Miller HH042002 Owner's manual

Miller
Brand
Miller
Model
HH042002
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller HH042002 is an electronically controlled mechanical device that moves the welding gun back and forth at an adjustable rate. It is designed for automatic welding operations in a horizontal plane. The degree and scope of adjustment is provided by the electronic control.

Miller HH042002 is an electronically controlled mechanical device that moves the welding gun back and forth at an adjustable rate. It is designed for automatic welding operations in a horizontal plane. The degree and scope of adjustment is provided by the electronic control.

November
1977
FORM:
OM-1085
Effective
With
Serial
No.
HH042002
MODEL
STOCK
NO
WELD
OSCILLATOR
008
644
ADDITIONAL
COPY
PRICE
55
CENTS
MODEL/STOCK
NO.
SERiAL/STYLE
NO.
DATE
PURCHASED
OWNERī‚’S
MANUAL
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
t~~ī‚’aP
L~P
~
ī‚‘i~.ī‚’aP
ī‚•~%~Thhī‚’
ī‚‘L~P
~
%.ī‚‘~P ī‚‘L~$~
ī‚‘~ī‚•~i~ī‚’
LIMITED
WARRANTY
(
EFFECTIVE:
NOVEMBER
1,
1976
This
warranty
supersedes
all
previous
MILLER
warranties
and
is
ex
clusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTYī‚—Miller
Electric
Mfg.
Co.,
Apple-
I.
Arc
welders,
power
sources,
and
components
I
year
ton,
Wisconsin
warrants
to
Customer
that
all
new
and
unused
2.
Original
main
power
rectifiers
3
years
~
Equipment
furnished
by
Miller
is
free
from
defect
in
workman-
(Labor
ī‚—
I
year
only)
ship
and
material
as
of
the
time
and
place
of
delivery
by
Miller.
3.
All
welding
guns
and
feeder/guns
90
days
No
warranty
is
made
by
Miller
with
respect
to
engines,
trade
~
accessories
or
other
items
manufactured
by
others.
Such
engines,
4.
All
other
Millermatic
Feeders
I
year
I
trade
accessories
and
other
items
are
sold
subject
to
the
warran-
provided
that
the
user
so
notifies
Miller
in
writing
within
thirty
~)
ties
of
their
respective
manufacturers,
if
any.
At
the
present
time,
(30)
days
of
the
date
of
such
failure.
the
manufacturerī‚’s
warranty
on
the
Mag-Diesel
engine
on
DEL-
200
is
limited
to
six
months
and
on
all
other
engines
to
one
year.
5.
Replacement
or
repair
parts
exclusive
of
labor
.
60
days
MILLER
warranty
does
not
apply
to
components
having
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
~I
normal
useful
life
of
less
than
one
(I)
year,
such
as
spot
welder
AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REP-
tips,
relay
and
consactor
points,
MILLERMATIC
parts
that
RESENTATION
AS
TO
PERFORMANCE,
AND
ANY
come
in
contact
with
the
welding
wire
including
nozzles
and
REMEDY
FOR
BREACH
OF
CONTRACT
WHICH,
BUT
nozzle
insulators
where
failure
does
not
result
from
defect
in
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICA
workmanship
or
material.
TION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
In
the
case
of
Millerī‚’s
breach
of
warranty
or
any
other
duty
COURSE
OF
DEALING,
INCLUDING
ANY
IMPLIED
with
respect
to
the
quality
of
any
goods,
the
exclusive
remedies
WARRANTY
OF
MERCHANTABILITY
OR
OF
FITNESS
#
therefor
shall
be,
at
Millerī‚’s
option,
(I)
repair
or
(2)
replace-
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
ment
or,
where
authorized
in
writing
by
Miller
in
appropriate
AND
ALL
EQUIPMENT
FURNISHED
BY
MILLER
IS
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
at
an
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
authorized
Miller
service
Station
or
(4)
payment
of
or
credit for
EXCEPT
AS
EXPRESSLY
PROVIDED
BY MILLER
~N
the
purchase
price
(less
reasonable
depreciation
based
upon
WRITING,
MILLER
PRODUCTS
ARE
INTENDED
FOR
~4
actual
use)
upon
return
of
the
goods
at
Customerī‚’s
risk
and
cx-
ULTIMATE
PURCHASE
BY
COMMERCIAL/INDUS
pense.
Upon
receipt
of
notice
of
apparent
defect
or
failure,
TRIAL
USERS
AND
FOR
OPERATION
BY
PERSONS
~
Miller
shall
instruct
the
claimant
on
the
warranty
claim
proce-
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
(
dures
to
be
followed.
MAINTENANCE
OF
WELDING
EQUIPMENT
AND
NOT
d
As
a
matter
of
general
policy
only,
Miller
may
honor
an
origi-
FOR
CONSUMERS
OR
CONSUMER
USE.
MILLERī‚’
nal
userī‚’s
warranty
claims
on
warranted
Equipment
in
the
event
WARRANTIES
DO
NOT
EXTEND
TO.
AND
NO
RE-
of
failure
resulting
from
a
defect
within
the
following
periods
SELLER
IS
AUTHORIZED
TO
EXTEND
MILLERī‚’S
WAR
from
the
date
of
delivery
of
Equipment
to
the
original
user:
RANTIES
TO,
ANY
CONSUMER.
ī‚“a
~
~
.;~,
~
.r
~ī‚‘t,
~
~
~
~
Jt,
ERRATA
SHEET
After
this
manual
was
printed,
refinements
in
equipment
design
occurred.
This
sheet
lists
exceptions
to
data
appearing
later
in
this
manual.
FILE
COPY
AMENDMENT
TO
SECTION
1
-
INTRODUCTION
RETURN
TO
FOLDER
Add
the
foUowing
NOTE
to
Figure
1
-1.
