Miller WELD OSCILLATOR User manual

May 1988
FORM: OM-1085C
Effective With Serial No. JF914709
~
// Millerfi
OWNERS
MODEL
WELD OSCILLATOR
MANUAL
IMPORTANT Read and understand the entire contents of both this
manual and the power source manual used with this unit, with special
emphasis on the safety material throughout both manuals, before in-
Miller Electrtc
stalling, operating,
Appleton, WI 54912 USA
maintaining this equipment. This unit and these
instructions are for use only by persons trained and experienced in the
safe operation of welding equipment. Do not allow untrained persons to
install, operate,
not
or
or
Mfg.Co.
AM~erG,o~pud Con~D~n~
P0. Box 1079
Tel. 414-734-9821
maintain this unit. Contact your distributor if you do
fully understand these instructions.
PRINTED IN U.S.A.
ADDITIONAL COPY PRICE 75 CENTS
.-
EFFECTIVE: FEBRUARY 16. 1988
This warranty supersedes all
LIMITED WARRANTY
tions
previous MILLER
-
Subject
warranties and is exclusive with
to the terms and condi-
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin
warrants to its
Distributor/Dealer that all
new
and unused
Equipment furnished by Miller is free from defect in workmanship and material as of the time and place of delivery by Miller.
No warranty is made by Miller with respect to engines, trade
accessories or other items manufactured by others. Such
engines, trade accessories and other items are sold subject to
the warranties of their respective manufacturers, if any
All
engines are warranted by their manufacturer for one year from
date of original purchase, except Tecumseh engines which
.
have
a two
specified below, Millers warranty does not apply
having normal useful life of less than one (1)
year, such as spot welder tips, relay and contactor points,
MILLERMATIC parts that come in contact with the welding
wire including nozzles and nozzle insulators where failure does
not result from defect in workmanship or material.
Except
to
~
~
~
~
?t~
~
year warranty,
as
Miller shall be required to
honorwarranty claims on warranted Equipment in the event of failure resulting from a defect
within the following periods fiom the date of delivery of Equipment to the original user:
1. Arc
3.
welders,
Original
(labor
~
~
~
p~rsources,
robots, and componenta
4. All
-
main power rectifiers
1 year only)
welding
guns,
feeder/guns
.
1 year
1 year
!~
~
warranties
expressed
or
implied.
In the case of Millets breach of warranty or any other duty
with respect to the quality of any goods, the exclusive remedies
therefore shall be, at Millets option (1) repair or (2) replacement
or, where authorized in
the reasonable cast of
writing by Miller in appropriate cases, (3)
repair or replacement at an authorized
Miller service station or (4) payment of or credit for the puithese
price (less reasonable depreciation based upon actuaI~use) upon
risk and expense. MILLERs
retum of the goods at Customers
option of repair or replacement will be F.O.B., Factory, at
Appleton, Wisconsin, or F.O.B., at a MILLER authorized service
facility, therefore, no compensation for transportation costs of
any kind will be allowed. Upon receipt of notice of apparent
defect or failure, Miller shall instruct the claimant on the warranty
claim procedures to be followed.
that Miller is notified in
90 days
1 year
..
60
days
6 months
writing
within
thirty (30) days
of the date of such failure.
As
a
matter of
submitted
BREACH OF CONTRACT WHICH, BUT FOR ThIS PROViSION,
MIGHT ARISE BY IMPLICATION, OPERATION OF LAW.
CUSTOM OF TRADE OR COURSE OF DEAUNG, INCLUDING
ANY IMPUED WARRANTY OF MERCHANTABIUTY OR OF
FITNESS FOR PARTICULAR PURPOSE, WiTH RESPECT TO
ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EX
CLUDED AND DISCLAIMED BY MILLER.
