OM-889B February 1993 Eff. w/Serial Number KC237900 Processes Automatic Welding Description Automatic Welding Sidebeam Travel Master SB-10D Visit our website at www.MillerWelds.
From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
TABLE OF CONTENTS Section No. Page No. SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. 1-2. General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 SECTION 2 – SPECIFICATIONS 2-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SECTION 3 – INSTALLATION 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. Location . .
Section No. Page No. SECTION 7 – SEQUENCE OF OPERATION 7-1. 7-2. 7-3. Gas Metal Arc Welding (GMAW) And Flux Cored Arc Welding (FCAW) - Continuous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gas Metal Arc Welding (GMAW) And Flux Cored Arc Welding (FCAW) - Spot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. GENERAL INFORMATION AND SAFETY A. General Information presented in this manual and on various labels, tags, and plates on the unit pertains to equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equipment. The nameplate of this unit uses international symbols for labeling the front panel controls.
S G K J I R H L M A B C D N E F P O O Q Q Side View Front View SD-122 295 Side View Inches Millimeters A B C D E F G H* I 1 14 12 16 24 40-1/2 6-1/4 54 79 25.4 355.6 304.8 406.4 609.6 1028.7 158.8 1371.6 2006.6 * Crossarm can also be mounted at 49-3/4 in. (1263.7 mm) or 58-1/4 in. (1479 mm). Front View J L M N O P Q R S 66-3/4 19-1/2 11-1/2 24 1 6 104-1/2 8 61-3/4 120 Millimeters 1695.5 495.3 292.1 609.6 25.4 152.4 2654.3 203.2 1568.
SECTION 3 – INSTALLATION 3-1. LOCATION (Figures 2-1 And 3-1) 1. Secure beam mounting post assemblies to floor (hardware must be customer supplied). 2. Install beam onto mounting post assemblies using supplied 1/2-13 x 1-1/4 in. hardware. Tighten screws, then loosen them 1/4 turn. Select an installation site which provides the following: 1. Mounting surface capable of supporting weight of Sidebeam assembly 2. Adequate space for carriage travel and equipment installation 3.
Motor Cord And Plug Bearing Bar Motor Release Lever Motor Adjustment Screw And Lock Nut Beam (Be sure beam rests on horizontal surface of mounting post assemblies.) Motor Motor Spring Ring Pinion Gear Motor Mounting Bracket 1/2-13 x 1-1/4 in. Leveling Screw (2 In Each Mounting Post).
. Install supplied pinion gear guard onto bottom side of motor casing. 1. Adjust position of front two cam rollers on carriage as follows: If applicable, remove the four screws securing the Carriage Control to the mounting bracket, and remove the control from the bracket. 10. 2. IMPORTANT: All directions, such as left or right, are with respect to the operator facing the carriage. Remove the securing screws from control wrapper, and remove wrapper. 3.
3-8. ELECTRICAL CONNECTIONS WARNING: ELECTRIC SHOCK can kill. • Do not touch live electrical parts. • Shut down Carriage Control and welding power source, and disconnect input power employing lockout/tagging procedures before inspecting, installing, or adjusting. Lockout/tagging procedures consist of removing plug from receptacle, padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.
WORN OR CUT CORD can cause serious personal injury or equipment damage. • Route and secure all cords from welding power source to Carriage Control and Automatic Weld Control over top of beam between carriage release lever and carriage motor casing. • Secure cords away from motor pinion gear and beam gear rack on back of beam. • Secure all cords away from work area.
*Terminals located on either terminal strip 1T or terminal strip 2T in weld control. 2. Remove the securing screws from control wrapper, and remove wrapper. To connect cord C to weld control, proceed as follows: 3. Loosen upper strain relief clamp on rear of control. a. For 2A models only, reinstall jumper link between terminals M and N of terminal strip 2T, and connect cord between terminals L and P of 2T. Proceed to Step 7. 4. To connect cord R to Carriage Control, proceed as follows: 6. a.