Specifications
~
If
erratic
motor
operation
is
noticed
at
minimum
speed
settings,
no
unit
defect
is
necessarily
present
but
rather
a
be/ow
specification
speed
caused
by
manufacturing
tolerances.
To
correct
this
condition,
slightly
increase
the
speed
settings.
AMENDMENT
TO
SECTION
3
-
FUNCTION
OF
CONTROLS
Add
the
following
NOTE
to
Section
3-5.
SPEED
CONTROLS
II.~1#~
If
erratic
motor
operation
is
noticed
at
minimum
speed
settings,
no
unit
defect
is
necessarily
present
but
rather
a
be/ow
specification
speed
caused
by
manufacturing
tolerances.
To
correct
this
condition,
slightly
increase
the
speed
settings.
AMENDMENT
TO
SECTION
6
-
TROUBLESHOOTING
See
page
2
for
circuit
diagram.
Item
Or
Dia.
Part
No.
Listed
Replaced
With
Page
No.
Mkgs.
in
Parts
List
Part
No.
Description
Quantity
Item
AA
601
873
601
874
NUT,
steel
.
hex
jam
3/8~24
Item
6
073
685
053
075
PLUG,
4
pin
MS-3106A-14S-2P
1
Item
26
052
180
053
429
BEAR
ING,
ball
(Eff
with
S/Nī‚’
HK230851)
1
Item
28
009
270
053
451
END
PLATE,
left
side
drive
(attaching
hardware
H
&
W)
(Eff
with
S/N
HK230851)
1
item
29
024
601
053
428
BEAR
ING,
ball
(Eff
with
S/N
HK230851)
1
Item
30
009
336
073
240
RING,
retaining~
external
(Eff
with
S/N
HK230851)
.
..
2
Item
50
009
274
059
568
BLOCK,
carriage
(Eff
with
S/N
HK230851)
1
item
52
009
269
053
452
END
PLATE,
right
side
drive
(attaching
hardware
H
&
W)
(EffwithS/NHK230851)
1
Item
70
SRi
022
073
035
914
RECTIFIER,
integrated
30
amp
400
volts
(attaching
hardware
E,
P
&
U)
1
Item
82
009
263
072
402
COVER,
top~
control
box
(attaching
hardware
C)
(Eff
w/JA437480(
Item
94
009
260
072
400
CHASSIS
(Eff
w/JA437480)
1
Item
D
602
095
Deleted
(Eff
w/JA437480)
Page
8
R84
605
914
035
887
RESISTOR,
carbon
film
0.25
watt
3300
ohm
1
VR1
082
722
VARISTOR,
0.6
watt
175
volts
dc
(Eff
w/JB495194(
1
BE
SURE
TOPROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
ī‚•i22/81
OM-lO85PageA
Amend
Figure
6-1.
Circuit
Diagram
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OM-1085
Page
B
TABLE
OF
CONTENTS
Section
No.
Page
No.
SECTION
1
ī‚—
INTRODUCTION
1
.
1.
General
1
1
-
2.
Receiving-Handling
1
1
-
3.
Description
1
1-4.
Safety
1
SECTION
2
ī‚—
INSTALLATION
2-1.
Location
1
2
-
2.
Interconnecting
Cable
Installation
1
2-
3.
Control
Cable
Installation
2
2
.
4.
Power
Cord
Installation
2
2-
5.
Remote
Control
Installation
2
2
-
6.
Remote
Start-Stop
Switch
Installation
2
2-
7.
Remote
Dwell
On
Left
Control
Installation
3
2
-
8.
Remote
Dwell
On
Right
Control
Installation
3
2
-
9.
Remote
Travel
Width
Control
Installation
3
2-10.
Remote
Center
Position
Control
Installation
3
2-11.
Remote
Speed
To
Left
Control
Installation
3
2-12.
Remote
Speed
To
Right
Control
Installation
3
SECTION
3
ī‚—
FUNCTION
OF
CONTROLS
3
-
1.
Power
Switch
4
3-
2.
Pilot
Light
4
3
-
3.
Condition
Switch
4
3
-
4.
Dwell
Controls
4
3
-
5.
Speed
Controls
4
3
-
6.
Travel
Width
4
3-
7.
Center
Position
4
3
-
8.
Travel
Width
And
Center
Position
Internal
Adjustments
4
SECTION
4
ī‚—
SEQUENCE
OF
OPERATION
4
-
1.
Initial
Adjustments
5
4-2.
Shutting
Down
5
SECTION
5
ī‚—
MAINTENANCE
5-1.
Control
6
5
-
2.
Drive
Motor
6
5-3.
Slide
6
5
-
4.
Drive
Belt
6
5
-
5.
Slide
Potentiometer
6
SECTION
6
ī‚—
TROUBLESHOOTING
PARTS
LIST
SECTION
1
-
INTRODUCTION
Input
Power
Speed
Dwell
Total
Slide
Travel
Width
Center
Adjustment
Dimensions
Weight
Control
Slide
Item
Net
Ship
115
Volts
ac~ā€“10%
Single
-
Phase
l6to
130
1PM
.1
to
2
seconds
5ī‚”
1/8ī‚”
to
.ī‚‘.
ī‚•
1
1/2
ā€“
1-1/2ī‚”
Width
11-1/4ī‚”
Height
9-3/8ī‚”
Depth
11-1/4ī‚”
Width
14
Height
14-3/8ī‚”
Depth
5ī‚”
Control
27
lbs.
28
lbs.
ī‚—
5
lbs.
32
lbs.
Slide
33
lbs.
CabIe~
5-1/2
lbs.