EXPRESSLY PROVIDED BY MILLER IN
INTENDED
FOR
ARE
PRODUCTS
PURCHASE BY COMMERCIAL/INDUSTRIAL
USERS AND FOR OPERATION BY PERSONS TRAINED AND
EXPERIENCED IN THE USE AND MAINTENANCE OF
EXCEPT
and torches
5. All other Millermatic Feeders
6. Replacement or repair parts, exclusive of labor
7. Batteries
provided
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTA
TION AS TO PERFORMANCE, AND ANY REMEDY FOR
3 years
11
~j
or
components
2. Load banks
]
other guarantees
no
general policy only, Miller may honor claims
by the original user within the foregoing periods.
.-....
.-
WRITING,
ULTIMATE
AS
MILLER
WELDING EQUIPMENT AND NOT FOR CONSUMERS OR
CONSUMER USE. MILLERS WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUThORIZED TO EXTEND
MILLERS WARRANTIES TO, ANY CONSUMER.
-..
.
ERRATA SHEET
After this manual was
to data
appearing
printed, refinements
in
equipment design occurred. This sheet lists exceptions
iater in this manual.
AMEN DMENT TO PARTS LIST
Amend Parts List as follows:
Effective With Seriai No. JJ503984
Dia.
Mkgs.
4-20
6999-
9-
**First
PC4
PC3
RC5
RC7
RC5
RC7
Part
No.
Replaced
089 479
128 673
047
009
009
073
073
123 154
With
497
296
124 771
294
124 770
687
Deleted
Deleted
515
digit represents page
+073 687
+073 515
Description
WASHER, shoulder 5/8 OD x .203 ID
LABEL, warning general precautionary
CIRCUIT CARD, HF filter
CIRCUIT CARD, HF filter
RECEPTACLE, 4 socket MS-3102A-14S-2S
RECEPTACLE, 11 socket MS-3102A-20-35S
digits following dash represent item no.
+These items removed from circuit cards and added to Control Box.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
no
-
d
Quantity
4
1
1
1
1
1
TABLE OF CONTENTS
SECTION 1
1
1
-
-
-
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1. Introduction
2. General Precautions
1
Welding
4
1 -3. Arc
1
-
1
6
4. Standards Booklet Index
SECTION 2
-
INTRODUCTION
2-1. General
2
2. Receiving-Handling
7
2
7
7
-
3. Description
2-4. Safety
-
SECTION 3
-
7
INSTALLATION
7
3-1. Location
3
2. Interconnecting Cable Installation
3
3. Control Cable Installation
7
-
-
3
3
-
4.
Power Cord Installation
5. Remote Control Installation
3
6. Remote Start-Stop Switch Installation
3 -7. Remote Dwell On Left Control Installation
3
8. Remote Dwell On Right Control Installation
-
-
-
9. Remote Travel Width Control Installation
3-10. Remote Center Position Control Installation
3-11. Remote Speed To Left Control Installation
3-12. RemoteSpeedTo Right Control Installation
3
-
SECTION 4
4
4
-
-
-
Pilot
Light
10
-
10
10
10
-
4 -6. Travel Width
4
4
-
-
Center Position
8. Travel Width And Center Position Internal
5
5
1.
-
11
7.
SECTION 5
2.
SECTION 6
-
6-3. Slide
6
4. Drive Belt
6
5. Slide Potentiometer
-
-
-
11
11
12
MAINTENANCE
6-1. Control
6-2. DriveMotor
SECTION 7
Adjustments
SEQUENCE OF OPERATION
Initial Adjustments
Shutting Down
-
8
9
9
9
9
9
9
10
10
3. Condition Switch
4-4. Dwell Controls
4
5. Speed Controls
4
8
8
8
OPERATOR CONTROLS
1. Power Switch
2.
No.
Page
Section No.
TROUBLESHOOTING
12
12
12
12
12
SECTION
1
SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE.
-
INTRODUCTION
We learn by experience.
Learning safety through personal experience, like a
child touching a hot stove is harmful, wasteful, and un
wise. Let the experience of others teach you.
1-1.
-
welding or cutting, (and chipping) to protect the eyes
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1 -3A.2.
Avoid
Safe practices developed from experience in the use of
welding and cutting are described in this manual.
Research, development, and field experience have
evolved reliable equipment and safe installation, opera
tion, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The
reason for the safe practices may not always be given.