AUTOMATIC 1DA Weld Control Rear View Of Carriage Control E Carriage Drive Motor F A 30 ft. (9 m) Voltage Sensing Cord B 5 ft. (1.5 m) Motor Control Cord C 10 ft. (3 m) Shunt Control Cord D 25 ft. (8 m) Electrical Input/Contactor Control/Voltage Control Cord E 6 ft. (1.8 m) Remote Start/Stop Cord (Spade Terminal Ends) F 6 ft. (1.8 m) Carriage Movement Control Cord (Friction Lug and Spade Terminal Ends) G Accessory/External Control Device Connection H 5 ft. (1.
AUTOMATIC 2A Weld Control Rear View Of Carriage Control E Carriage Drive Motor F Welding Power Source H F A E B G 115 VAC Cord And Plug D C A 25 ft. (8 m) Voltage Sensing Cord B 5 ft. (1.5 m) Motor Control Cord C 25 ft. (8 m) Electrical Input/Contactor Control/Voltage Control Cord D 10 ft. (3 m) Shunt Control Cord E 5 ft. (1.5 m) Remote Start/Stop Cord F 6 ft. (1.8 m) Carriage Movement Control Cord G Accessory/External Control Device Connection H 5 ft. (1.
4-3. SKIP WELDING CONNECTIONS IMPORTANT: Automatic Weld Controls without a digital panel are not capable of Skip Welding. B. Required Equipment The following cords must be obtained by the customer for skip weld connections: 1. A cord of proper type and length to make connections in the Automatic Weld Control. The cord should be a five-conductor cord connected to a triple-pole, single-throw switch. One conductor of the cord should tie together two switch commons of the triple-pole, single-throw switch.
5. Use Figure 4-1 to locate leads 1, 2, and 3 from the triple-pole, single-throw switch. IMPORTANT: The switch leads are not numbered. The leads are referred to as leads 1, 2, and 3 in Figure 4-1 to simplify installation. 6. Install lead 1 to terminal A of terminal strip 2T. 7. Use Table 4-2 to install leads 2 and 3 to appropriate terminals of terminal strip 1T. 8. Locate receptacle RC10 on component mounting panel on rear panel of unit. Connect one of the remaining leads to 3/16 in.
E. Connections To Sidebeam Carriage Control WARNING: Read and follow safety information at beginning of entire Section 4-3 before proceeding. 1. If applicable, remove the four screws securing the Carriage Control to the mounting bracket, and remove the control from the bracket. 2. Remove the securing screws from control wrapper, and remove wrapper. 3. Loosen upper strain relief clamp on rear of control, and route remaining end of four-conductor cord through clamp to terminal strip 1T. 4.
7. Reposition and secure control onto mounting bracket. switch is closed, or the unit receives a command from an external weld control. 8. Install remaining end of interconnecting cord to Automatic Weld Control according to its Owner’s Manual. To install the Fixture Delay switch, proceed as follows: 1. Remove the four screws securing the Carriage Control to the mounting bracket, and remove the control from the bracket. 2. Remove the securing screws from control wrapper, and remove wrapper. 3.
IMPORTANT: If the optional Limit Switch is installed, use a momentary-contact switch(es) for remote start and stop control (see Step 4). Using a maintainedcontact (relay) for remote start and stop control will render the optional Limit Switch inoperative. 4. a. Connect normally-open contact of pole corresponding to movement right to terminal E on terminal strip 2T and to terminal F on terminal strip 1T. a.
Connect To Terminal F On Terminal Strip 2T Travel Right Switch Position Connect To Terminal D On Terminal Strip 1T Reinstall and secure control wrapper. 8. Reposition and secure control onto mounting bracket. 5-5. REMOTE TRAVEL SPEED CONTROL (Figure 5-3) Travel Left Switch Position Connect To Terminal F On Terminal Strip 1T Connect To Terminal G On Terminal Strip 1T 7. Connect To Terminal E On Terminal Strip 2T Connect To Terminal E On Terminal Strip 1T Ref. SA-121 140 Figure 5-2.