May
be
internally
adjusted
up
to
5ī‚”
~The
Oscillator
comes
complete
with
10
foot
motor,
control,
and
power
cords.
Figure
1-1.
Specifications
1
-1.
GENERAL
This
manual
has
been
prepared
especially
for
use
in
familiar
izing
personnel
with
the
design,
installation,
operation,
main
tenance,
and
troubleshooting
of
this
equipment.
All
informa
tion
presented
herein
should
be
given
careful
consideration
to
assure
optimum
performance
of
this
equipment.
1
-2.
RECEIVING-HANDLING
Prior
to
installing
this
equipment,
clean
all
packing
material
from
around
the
unit
and
carefully
inspect
for
any
damage
that
may
have
occurred
during
shipment.
Any
claims
for
loss
or
damage
that
may
have
occurred
in
transit
must
be
filed
by
the
purchaser
with
the
carrier.
A
copy
of
the
bill
of
lading
and
freight
bill
will
be
furnished
by
the
carrier
on
request
if
occasion
to
file
claim
arises.
When
requesting
information
concerning
this
equipment,
it
is
essential
that
Model
Description
and/or
Stock
Number
and
Serial
(or
Style)
Numbers
of
the
equipment
be
supplied.
1-4.
SAFETY
The
following
definitions
apply
to
CAUTION,
IMPORTANT,
and
NOTE
blocks
found
throughout
this
manual:
!
ī‚—
Under
this
heading,
installation,
operating,
and
main-
ī‚—
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
create
a
hazard
to
per
sonnel.
:T=1~
Under
this
heading.
installation,
operating,
and
main
tenance
procedures
or
practices
will
be
found
that
if
not
carefully
followed
may
result
in
damage
to
equip.
ment.
1
-
3.
DESCRIPTION
This
Unit
is
an
electronically
controlled
mechanical
device
that
moves
the
welding
gun
back
and
forth
at
an
adjustable
rate
(see
Figure
1-11.
The
degree
and
scope
of
adjustment
is
provided
by
the
electronic
control.
This
Weld
Oscillator
is
designed
for
automatic
welding
operations
in
a
horizontal
plane.
NOTE
Under
this
heading,
explanatory
statements
will
be
found
that
need
special
emphasis
to
obtain
the
most
efficient
operation
of
the
equipment.
SECTION
2
-
INSTALLATION
2-1.
LOCATION
See
Figure
2-1
for
dimensional
information
on
the
Weld
Oscillator.
Lead
lengths
must
be
considered
when
installing
the
Weld
Oscillator
(10
foot
motor,
control,
and
power
cords
are
supplied(.
Suitable
space
should
be
allowed
for
making
necessary
connections.
A.
Control
(Figure
2-1,
Item
A)
Holes
are
provided
in
the
base
supports
for
mounting
purposes.
Mount
the
control
in
the
desired
place.
B.
Slide
(Figure
2-1,
Item
B)
Holes
are
provided
in
the
feet
of
the
slide
housing
for
mounting
purposes.
Mount
the
slide
in
the
desired
place.
h
Id
b
td
:h
th
mo
tor
up
~on
top)
to
keep
the
motor
and
cables
free
from
heat
and
weld
spatter
I
C.
Gun
Mounting
Plate
(Figure
2-1,
Item
C)
Holes
are
provided
in
the
gun
mounting
plate
to
allow
the
desired
gun
to
be
adapted
to
it.
Mount
the
desired
gun
to
the
gun
mounting
plate.
IMPORTANT
Ensure
that the
screws
that
hold
the
gun
to
the
gun
mounting
plate
do
not
protrude
through
the
mounting
plate
since
they
may
hit
the
slide
cover
and
impede
operation
(see
Figure
2-1,
Item
C).
I
2-2.
INTERCONNECTING
CABLE
INSTALLATION
(Figure
2-1)
Connect
the
11-pin
plug
from
the
interconnecting
cable
to
the left-hand
receptacle
on
the
control.
Connect
the
re
maining
11-socket
end
to
the
corresponding
receptacle
on
the
slide.
When
inserting
plugs
into
receptacles,
align
plug
keyways
with
receptacle
keys,
and
rotate
the
threaded
collar
securely
onto
the
receptacle.
U
U
I
U
U
OM-1085
Page
1
5ī‚”
5/8ī‚”
14ī‚”
*14.3/8ī‚”
to
bottom
of
mounting
feet
1ī‚’ī‚’
TB-052
314
Figure
2-1.
Weld
Oscillatorī‚’s
Dimensions
2-5.
REMOTE
CONTROL
INSTALLATION
This
Oscillator
is
designed
with
remote
control
capability.
When
installing
any
remote
control,
the
following
steps
must
be
taken:
A.
Disconnect
the
power
cable
from
the
115
volts
ac
power
supply.
B.
Remove
the
outer
enclosure
frOm
the
control.
C.
Route
leads
through
cable
clamp
connector
on
lower
right-hand
side
of
control
front
panel
(see
Figure
2-1
and
up
through
plastic
clamp
by
terminal
strips
(see
Figure
3-2).
D.
Make
connections
as
instructed
to
terminal
strips
iT
and
2T
(see
Figure
2-3).
E.
The
necessary
remote
control(s)
must
be
supplied
by
the
customer.
2-6.
REMOTE
START-STOP
SWITCH
INSTALLATION
2
-
3.
CONTROL
CABLE
INSTALLATION
(Figure
2-1)
Connect
the
4-pin
plug
from
the
control
cable
to
the
center
receptacle
on
the
control.
Connect
the
remaining
4-socket
end
to
the
corresponding
receptacle
on
the
slide.
When
inserting
plugs
into
receptacles,
align
plug
keyways
with
receptacle
keys,
and
rotate
the
threaded
collar
securely
onto
the
receptacle.