Some are based on common sense, others may require
technical volumes to explain. It is wiser to follow the
oily
or
greasy
clothing. A spark
may
Hot metal such as electrode stubs and
never be handled without gloves.
ignite
them.
workpieces
should
Medical first aid-and eye treatment. First aid facilities
a qualified first aid person should be available for
each shift unless medical facilities are close by for im
mediate treatment of flash burns of the eyes and skin
and
burns.
rules.
worn when working on overhead or
confined space. A hard hat should be worn when
others work overhead.
Ear
Read and understand these safe
practices before at
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par
ticular equipment used and their instruction manuals,
for personal safety and for the safety of others.
Failure to observe these safe practices may cause
serious injury or death. When safety becomes a habit,
the equipment can be used with confidence.
practices are divided into two Sections:
General Precautions, common to arc welding and
cutting; and 2 Arc Welding (and Cutting) (only).
These safe
1
-
-
Reference standards: Published Standards on safety are
also available for additional and more complete pro
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANSI Z49.1 is
the most
complete.
Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip
ment installation, use, and service.
The National Electrical
in
plugs should be
a
Flammable hair
sons
intending
material.
Burn Prevention
protective clothing gauntlet gloves designed for
welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuff less trousers
to avoid entry of sparks and slag.
use
-
in
Wear helmet with
safety goggles
or
should not be used by per
cut.
Toxic Fume Prevention
B.
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them
with adequate ventilation as described in ANSI Stan
dard Z49.1 listed 1 in Standards index. NEVER ventilate
with oxygen.
cadmium -, zinc -, mercury -, and beryllium
similar materials, when welded (or cut) may
and
bearing
produce harmful concentrations of toxic fumes. Ade
quate local exhaust ventilation must be used, or each
person in the area as well as the operator must wear an
air-supplied respirator. For beryllium, both must be us
Lead
-
-,
ed.
Metals coated with
tilated,
DIfferent arc welding processes, electrode alloys,
and fluxes can produce different fumes, gases,
and radiation levels. In addition to the information
In this manual, be sure to consult flux and elec
trode manufacturers for specific technical data
and precautionary measures concerning their
Wear
weld
or
containing materials that
emit
toxic fumes should not be heated unless coating is
removed from the work surface, the area is well ven
1-2. GENERAL PRECAUTIONS
A.
preparations
to
or
or
Work in
tilated
a
the operator
wears an
air-supplied respirator.
confined space only while it is being ven
necessary, while wearing an air-supplied
and, if
respirator.
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen con
centration dangerously. Do not bring gas cylinders into
a confined space.
Leaving confined space, shut OFF gas supply at source
prevent possible accumulation of gases in the space
if downstream valves have been accidently opened or
left open. Check to be sure that the spae is safe before
re-entering it.
to
glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
OM-1085 Page 1
highly toxic gas, and other lung and eye irritating pro
ducts. The ultraviolet (radiant) energy of the arc can
decompose trichloroethylene and per
chloroethylene vapors to form phosgene. DO NOT
also
WELD
where solvent vapors
or cut
can
be drawn into
cutting atmosphere or where the radiant
welding
energy can penetrate to atmospheres containing even
of trichloroethylene or per
minute
amounts
chloroethylene.
the
or
C.
Fire and
Explosion
never be welded on or cut, unless container has first
been cleaned as described In AWS Standard A6.O,
listed 7 in Standards index.
This includes: a thorough steam or caustic cleaning (or
solvent or water washing, depending on the com
bustibles solubility) followed by purging and inerting
with nitrogen or carbon dioxide, and using protective
equipment as recommended in A6.O. Waterfilling just
below working level may substitute for inerting.
a
Prevention
A container with unknown contents should be cleaned
(see paragraph above). Do NOT depend on sense of
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated
material; misuse of compressed gases and cylinders;
Hollow castings
and short circuits.
welding
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or
doors, and through wall or floor openings, out of sight
of the goggled operator. Sparks and slag can fly 35 feet.