SECTION 6 – OPERATOR CONTROLS Digital Meter Jog Speed Control Fuse F1 (See Section 8-2) Circuit Breaker CB1 (See Section 8-2) Power Switch Optional Delay Time Control Start Push Button Stop Push Button Jog Direction Switch Travel Direction Switch Travel Speed Control SA-122 296 Figure 6-1. Operator Controls 6-1. POWER SWITCH (Figure 6-1) POWER ON V OFF Placing the POWER switch in the ON position energizes the Carriage Control circuitry.
CAUTION: CHANGING POSITION OF WELD TRAVEL DIRECTION SWITCH while carriage is moving can damage unit. • Allow carriage to stop completely before changing travel direction. • Do not change position of TRAVEL DIRECTION switch (except to center (off) position) while carriage is moving. 6-5. 6-7.
SECTION 7 – SEQUENCE OF OPERATION WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause serious injury; IMPROPER AIR FLOW AND EXPOSURE TO ENVIRONMENT can damage internal parts. • Do not touch live electrical parts. • • Keep all covers in place while operating. WORN OR CUT CABLES can cause serious personal injury or equipment damage.
IMPORTANT: If Skip welding function is installed and BURNBACK and CRATER TIME controls are both set at minimum (0 seconds), unit may not advance at jog speed. To ensure proper Skip welding function, both the BURNBACK and CRATER TIME controls must be set to appropriate times for weld process. 10. 8. a. Set wire feed speed controls and weld cycle timers to desired positions to program the weld cycle as instructed in weld control Owner’s Manual.
SECTION 8 – MAINTENANCE & TROUBLESHOOTING IMPORTANT: Every six months inspect the labels on the unit for legibility. All precautionary labels must be maintained in a clearly readable state and replaced when necessary. See Parts List for part number of precautionary labels. Lockout/tagging procedures consist of removing input plug from receptacle, padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.
CAUTION: DISASSEMBLY OF MOTOR FIELD MAGNETS can result in personal injury and equipment damage. • Limit drive motor repairs to brush replacement. The field magnets are very strong. If disassembly is attempted, injury to fingers and hands may result from the rotor being drawn back into the motor. The field magnets are matched sets and operation may be affected if the magnets are tampered with. Warranty is void if the motor is tampered with.
Long-Nose Pliers Lockout/tagging procedures consist of removing input plug from receptacle, padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device. Spring Assembly Brush Box Tab Brush Brush Box MOVING PARTS can cause serious injury. • Keep clear of pinch points. HOT SURFACES can cause severe burns. • Allow cooling period before servicing. IMPORTANT: Spring assembly hooks here. S-0089 Figure 8-3.
Table 8-1. Troubleshooting (Continued) TROUBLE PROBABLE CAUSE REMEDY Carriage and auxiliary equipment (if applicable) do not start when START button PB1 is pressed. Improper jumper connections. Check and correct jumper connections according to Section 5 or the circuit diagram. Relay CR1. Check and replace CR1, if necessary. Auxiliary equipment start signal not received.
Notes OM-889 Page 25
SECTION 9 – ELECTRICAL DIAGRAMS Diagram 9-1.
Circuit Diagram No.
OM-889 Page 28 Diagram 9-2. Wiring Diagram Wiring Diagram No.
OM-889 Page 29 Diagram 9-3. Circuit Diagram For Motor Control Board PC1 Circuit Diagram No.
OM-889 Page 30 Diagram 9-4. Circuit Diagram For Timer Board PC2 Circuit Diagram No.
Circuit Diagram No. SA-094 456-A Diagram 9-5. Circuit Diagram For Tachometer Board PC3 Circuit Diagram No. SA-119 758 Diagram 9-6.