This
graph
represents
recommended
weight
limits
at
various
distances
from
the
mounting
plate.
The
Oscillator
will
carry
these
loads
at
max.
speed
with
no
abnormal
wear.
CENTER
OF
GRAVITY
IINCHES
FROM
MOUNTING
PLATE
TA-052
831
Figure
2-2.
Torgue
Curves
2-
4.
POWER
CORD
INSTALLATION
(Figure
2-1)
Connect
the
3.prong,
twistlock
plug
from
the
power
cable
to
the
right-hand
receptacle
on
the
control.
Insert
the
plug
and
rotate
it
clockwise.
Connect
the
remaining
end
to
a
115
volts
ac.
single-phase
power
supply.
PAYLOAD
POUNDS
:
~
iT
8
53
3
54
7
46
2
45
12
49
13
14
15 16
o
~
Iīƒ˜~V1
~7~lJI~Zll
~IIļ¬Hļ¬IIļ¬lIł
O
2T
9
50
47
48
55
56
24
51
26
52
21
22
TA-052
318
Figure
2-3.
Terminal
Strips
If
Remote
Start-Stop
capability
is
desired,
connect
a
nor
mally-closed
switch
to
terminals
21
and
22
on
terminal
strip
2T.
For
the
remote
switch
to
be
operational,
switch
(S2(
must
be
in
the
RUN
position.
Page
2
2-7.
REMOTE
DWELL
ON
LEFT
CONTROL
INSTAL
LATION
If
Remote
Dwell
On
Left
capability
is
desired,
remove
the
jumper
link
across
terminals
51
and
24
on
terminal
strip
2T,
and
connect
a
potentiometer
(of
equal
value
to
R7;
see
Parts
List)
to
terminals
9
and
24
on
terminal
strip
2T
(see
Figure
2-4).
24
Figure
2-4.
Remote
Potentiometer
Connections
2-8.
REMOTE
DWELL
ON
RIGHT
CONTROL
INSTAL
LATION
If
Remote
Dwell
On
Right
capability
is
desired,
remove
the
jumper
link
across
terminals
26
and
52
on
terminal
strip
2T,
and
connect
a
potentiometer
(of
equal
value
to
R6;
see
Parts
List)
to
terminals
9
and
26
on
terminal
strip
2T
(see
Figure
2-5).
Figure
2-5.
Remote
Potentiometer
Connections
2-9.
REMOTE
TRAVEL
WIDTH
CONTROL
INSTAL
LATION
If
Remote
Travel
Width
capability
is
desired,
remove
the
jumper
link
across
terminals
13
and
14,
and
across
12
and
49
on
terminal
strip
1
T.
Connect
a
potentiometer
(of
equal
value
to
R12;
see
Parts
List)
to
terminals
12
and
13
(on
terminal
strip
iT)
and
terminal
9
(on
terminal
strip
2T(.
(See
Figure
2-6.)
Figure
2-6.
Remote
Potentiometer
Connections
2-10,
REMOTE
CENTER
POSITION
CONTROL
INSTAL
LATION
If
Remote
Center
Position
capability
is
desired,
remove
the
lumper
link
across
terminals
47
and
48
(on
terminal
striD
2T)
and
across
15
and
16
(on
terminal
strip
iT).
Connect
a
potentiometer
(of
equal
value
to
RiO;
see
Parts
List)
to
terminals
48
and
55
(on
terminal
strip
2T)
and
terminal
15
(on
terminal
strip
iT). (See
Figure
2-7.)
15
55
48
Figure
2-7.
Remote
Potentiometer
Connections
2-11.
REMOTE
SPEED
TO
LEFT
CONTROL
INSTAL
LATION
If
Remote
Speed
To
Left
capability
is
desired,
remove
the
jumper
link
across
terminals
53
and
8
on
terminal
strip
IT.
and
Connect
a
potentiometer
(of
equal
value
to
R5;
see
Parts
List)
to
terminals
53
and
46
on
terminal
strip
1
T
(see
Figure
2-8).
53
Figure
2-8.
Remote
Potentiometer
Connections
2-12.
REMOTE
SPEED
TO
RIGHT
CONTROL
INSTAL
LATION
If
Remote
Speed
To
Right
capability
is
desired,
remove
the
jumper
link
across
terminals
3
and
54
on
terminal
strip
1
T,
and
Connect
a
potentiometer
(of
equal
value
to
R4;
see
Parts
List)
to
terminals
54
and
45
on
terminal
strip
iT
(see
Figure
2-9).
Figure
2-9.
Remote
Potentiometer
Connections
NOTE
NOTE
If
multi-remote
speed
adjustments
(more
than
one
of
either
left
or
right)
are
desired,
then
an
optional
multi-pass
Circuit
card
must
be
installed.
(Contact
Factory
Sales
Department).
I
26
46
54
45
With
multi-Travel
Width
or
multi-Center
Position
remote
potentiometers,
switching
must
be
done
with
the
type
of
relay
that
has
gold
alloy
cross
bar
type
contacts
or
the
equivalent.
I
OM-1085
Page
3
SECTION
3-FUNCTION
OF
CONTROLS
3-
1.
POWER
SWITCH
(Figure
3-1)
Placing
the
POWER
switch
in
the
ON
position
applies
115
volts
ac
to
the
Unit
and
places
it
in
an
operational
status.
Placing
the
POWER
switch
in
the
OFF
position
shuts
the
Oscillator
down.
Placing
the
POWER
switch
in
the
OFF
position
does
not
remove
power
from
all
of
the
Oscillators
internal
circuitry.
Completely
terminate
all
electrical
power
to
the
Oscillator
by
removing
the
115
volts
ac
plug
from
its
power
supply
before
attempting
any
inspection
or
work
inside
the
unit.