Explosive atmospheres. Never weld or cut where the air
dust, gas, or liquid vapors (such
as gasoline).
smell
short circuits.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, yen
tilators. If the work cannot be moved, move com
1.
Pressure
protection with
covers or
touching combustibles
on
work should be
explode.
on
shields.
opposite sides should
(or cut). Walls, ceilings, and floor
protected by heat-resistant
near
covers or
Regulators
Regulator relief valve is designed
snug-fitting, fire-resistant
welded
can
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-i, SAFE
GASES
IN
COMPRESSED
OF
HANDLING
CYLINDERS, listed ii in Standards index.
regulator from
not be
containers must be vented before
Compressed Gas Equipment
bustibles at least 35 feet away out of reach of sparks
and heat; or protect against ignition with suitable and
Walls
or
cutting. They
explosion:
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause
or
to determine if it is safe to weld or cut.
may contain flammable
D.
To prevent fires and
sight
or
protect
any
to
protect only the
overpressure; it is not intended to
downstream equipment. Provide such
one or more
relief devices.
Never connect a regulator to a
gas other than that for which
cylinder containing
the regulator was
designed.
shields.
faulty regulator from service immediately
repair (first close cylinder valve). The following
symptoms indicate a faulty regulator:
Remove
Fire watcher must be
standing by with suitable fire ex
tinguishing equipment during and for some time after
welding or cutting if:
for
if gas leaks externally.
Leaks
if delivery pressure
Excessive Creep
rise with downstream valve closed.
-
a.
appreciable combustibles (including building
construction)
b.
are
within 35 feet
appreciable combustibles are further than 35
can be ignited by sparks
openings (concealed or visibe) in floors or
feet but
c.
walls
within
35
feet
may
expose
combustibles
roofs,
radiant
or
or
adjacent to walls, ceilings,
metal partitions can be ignited by
conducted heat.
permit should be obtained before operation to
supervisors approval that adequate precautions
Hot work
ensure
have been taken.
After work is done, check that
glowing embers, and flames.
area
Faulty Gauge
-
if gauge
pointer
stop pin when pressurized,
nor
is free of sparks,
does not
returns
to
move
to
off
stop pin
after pressure release.
Repair. Do NOT attempt repair. Send faulty
regulators for repair to manufacturers designated
repair center, where special techniques and tools
are used by trained personnel.
2.
Cylinders
be
Cylinders
must
leaks and
damage
to
handled carefully to prevent
their walls, valves, or safety
devices:
electrical circuit contact with cylinders in
cluding third rails, electrical wires, or welding cir
cuits. They can produce short circuit arcs that may
Avoid
An empty container that held combustibles, or that can
produce flammable or toxic~vapors when heated, must
lead to
OM-1085 Page 2
continues
com
bustibles to sparks
d.
-
a
serious accident. (See i -3C.)
ICC
DOT
or
marking must be on each cylinder. It is
safety when the cylinder is properly
Coil
excess
hose to prevent kinks and
tangles.
assUrance of
an
handled.
Protect hose from
damage by sharp edges, and by
sparks, slag, and open flame.
cylinders with
rely on color to
Notify supplier if unmarked.
gas content. Use only
gas marked on them; do not
Identifying
f
name
identify
gas
NEVER
DEFACE
markings
content.
on a
alter
or
number,
name,
illegal
It is
cylinder.
or
other
dicate leaks.
Repair leaky or worn hose by cutting
ing (1-2D3). Do NOT use tape.
Prohibited use. Never use a cylinder or its contents for
other than its intended use, NEVER as a support or
roller.
or secure
cylinders
they
so
cannot be knocked
area out
and splic
Proper Connections
4.
promptly.
Locate
regularly for leaks, wear, and loose con
pressured hose in water; bubbles in
nections. Immerse
and hazardous.
Empties: Keep valves closed, replace caps securely;
mark MT; keep them separate from FULLS and
return
Examine hose
cylinder valve outlet of impurities that may clog
damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
outlet away from people and sources of ignition. Wipe
Clean
orifices and
with
a
clean lintless cloth.
over.
regulator to cylinder. Before connecting, check
regulator label and cylinder marking agree, and
that the regulator inlet and cylinder outlet match.