OM-889 Page 32 55 1 54 Fig 10-2 2 53 3 4 5 7 52 8 51 9 2 10 12 13 14 15 48 44 43 42 41 40 29 37 28 38 27 39 24 36 33 32 31 30 35 45 23 Includes Items 23, 24 46 44 26 25 22 34 43 47 21 49 50 7 6 19 20 not available unless listed. Ref. SD-122 293-A . Hardware is common and Figure 10-1.
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Main Assembly (Section A) . . . 1 . . . . . . . . . . . . . . 128 972 . . . 2 . . . . . . . . . . . . . . . 119 730 . . . 3 . . . . . . . . . . . . . . . 119 743 . . . 4 . . . . . . . . . . . . . . . 119 731 . . . 5 . . . . . . . . . . . . . . . 119 744 . . . 6 . . . . . . . . . . . . . . . 119 738 . . . 7 . . . . . . . . . . . . . . . 119 657 . . . 8 . . . . . . . . . . . . . . 120 122 . . . 9 . . . . . . . . . . . . . . . 118 806 . . 10 .
Item No. Dia. Mkgs. Part No. Description Quantity Figure 10-1. Main Assembly (Section A) (Continued) . . 49 . . . . . . . . . . . . . . 120 821 . . 50 . . . . . . . . . . . . . . 601 881 . . 51 . . . . . . . . . . . . . . . 119 737 . . 52 . . . . . . . . . . . . . . . 115 070 . . 53 . . . . . . . . . . . . . . . 117 987 . . 54 . . . . . . . . . . . . . . 122 630 . . 55 . . . . . . . . . . . . . . 601 965 . . . . . . . . . . . . . . . . . . . 092 176 . . . . . . . . . . . . . . . . . . . 047 636 . . . .
Item No. Part No. Description Quantity Figure 10-1. Main Assembly (Section B) ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... 1 ......... 2 ......... 3 ......... 4 ......... 5 ......... 6 ......... 7 ......... 8 ......... 9 ......... 10 . . . . . . . . 11 . . . . . . . . . 12 . . . . . . . . 13 . . . . . . . . 14 . . . . . . . . 15 . . . . . . . . 16 . . . . . . . .
OM-889 Page 36 47 46 45 37 39 44 48 43 53 42 52 2 1 51 3 49 41 6 7 40 8 9 10 11 Figure 10-2. Control Box 50 5 4 39 38 37 26 12 13 14 15 27 16 28 25 17 19 24 23 22 36 35 34 21 20 30 33 32 31 29 18 not available unless listed. SC-122 376-B .
Item No. Dia. Mkgs. Part No. Description 128 972 Figure 10-2. Control Box (Fig 10-1 Item 1) . . . 1 . . . . . . . . . . . . . . 123 154 . . . 2 . . . . . . . . . . . . . +115 937 . . . 3 . . . . PC2 . . . . . . 115 052 . . . . . . . . . . . . . . . . . . . 057 084 . . . . . . . . PLG10 . . . . 117 718 . . . . . . . . . . . . . . . . . . . 108 895 . . . . . . . . PLG2 . . . . . 115 091 . . . . . . . . . . . . . . . . . . . . 113 746 . . . . . . . . PLG8 . . . . 131 054 . . . . . . . . . . . . . . . . .
Item No. Dia. Mkgs. Part No. 128 972 . . 41 . . 42 . . 43 . . 44 . . 45 . . 46 . . 47 . . 48 . . 49 . . 50 . . 51 . . 52 . . 53 . . . . . . . . . . . . . . . 115 940 . . . . . . . . . . . . . . . . 046 432 . . . . . . . F1 . . . . . *073 426 . . . . . . . . . . . . . . . . 079 725 . . . . . . . . . . . . . . . . 097 922 . . . . . . . . . . . . . . . . 021 385 . . . . . . . . . . . . . . . . . 117 843 . . ......................... . . . . . S4 . . . . . 088 409 . . . . . . . R4 . . . . . 603 856 . . . .
Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number.