~ding
is
n
ot
!ng
perf
~m
ed
,
do
n
ot
leave
the
unit
in
the
STAND
BY
position
for
prolonged
periods
of
time.
Instead,
shut
the
unit
down
by
placing
the
POWER
switch
in
the
OFF
position.
I
C.
RUN
This
position
is
the
primary
working
condition
of
the
unit.
All
front
panel
controls
are
adjustable
while
welding
in
this
condition.
J
3
-4.
DWELL
CONTROLS
(Figure
3-1)
3-
2.
PILOT
LIGHT
(Figure
3-1)
A
pilot
light
is
provided
on
the
front
panel
to
indicate
that
the
POWER
switch
is
ON
and
that
the
unit
is
energized.
3
-
3.
CONDITION
SWITCH
(Figure
3-1)
A.
SET-UP
This
position
permits
accurate
readjustment
of
the
CENTER
POSITION
(without
readjusting
the
other
controls)
by
shorting
out
the
TRAVEL
WIDTH
potentiometer
thus
reducing
the
TRAVEL
WIDTH
to
zero.
U
m
I
The
CENTER
POSITION
control
is
fully
operational
in
the
SET-UP
and
RUN
conditions,
but
only
partially
operational
in
the
STAND
BY
condition.
B.
STANDBY
This
position
automatically
centers
and
electrically
locks
the
gun
in
place.
In
this
position
the
front
panel
controls
(with
the
exception
of
the
CENTER
POSITION
control)
will
be
inoperative.
The
CENTER
POSITION
control,
if
rotated,
will
cause
the
gun
to
move,
but
in
one
direction
only
and
without
return
capability.
These
controls
(DWELL
ON
LEFT
and
DWELL
ON
RIGHT)
regulate
the
length
of
time
that
the
gun
will
remain
at
either
end
of
its
set
TRAVEL
WIDTH
before
reversing
direction.
These
controls
are
calibrated
in
percent
and
provide
from
.1
to
2
seconds
of
adjustment.
3-
5.
SPEED
CONTROLS
(Figure
3-1)
These
controls
(SPEED
TO
LEFT
and
SPEED
TO
RIGHT)
regulate
the
rate
at
which
the
gun
will
travel
from
one
end
of
the
TRAVEL
WIDTH
to
the
othe.
These
controls
are
calibrated
in
percent
and
provide
from
16
to
130
ipm
of
adjustment.
3-
6.
TRAVEL
WIDTH
(Figure
3-1)
This
Control
regulates
the
width
of
oscillation
and
is
calibrated
in
percent.
The
TRAVEL
WIDTH
is
factory
set
to
provide
1/8ī‚”
to
1.1/2ī‚”
of
adjustment.
This
control
may
be
internally
adjusted
up
to
5
(see
Section
3-7).
3
-
7.
CENTER
POSITION
(Figure
3-1)
This
control
adjusts
the
center
of
oscillation
to
the
right
or
to
the
left.
This
control
is
calibrated
to
provide
1-1/2ī‚”
of
adjustment
from
the
actual
center
of
the
slide.
3-8.
TRAVEL
WIDTH
AND
CENTER
POStTION
IN
TERNAL
ADJUSTMENTS
(Figure
3-2)
To
make
internal
adjustments,
proceed
as
follows:
Figure
3.1.
Weld
Oscillator
Controls
TA-052
315
Page
4
A.
Place
the
POWER
switch
in
the
OFF
position
(Condition
Switch
should
be
in
the
RUN
position).
Placing
the
POWER
switch
in
the
OFF
position
does
not
remove
power
from
all
of
the
Oscillators
internal
circuitry.
Completely
terminate
all
electrical
power
to
the
Oscillator
by
removing
the
115
volts
ac
plug
from
its
power
supply
before
attempting
any
inspection
or
work
inside
the
unit.
B.
Remove
the
power
cable
from
the
115
volts
ac
power
supply.
c.
Remove
the
outer
enclosure
from
the
control.
D.
The
TRAVEL
WIDTH
may
be
internally
adjusted
by
rotating
potentiometer
CR13)
in
a
counterclockwise
di.
rection
to
increase
the
travel.
However,
if
the
TRAVEL
WIDTH
is
internally
increased,
the
CENTER
POSITION
sensitivity
must
be
internally
decreased
by
rotating
potentiometer
(R9
and
Rh,
a
dual
potentiometer)
in
a
clockwise
direction.
(The
CENTER
POSITION
sensitivity
must
be
decreased
so
that
the
slideī‚’s
internal
components
do
not
hit
the
end(s)
of
the
housing).
See
Figure
3-2
for
location
of
internal
adjusting
points.
E.
Replace
outer
enclosure
onto
control,
and
secure
it
in
place.
F.
Connect
the
power
cable
to
its
115
volts
ac
power
supply.
G.
Place
the
POWER
switch
in
the
ON
position,
and
check
for
satisfactory
operation.
If
it
has
not
been
achieved,
TA.052
705
repeat
Steps
A
to
G
until
the
desired
operation
is
obtained.
Figure
3-2.
Internal
Components
SECTION
4
-
SEQUENCE
OF
OPERATION
4-
1.
INITIAL
ADJUSTMENTS
Never,
under
any
circumstances,
operate
the
weld
oscillator
with
any
portion
of
the
Outer
enclosure
removed.
In
addition
to
a
hazard,
improper
cooling
may
result
in
damage
to
the
weld
oscillator
com
ponents.
Warranty
is
void
if
the
weld
oscillator
is
operated
with
any
portion
of
the
outer
enclosure
removed.
1.
Make
all
necessary
connections
as
instructed
in
Section
2.
2.