NEVER CONNECT a regulator designed for a particular
gas or gases to a cylinder containing any other gas.
Match
Passageways and work areas. Keep cylinders
areas where they may be struck.
Transporting cylinders.
With
crane, use
a
clear of
a secure
sup
platform or cradle. Do NOT lift cylinders
off the ground by their valves or caps, or by chains,
port such
as a
slings,
magnets.
or
Do NOT expose
slag, and flame,
cylinders
to excessive
etc. that may cause
heat, sparks,
rupture. Do
Stuck valve. Do NOT
that
Mixing
con
Cool with water spray
hammer
use a
can not
be
or
retighten using properly fitting wrench.
not
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
cylinder valve
your supplier.
Tighten connections. When assembling threaded
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
allow contents to exceed 130F.
where such exposure exists.
a
that the
wrench to open
CGA adapter (available from your sup
and regulator, if one is required.
Use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
Adapters. Use
a
plier)
cylinder
between
Regulator outlet (or hose) connections may be iden
tified by right hand threads for oxygen and left hand
threads (with grooved hex on nut or shank) for fuel gas.
opened by hand. Notify
5.
gases. Never try to mix any gases in
cylinder.
a
Pressurizing Steps:
regulator of residual gas through suitable vent
opening cylinder (or manifold valve) by turning
adjusting screw in (clockwise). Draining prevents ex
cessive compression heat at high pressure seat by
allowing seat to open on pressurization. Leave adjusting
screw engaged slightly on single-stage regulators.
Drain
before
Never refill any
cylinder.
Cylinder fittings should
never
be modified
or
exchang
ed.
3.
Hose
Prohibited
for the
Stand to side of
use.
Never
specified gas.
hose other than that designed
general hose identification rule
use
A
is: red for fuel gas, green for oxygen, and black for inert
gases.
Use ferrules or clamps designed for the hose (not or
dinary wire or other substitute) as a binding to connect
hoses to fittings.
tubing splices.
splice hose.
No copper
tings
to
Avoid
long
only standard brass fit
ground
to
while
opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in
creases slowly. When gauge is pressurized
(gauge
reaches regulator maximum) leave cylinder valve in
following position: For oxygen, and inert gases, open
fully to seal stem against possible leak. For fuel gas,
open to less than one turn to permit quick emergency
shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
prevent kinks and abuse. Suspend
keep it from being
otherwise damaged.
hose off
on, or
runs to
Use
regulator
run
over,
stepped
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capful of Ivory
OM-1085
Page 3
Liquid* or equivalent per gallon of water). Bubbles in
dicate leak. Clean off soapy water after test; dried soap
is combustible.
Protect filter plate with
Cracked
clear
a
broken helmet
or
worn; radiation can pass
User
E.
Cracked, broken,
leaky or defective equipment from service im
mediately for repair. See User Responsibility statement
in equipment manual.
supply
broken, pitted,
loose filter plates must be replaced
Replace clear cover plate when
spattered.
or
IMMEDIATELY.
at source and drain gas.
or
struck.
eyes
Rope Staging-Support
G.
shield should NOT be
to cause burns.
through
Flash goggles with side shields MUST be worn under
the helmet to give some protection to the eyes should
the helmet not be lowered over the face before an arc is
Leaving EquIpment Unattended
Close gas
or
plate.
Responsibilities
Remove
F.
cover
Looking at an arc momentarily with unprotected
(particularly a high intensity gas-shielded arc) can
retinal burn that may leave
in the field of vision.
cause a
area
Rope staging-support should not be
cutting operation; rope may burn.
used for
welding
a
permanent dark
or
3.
1-3. ARC WELDING
Comply with precautions in
1-1, 1 -2, and this section. Arc Welding, properly done,
is a safe process, but a careless operator invites trouble.
