked every 1000 hours of operation. Replace brushes if worn. Failure to
replace worn brushes can cause damage to the motor and motor control.
A. Part Diameter Adjustments
The TD-1000A and TI-1000A can turn a ½″ (12 mm) to 32″ (815 mm) diameter part. The rubber wheels
(PIN 8-724) are factory set in the lower axle location holes on the base (P/N TD-1000-2). This enables
turning of a 3″ (75 mm) to 32″ (815 mm) diameter part. To turn a ½″ (12 mm) to 10″ (255 mm) diameter
part, move the rubber wheels to the upper axle location holes by removing the ½″ (12 mm) nuts and
bolts that hold the wheels in place. After moving the wheels to the upper position on the TD-l000A, the
rod end (P/N VIO) will have to be adjusted by loosening the jam nut (Item 15) and backing out the
modified bolt (Item 5) until positive traction is achieved.
The rod end (P/N VFlO, Item 6) controls the positive traction that the drive roller assembly (P/N TD-
1000-4) has against the rubber wheel. If the surface of the rubber wheel becomes worn through use, the
rod end will have to be adjusted by loosening the jam nut (Item 15) and backing out the modified bolt
(Item 5) until positive traction is achieved.
TD-1000A Turning Roll Driver
13
Mounting holes have been provided in the base of the unit. Mount the units to your tooling or select a
mounting system from our Benchmaster component parts. See parts drawings of the TD-l000A and TI-
l000A for dimensional mounting information on the bases.
B. Motor Control Adjustment KBIC-120-1/8
1) General
The horsepower resistor value has been selected and inserted in the motor control. 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 re-adjusted.
2) 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 hp have very low armature
resistance (1h to 4 ohms). 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:
a) 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 1h speed. Turn
CL potentiometer to counterclockwise position.
b) Connect an AC ammeter in series with AC input line or DC ammeter in series with armature
lead.
c) Lock shaft or motor (be sure CL potentiometer is in counterclockwise position).
d) Apply AC power and rotate CL potentiometer clockwise, slowly.
i. If AC ammeter is used, set CL at .8 times motor rating.
ii. If DC ammeter is used, set CL at 1.2 times motor rating.
3) 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 of full set- ting). 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:
a) Set IR comp pot at approximately 50% of travel. Run motor at approximately 1/3 speed and
record RPM.
b) Run motor with maximum load and adjust IR comp trimpot so that the mo- tor speed under
load equals the un- loaded speed per step 1.
c) 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 minimum speed change under large variations
to applied load.
NOTE
TD-1000A Turning Roll Driver
14
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.
4) Maximum Speed Adjustment
Turn main speed potentiometer to full speed (maximum clockwise direction). Adjust maximum
speed trimpot to new desired setting. Verify the maximum voltage to the motor does not exceed
the motor rating.
NOTE
Some motors may become unstable if maximum speed is adjusted above mo· tor's rated RPM.
For moderate changes in the maximum speed, there will be 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 setting is set at a higher than zero setting.
5) Minimum Speed Adjustment
If a higher than zero minimum speed is de- sired, re-adjust 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 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.
C. Reducing Turning Roll “Creep”
When rotating parts on a set of Turning Rolls, one drawback is the tendency of the part to creep to
one side. The TD-l000A can be equipped with the optional Turning Roll end stop, P/N 7010, to
eliminate this affect. The part comes in contact with the end stop and creeping is stopped as long as
rotation direction is not changed. The end stop is equipped with bearings so the part can rotate
smoothly.
TD-1000A Turning Roll Driver
15
SECTION IV
PARTS LIST
The following pages provide a detailed parts list of all the elements of the TD-l000A turn- ing roll driver.
They are arranged so that the parts list on the left hand page corresponds to the assembly illustrated on
the right hand page. Item numbers shown in the parts list refer to those numbers contained in the bal-
loon in the drawing. The quantities shown are the number of items used in that particular assembly.
Two columns are included in the list to show the spare parts which are recommended to 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 use 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 appropriate page numbers are listed:
Turning Roll Driver . . . . . . . . . . . . . . . 12/13
Idler Rolls . . . . . . . . . . . . . . . . . . . . . . . 14/15
Drive Roll Control Box . . . . . . . . . . . . . 16/17
Drive Roll Contro1/Footswitch . . . . . . . 18/19
TD-1000A Turning Roll Driver
16
Turning Roll Driver
TD-1000A
Recommended Spares
Item No.
Description
Qty
Level I
Level II
2
Base Assembly
1
3
Top Plate Assembly
1
4
Drive Roller Assembly
1
5
Modified Bolt
1
6
Rod End
1
7
Flat Washer
1
8
Hex Head Screw
1
9
Polyurethane 8″ Diameter Wheel
2
10
Flat Washer
4
11
Hex Head Screw
2
12
Thin Elastic Stop Nut
2
13
Motor
1
1
1
Includes:
Brush Cap
Brush Holder
Brush Motor
Armature Bearing
Armature
14
Drive Roll Control Assembly
1
15
Hex Jam Nut
1
16
No. 3 Handle
1
17
Hex Head Screw
4
18
Lock Washer
4
19
But Head Screw
4
20
But Head Screw
2
21
Lock Washer
2
22
Nut
2
TD-1000A Turning Roll Driver
17
TD-1000A Turning Roll Driver
18
Idler Rolls
TI-1000A
Recommended Spares
Item No.
Part No.
Description
Qty
Level I
Level II
2
TI-1000-2
Idler Base Assembly
1
3
TD-1000A-9
Polyurethane Wheel
2
4
3/4
Flat Head Washer
4
5
1/2-13x4
Hex Head Screw
2
6
Thin Elastic Stop Nut
2
TD-1000A Turning Roll Driver
19
TD-1000A Turning Roll Driver
20
Drive Roll Control Box w/KB Module
TD-1000-14B
Recommended Spares
Item No.
Description
Qty
Level I
Level II
2
Turning Roll Control Enclosure
1
3
Switch, 4 PDT
1
4
Fuse Holder
1
5
3 Amp Fuse
1
5
5
6
Switch, SPST
1
7
Relay
1
8
Varistor
1
9
Disc. Cap., .025 MFD, 500 VDC
2
10
Turning Roll Control Face Plate
1
11
Motor Control
1
1
1
12
Potentiometer
1
13
Knob
1
14
Cord Grip
1
15
Cable w/molded 115 VAC, 3 Pin Plug
1
16
3 Pin Socket
1
17
Screw
1
18
Brake Resistor
1
1
1
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Miller MH000000 Owner's manual

MH000000
Miller
Brand
Miller
Model
MH000000
Category
Welding System
Type
Owner's manual
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