Place
the
POWER
switch
on
the
Oscillator
in
the
ON
position.
__________________
3.
Place
the
Condition
Switch
in
the
SET-UP
position.
4.
Adjust
the
CENTER
POSITION
control
so
that
the
gun
is
centered
over
the
work
as
desired.
5.
Place
the
Condition
Switch
in
the
RUN
position.
6.
Adjust
the
TRAVEL
WIDTH
control
for
the
desired
travel
width.
Adjust
the
Speed
Controls
for
the
desired
speeds.
Adjust~
the
Dwell
Controls
for
the
desired
dwells.
U
Terminal
U
I
Potentiometer
(R9
and
Ri
l.a
dual
potentiometer)
For
Center
Position
I
I
CAUTION
U
I
Prior
to
welding,
it
is
imperative
that
p
clothing
(welding
coat
and
gloves)
and
eye
(glasses
and/or
welding
helmet)
be
put
on.
comply
may
result
in
serious
and
even
bodily
damage.
~protective
protection
Failure
to
permanent
9.
Commence
welding.
NOTE
U
I
U
When
the
Condition
switch
is
moved
from
the
STAND
BY
position
to
the
RUN
position,
the
slide
will
always
start
in
a
direction
away
from
the
drive
motor.
7.
8.
NOTE
I
All
of
the
front
panel
controls
may
be
adjusted
while
i
welding.
-
4-
2.
SHUTTING
DOWN
1.
Place
the
Condition
Switch
in
the
STAND
BY
position.
2.
Place
the
POWER
switch
on
the
Oscillator
in
the
OFF
position.
OM-1085
Page
5
SECTION
5
-
MAINTENANCE
U
Placing
the
POWER
switch
in
the
OFF
position
does
not
remove
power
from
all
of
the
Oscillators
internal
circuitry.
Completely
terminate
all
electrical
power
to
the
Oscillator
by
removing
the
115
volts
ac
plug
from
its
power
supply
before
attempting
any
inspection
or
work
inside
the
unit.
.~
ī‚—-I
Retighten
bolts.
Before
replacing
cover,
inspect
drive
gears.
plastic
gears,
etc..
for
dirt;
if
necessary
brush
off
and
blow
Out
with
a
clean,
dry
airstream.
Replace
cover.
5
-
5.
SLIDE
POTENTIOMETER
(See
Parts
List)
If
it
should
become
necessary
to
replace
the
slide
potenti
ometer,
proceed
as
follows:
1.
Remove
cover
over
drive
belt.
5-1.
CONTROL
The
control
requires
no
periodic
maintenance.
5-2.
DRIVE
MOTOR
The
drive
motor
requires
no
initial
service
nor
any
periodic
maintenance.
rī‚”i
Do
not
disassemble
the drive
motor.
Synchronous
stepping
motors
will
be
adversely
affected
if
taken
apart.
5
-3.
SLIDE
The
outside
of
the
unit,
particularly
around
the
neoprene
seals,
should
be
kept
clean
by
blowing
it
off
with
a
clean,
dry
airstream.
Periodically,
depending
on
conditions
and
usage,
it
may
become
necessary
to
clean
and
lubricate
the
slide.
Remove
gun,
mounting
plate,
and
slide
cover.
Wipe
the
two
shafts
clean.
Lubricate
the
two
linear
ball
bearings
with
a
light
weight
(No.
20(
oil;
the
oil
holes
are
facing
up
for
ease
of
service.
Do
not
overoil.
Wipe
ball
screw
shaft
clean,
and
apply
a
thin
coat
of
heavy
weight
(No.
90)
oil
to
this
shaft.
Replace
cover,
mounting
plate,
and
gun.
5.4
DRIVE
BELT
The
drive
belt
is
a
toothed-type
timing
belt
and
should
not
need
servicing.
However,
should
adjustment
or
replacement
be
required,
provisions
are
made
for
tensioning
the
belt.
Remove
cover
over
drive
belt.
Loosen
the
four
halts
in
the
slotted
holes,
and
slide
the
belt
housing
toward
the
motor
end.
The
belt
should
be
sung,
but
not
overtightened.
2.
Loosen
set
screws,
and
remove
gear
from
potenti
ometer
shaft.
3.
Remove
the
two
screws
holding
the
potentiometer
mounting
plate.
4.
Remove
the
nut
holding
the
potentiometer
to
mount
ing
plate,
slide
potentiometer
out,
and
allow
it
to
hang
free.
5.
Install
new
potentiometer
(see
Parts
List)
in
mounting
plate.
6.
Unsolder
wires
from
old
potentiometer,
and
resolder
wires
to
the
labeled
terminals
on
new
potentiometer
as
follows:
white
to
slider
(S),
red
to
counterclockwise
(CCW),
and
black
to
clockwise
(CW).
7.
Reinstall
gear
onto
potentiometer
shaft,
and
tighten
set
screws
(hub
on
gear
should
be
flush
with
end
of
shaft).
8.
Manually
move
the
gun
mounting
plate
to
the
center
of
the
slide.
9.
Turn
gear
on
slide
potentiometer
to
one
extreme,
and
then
back
it
off
five
turns.
10.
Align
gear
on
slide
potentiometer
with
small
gear
on
ball
screw.
U
NOTE
I
A
small
amount
of
backlash
should
be
maintained
between
these
two
gears.
11.
Insert
screws,
and
secure
the
potentiometer
mounting
plate.
SECTION
6
-
TROUBLESHOOTING
Hazardous
voltages
are
present
on
the
internal
Circuit
ry
of
the
weld
oscillator
as
long
as
power
is
connected
to
the
unit.
Disconnect
power
before
attempting
any
inspection
or
work
on
the
inside
of
the
unit.