The equipment carries high currents at significant
voltages. The arc is very bright and hot. Sparks fly,
fumes rise, ultraviolet and infrared energy radiates,
weidments are hot, and compressed gases may be us
ed. The wise operator avoids unnecessary risks and pro
tects himself and others from accidents. Precautions
are described here and in standards referenced in index.
-
Protection of
Enclosed
separate
Nearby Personnel
For production welding, a
area.
enclosed bay is best. In open areas,
operation with low-reflective, non-
welding
room or
surround
the
combustible
screens or
tion, particularly
at
panels. Allow for free air circula
floor level.
Viewing the weld. Provide face shields for all persons
who will be looking directly at the weld.
Others working in
area.
See that all persons
are
wearing
flash goggles.
Burn Protection
A.
Before
Comply
with
The
welding
tion
can
precautions
in 1-2.
is intense and visibly bright. Its radia
eyes, penetrate lightweight clothing,
reflect from light-colored surfaces, and burn the skin
and eyes. Skin burns resemble acute sunburn, those
from
gas-shielded
1.
are
to
weld, make
sure
that
screen
flaps
or
closed.
arc
damage
DONT
GET
TIONS.
starting
bay doors
arcs
are
BURNED;
Protective
more
severe
COMPLY
and
WITH
B.
Toxic Fume Prevention
Comply
with
precautions
in 1 -2B.
painful.
PRECAU
Generator engine exhaust must be vented to the outside
air. Carbon monoxide
Clothing
C.
long-sleeve clothing (particularly for gas-shielded
to gloves, hat, and shoes (1 -2A). As
necessary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fireresistant leggings. Avoid outergarments of untreated
Wear
Fire and
Comply
with
can
kill.
Explosion Prevention
precautions
in 1 -2C.
arc) in addition
Equipments
rated
welding equipment.
capacity. Do not overload arc
It may overheat cables and cause a
fire.
cotton.
Bare skin
protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button
pockets to prevent entry of sparks.
2.
Eye and Head Protection
Loose cable connections may overheat
fire.
arc.
NEVER look at
an
helmet or shield containing a filter plate shade
12 or denser must be used when welding. Place
over face before striking arc.
Welding
no.
Trademark
OM-1085
Page 4
of Proctor & Gamble.
flash and
Never strike an arc on a cylinder or other pressure
vessel. It creates a brittle area that can cause a violent
rupture or lead to such a rupture later under rough
handling.
Protect eyes from exposure to
electric arc without protection.
or
cause a
D.
Compressed Gas Equipment
Comply
with
precautions
in 1 -2D.
2.
Shock Prevention
E.
Exposed hot conductors or other bare metal in the
welding circuit, or in ungrounded, electrically-HOT
equipment can fatally shock a person whose body
DO NOT STAND, SIT, LIE,
a conductor.
LEAN ON, OR TOUCH a wet surface when welding,
without suitable protection.
becomes
To protect
Fully insulated electrode holders should be used. Do
NOT
3.
ness or sweat can not
be avoided. Sweat,
water, or
electrically HOT
sea
and an
reduces the body surface
electrical resistance, enabling dangerous and possibly
lethal currents to flow through the body.
-
or
holders with
protruding
screws.
Connectors
Fully insulated lock-type connectors should be used
join welding cable lengths.
4.
part
use
to
against shock:
Keep body and clothing dry. Never work in damp area
without adequate insulation against electrical shock.
Stay on a dry duckboard, or rubber mat when damp
moisture
Electrode Holders
between
body
grounded
metal
-
Cables
Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
lethal shock
or damaged insulation to avoid possibly
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
-
Keep cable dry, free of oil and grease, and protected
sparks.
from hot metal and
1.
Grounding the Equipment
5.
When arc welding equipment is grounded according to
the National Electrical Code, and the work is grounded
according to ANSI Z49.1 Safety In Welding And Cut
ting, a voltage may exist between the electrode and
any conducting object. Examples of conducting objects
include, but are not limited to, buildings, electrical
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
6.
tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power
source
Terminals And Other Exposed Parts
Electrode
a.
Equipment with output on/off control (con
tactor)
is
off.