Trouble
shooting
of
internal
circuitry
should
be
performed
by
qualified
personnel
only
It is
assumed
that
proper
installation
has
been
made,
according
to
Section
2
of
this
manual,
and
that
the
weld
oscillator
has
been
functioning
properly
until
this
trouble
developed.
Use
this
chart
in
conjunction
with
the
Circuit
diagram
while
performing
troubleshooting
procedures.
If
the
trouble
is
not
remedied
after
performing
these
procedures,
the
nearest
Factory
Authorized
Service
Station
should be
contacted.
In
all
cases
of
equipment
malfunction,
the
manufacturerī‚’s
recommendations
should
be
strictly
followed.
L
The
following
chart
is
designed
to
diagnose
and
provide
remedies
for
some
of
the
troubles
that
may
develop
in
this
weld
oscillator.
.
Page
6
TROUBLE
PROBABLE
CAUSE
REMEDY
Unit
completely
inoperative
(pilot
light
(PL)
not
on).
-
Open
line
fuse.
Replace
open
line
fuse.
Unit
completely
inoperative
(pilot
light
(PL)
on).
Fuse
(Fl)
open.
Replace
fuse
(Fl).
Erratic
operation.
Plug(s)
not
secure
in
receptacles(s),
Check
all
plugs,
and
ensure
that
they
are
secure
in
receptacles.
Slide
stalled
and
motor
hums.
Obstruction
or
excessive
loading.
Remove
obstruction
and/or
reduce
loading.
POWER
switch
(Si)
must
be turned
OFF
and
then
back
ON
to
restart
oscillator.
1f
it
becomes
necessary
to
replace
any
fuse
in
the
Weld
Oscillator,
ensure
that
a
fuse
of
the
proper
size
is
used.
OM-1085
Page
7
C.)
th
IC)
C
0
C.)
0
z
C
4-
U
C.)
~o
a
00
0
~o
~o
00
~a
~o
~o
~o
~o
~O
00
_o
~o
~o
~o
ī‚•ī‚‘o
~a
~o
~a
-o
~o
~o
~o
ī‚‘a
-o
I
ī‚—
I
-~
~(
0
~n~i
ī‚—~~y--~~-
J_~_
_J~0
I
I
-
ī‚—~-~-
ī‚—Em
~i~)
1~I
rī‚—-ī‚—
~
I
a
I~I
_J_~_J~.
~-~I
I
I
I
ī‚—E~i1-ī‚—
I
I
a
I
I
_I;l___E~I1_~:
ī‚—~
1j~:
~
~
I
~I
aI
~I
ī‚—~Cī‚—ī‚—ī‚—
I
~
Iyyy
E-
ī‚—~-ī‚—
I
I
~,
~,
~
:
~I
~
I
T~ī‚’~Y~Y1
-~i~I~
ī‚°
ī‚‘~
I
0
~
I.
-
-4E--
-~
~
I
-
I
E
S
4-
U
S
C.)
I
DI
U.
L~tr
~t
~
-~t;
-:
~-~ī‚€_
~
i__JL~
~
~
~IE
I
~IE-~,I
ī‚—
-
H
I
Page
8
November
1977
FORM:
OM-1
085
Effective
With
Serial
No.
HH042002
MODEL
Weld
Oscillator
STOCK
NO.
008 644
MODEL/STOCK
NO.
SERIAL/STYLE
NO.
DATE
PURCHASED
PARTS
LIST
MILLER
ELECTRIC
MFG.
CO.
APPLETON,
WISCONSIN,
USA
54911
NWSA
CODE
NO.
4579
Item
No.
Factory
Part
No.
Figure
A
Main
Assembly
Description
Quantity
1
009
286
SLIDE,
oscillator
(See
Fig.
B
Page
4)
1
2
009
266
CABLE,
control
(consisting
of)
1
3
073
686
.
PLUG,
4
socket
MS-3106A-14S-2S
1
4
039
828
.
STRAIN
RELIEF,
receptacle/plug
3057~6
2
5
601
469
.
CABLE.
power.
shielded
l8ga
3/c
(order
by
foot)
10
ft.
6
073
685
.
PLUG,
4
pin
97-3106A-14S-2P-639
1
7
075
044
CABLE,
interconnecting
10
ft
(consisting
of)
1
8
073
139
.
CORD,
portable
No.
16
6/c
(order
by
foot)
10
ft.
9
039
734
.
CLAMP,
cable
2
10
073
517
.
PLUG,
11
pin
MS-3106A-20-33P
1
11
073
516
.
PLUG,
11
socket
MS-3106A-20-33S
1
12
009 285
CONTROL
BOX
(See
Figure
C
Page
6)
1
13
052
723
CORD
ASSEMBLY
(consisting
of)
1
14
056
442
.
CONNECTOR
BODY,
twistlock
-
grounded
2P3W
1
15
073
690
.
CAP,
straight
.
grounded
2P3W
1
16
600
341
.
CORD,
portable
No.
16
3/c
(order
by
foot)
12
ft.
Fig
B
1
2
7
4
6
TB-052
310
Figure
A
ī‚—
Main
Assembly
BE
SURE
TO
PROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM.1085
Page
1
Item
Dia.
Factory
No.
Mkgs.
Part
No.
Description
Quantity
Attaching
Hardware
For
Figure
B
A
602
070
SCREW,
machine
.
steel
truss
hd
6-32
x
3/8
B
605
472
SCREW,
machine
.
steel
fillister
hd
6-32
x
1/2
C
602
101
SCREW,
machine
.
steel
round
hd
10-24
x
5/8
D
052
777
SCREW,
machine
-
steel
flat
hd
10-24
x
5/8
E
602
116
SCREW,
machine
-
steel
round hd
10-24
x
2-1/4
F
602
023
SCREW,
cap
-
steel
socket
hd
10-24
x
3/4
G
602
178
SCREW,
set
.
steel
socket
hd
1/4.20
x
3/4
H
601
926
SCREW,
cap
-
steel
hex hd
1/4.20
x
5/8
J
602
004
SCREW,
cap-steel
socket
hd
1/4-20
x
3/4
K
602
008
SCR
EW,
cap
-
steel
socket
hd
1/4-20
x
1
L
602
143
SCREW,
self-tapping
-
round
hd
6-32
x
3/4
M
602
169
SCREW,
set
-steel
socket
hd
8-32
x
3/16
N
604
804
SCREW,
sheet
-
metal
hex
hd
No.
8
x
3/8
P
602
238
WASHER,
flat
-
steel
3/16
0
602
241
WASHER,
flat
-
steel
SAE
1/4
R
603 586
WASHER,
flat
-
steel
SAE
No.
6
T
602
203
WASHER,
lock
-
steel
split
No.
10
U
602
200
WASHER,
lock
-
steel
split
No.
8
V
602
198
WASHER,
lock
-
steel
split
No. 6
W
602
207
WASHER,
lock
-
steel
split
1/4
X
602
213
WASHER~
lock
-steel
split
3/8
Y
601
861
NUT,
steel
-
hex
10-24
Z
601
859
NUT,
steel
-
hex
6-32
AA
601
873
NUT,
steel
-
hex
full
3/8-24
OM-1085
Page
2
N
N
0
I-
0
4-
a,
U
a,
U,
a,
a,)
U..
Page
3
21
009272
1
22
009
259
1
23
009290
1
24
009
240
1
25
009256
1
26
052
180
1
27
009 255
2
28
009
270
1
29
024601
2
30
009
336
4
31
009291
1
32
009
252
2
33
009
283
1
34
009
264
1
35
009 243
1
36
009276
1
37
010142
2
38
010116
1
39
009
244
1
40
077
175
1
41
076624
1
42
009
337
4
43
009
287
1
44
009
289
1
45
009
262
1
46
R8
009237
1
47
009241
1
48
009
253
1
49
009
239
1
50
009
274
1
51
009
257
1
52
009 269
1
53
009
279
1
54
009251
1
55
009
250
1
56
009278
4
BE
SURE TO
PROVIDE
STOCK,
MODEL,
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
Item
Dia.
No.
Mkgs.
Factory
Part
No.
Description
Quantity
Figure
B
009 286
Slide,
Oscillator
(See
Fig.
A
Page
1
Item
1)
Mot
R
C4
RC6
MOUNTING
PLATE,
drive
(attaching
hardware
N)
COVER
(attaching
hardware
D)
SHAFT,
oscillator
(attaching
hardware
G)
SHAFT,
oscillator
(attaching
hardware
G)
STRIP,
support
SCREW/NUT,
ball
-
drive
BAR,
side
(attaching
hardware
D)
END
PLATE,
left
side
drive
(attaching
hardware
H
&
W)
BEARING,
ball
RING,
retaining
-
internal
PILLOW
BLOCK,
3/4
shaft
-
thin
ball
bushing
(attaching
hardware
F)
SPACER,
mounting
-
potentiometer
PULLEY,
gearbelt
HOUSING,
drive
(attaching
hardware
H,
Q
&
W)
INSULATOR,
mounting
-
motor
MOTOR
(attaching
hardware
C,
P.
5,
1
&
B)
CLAMP,
nylon
5/16
clamp
dia
(attaching
hardware
A,
V
&
Z)
GROMMET,
rubber
3/8
ID
x
1/2
mounting
hole
PANEL,
mounting
-
connectors
receptacle
(attaching
hardware
A,R,V&Z)
RECEPTACLE,
11
pin
MS-3102A-20-33P
(attaching
hardware
L)
RECEPTACLE,
4
pin
MS-3102A-14S-2P
(attaching
hardware
L)
BUSHING,
flanged
0.194
ID
x
3/8
OD
x
5/16
PULLEY,
gearbelt
BELT,
gear
17
inches
long
COVER,
drive
(attaching
hardware
N)
POTENTIOMETER,
WW
10
turn
1.5
watt
10K
ohm
GEAR,
potentiometer
(attaching
hardware
M)
GEAR,
ball
.
screw
(attaching
hardware
M)
BRACKET,
mounting
-
potentiometer
(attaching
hardware
E,
P
&
T)
BLOCK,
carriage
PAN,
base
END
PLATE,
right
side
drive
(attaching
hardware
H
&
W)
MOUNTING,
flange
-
ball
nut
(attaching
hardware
K)
CLAMP,
retainer
-
seal
(attaching
hardware
B,
V
&
Z)
SEAL,
clamp
-
retainer
FOOT,
closer
.
seal
(attaching
hardware
U)
Attaching
Hardware
for
Figure
B
(See
Page
2)
OM.1085
Page
4
K
0
0
2
4-
C
(3
ī‚‘3
0
ci
U.
Co
N
-
0
0
C,
(.4
It)
p
C
I.
N
0
4
N
I
0
Cl
U.
N
0
~0
(0
\
et
(0
(0
m
cī‚’~
ī‚‘-0
10
0
000
ID
,-
e
I
I
r~
N
C.,
U
CI
LI.
U.
Page
5
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Miller HH042002 Owner's manual

Miller
Brand
Miller
Model
HH042002
Category
Welding System
Type
Owner's manual
This manual is also suitable for

Miller HH042002 is an electronically controlled mechanical device that moves the welding gun back and forth at an adjustable rate. It is designed for automatic welding operations in a horizontal plane. The degree and scope of adjustment is provided by the electronic control.

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