Welding power sources for use with the gas
metal arc welding (GMAW), gas tungsten
arc welding (GTAW) and similar processes
normally are equipped with devices that per
mit on-off control of the welding power out
put. When so equipped the electrode wire
becomes electrically HOT when the power
source switch is ON and the welding gun
installing, connect the frames of each unit such
as welding power source, control, work table, and
water circulator to the building ground. Conductors
must be adequate to carry ground currents safely.
Equipment made electrically HOT by stray current may
shock, possibly fatally. Do NOT GROUND to electrical
conduit, or to a pipe carrying ANY gas or a flammable li
quid such as oil or fuel.
When
switch is closed. Never touch the electrode
wire or any conducting object in contact
with the electrode circuit unless the welding
power source is off..
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip
ment ground lead to the third (live) wire, or the equip
a dangerous condi
ment will become electrically HOT
tion that can shock, possibly fatally.
b.
Equipment without output on/off control
(no contactor)
Welding
-
metal
cesses
welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
sources
used with shielded
welding (SMAW) and similar pro
may not be equipped with welding
power output on-off control devices. With
such equipment the electrode is electrically
HOT when the power switch is turned 0N
Never touch the electrode unless the
welding power source is off.
Before
frames at connections.
If a line cord with a ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a threeprong plug is added for connection to a grounded
mating receptacle, the ground lead must be connected
to the ground prong only. If the line cord comes with a
three~prong plug, connect to a grounded mating recep
tacle. Never remove the ground prong from a plug, or
use a plug with a broken oft ground prong.
power
arc
7.
Safety Devices
Safety devices such as interlocks and circuit breakers
should not be disconnected or shunted out.
Before installation, inspection, or service, of equip
ment, shut OFF all power and remove line fuses (or lock
-
OM-lO85Page5
red-tag switches)
to prevent accidental turning ON of
power. Disconnect all cables from welding power
source, and pull all 115 volts line-cord plugs.
or
Do not open power circuit or change polarity while
welding. If, in an emergency, it must be disconnected,
guard against shock burns, or flash from switch arcing.
6.
ANSI Standard Z49.2, FIRE PREVENTION IN
THE USE OF CUTTING AND WELDING PRO
CESSES obtainable from the American National
Standards Institute, 1430 Broadway, New York,
NY 10018.
7.
AWS Standard A6.0, WELDING AND CUT
TING CONTAINERS WHICH HAVE HELD COM
BUSTIBLES obtainable from the American
Welding Society, 550 Le Jeune Rd.
P.O. Box 351040, Miami FL 33135.
8.
NFPA Standard 51, OXYGEN
FUEL GAS
SYSTEMS FOR WELDING AND CUTTING ob
tainable from the National Fire Protection
Association, 470 Atlantic Avenue, Boston, MA
02210.
9.
NFPA Standard 70-1978, NATIONAL ELEC
TRICAL CODE obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
10.
NFPA Standard 51 B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, 470 Atlantic Avenue,
Boston, MA 02210.
11.
CGA Pamphlet P-i, SAFE HANDLING OF COM
PRESSED GASES IN CYLINDERS obtainable
from the Compressed Gas Association, 500 Fifth
Avenue, New York, NY 10036.
12.
CSA Standard Wi 17.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the
Canadian Standards Association, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada M9W iR3.
13.
WELDING
SAFETY
NWSA
booklet,
BIBLIOGRAPHY obtainable from the National
Welding Supply Association, 1900 Arch Street,
Philadelphia, PA 19103.
14.
American Welding Society Standard AWSF4.1
Recommended Safe Practices for the Prepara
tion for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances,
obtainable from the American Welding Society,
550 LeJeune Rd. P.O. Bc~c 351040, M~, FL 33135.
15.
ANSI Standard Z88.2~Practice for Respiratory
Protection obtainable from the American Na
tional Standards Institute, 1430 Broadway, New
York, NY 10018..
Leaving equipment unattended. Always shut OFF and
disconnect all power to equipment.
Power disconnect switch must be available
welding
F.
power
near
the
source.
Protection For Wearers Of Electronic Life
Devices (Pacemakers)
Support
Magnetic
fields
from
high
currents
can
affect
pacemaker operation. Persons wearing electronic life
support equipment (pacemaker) should consult with
their doctor before going
spot welding operations.
near arc
welding, gouging,
or
1-4. STANDARDS BOOKLET INDEX
more information, refer to the following standards
their latest revisions and comply as applicable:
For
or
1.
ANSI Standard Z49.1, SAFETY IN WELDING
AND CUTTING obtainable from the American
Welding Society, 550 Le Jeune Rd, P.O. Box
351040, Miami, FL 33135.
2.
NIOSH, SAFETY AND HEALTH IN ARC
WELDING AND GAS WELDiNG AND CUTTING
obtainable from the Superintendent of
Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
3.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the U.S. Govern
ment Printing Office, Washington, D.C. 20402.
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
5.
ANSI Standard Z41.1, STANDARD FOR MENS
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway, New York, NY 10018.
OM-1085
Page
6
-
SECTION 2
Input
-
Total Slide
Speedt
Power
Dwell
Travel
INTRODUCTION
Dimensions
Center
Width
Adjustment
~.
115 Volts
1/8
.1 to
130
Single
5
2 seconds
Width
Width
14
Net
Ship
Control
27 lbs.
32 lbs.
Slide
28 lbs.
33 lbs.
5 lbs.
5-1/2 lbs.
14-3/8
9-3/8
1-1 ~
Item
Height
Height
–1-1/2
to
1PM
Phase
Slide
11-1/4
l6to
ac.– 10%
Weight
Control
Depth
Depth
Cable
5
11-1/4
May be internally adjusted up to 5
Oscillator comes complete with 10 foot motor, control, and power cords.
tlf erratic motor operation is noticed at minimum speed settings, no unit defect is necessarily present but rather a
below specification speed caused by manufacturing tolerances. To correct this condition, slightly increase the speed
setting.
The
Figure 2-1. Specifications
2
-
1. GENERAL
especially
for
familiarizing personnel
in
installation,
design,
has been prepared
with the
This manual
-
use
maintenance,
operation,
and
equipment. All information
and on various labels, tags, and plates
on the unit should be given careful consideration to
assure optimum performance of this equipment.
troubleshooting
presented herein
this
of
gun back and forth at an adjustable rate (see Figure
2-1). The degree and scope of adjustment is provided
by the electronic control. This Weld Oscillator is design
ed for automatic welding operations in a horizontal
plane.
2
-
4. SAFETY
CAUTION,
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 will be furnished by the manufacturer on re
quest if occasion to file claim arises.
2
-
-
-
The
following definitions apply
IMPORTANT,
and
NOTE
blocks
to
found
throughout this manual:
~
Under this heading,
installation,
operating, and maintenance procedures or practices will
be found that if not carefully followed may create a
hazard to personnel.
this heading,
IMPORTANT Under
installation,
operating, and maintenance procedures or practices will
be found that if not carefully followed may result in
damage to equipment.
______________
When
requesting information concerning this equip
ment, it is essential that Model Description and Serial
(or Style) Numbers of the equipment be supplied.
heading, explanator, statements
special emphasis to obtain the
efficient operation of the equipment.
I~Is~I~ Under this
This unit is an electronically
3. DESCRIPTION
controlled mechanical device that moves the welding
2
-
-
SECTION 3
3
-
1.
LOCATION
information
-
See Figure 3-1
for dimensional
the Weld Oscillator. Lead
on
-
lengths
will be found that need
most
INSTALLATION
C.
Gun Mounting Plate (Figure 3-1, Item C)
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
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.
connections.
IMPORTANT Ensure that the
screws
that hold the
______________
A.
Holes
Control
are
(Figure 3-1,
provided
in the base supports for
purposes. Mount the control in the desired
B.
Holes
Slide
are
mounting
place.
gun to the gun mounting plate do not protrude through
the mounting plate since they may hit the slide cover
Item A)
(Figure 3-1,
mounting
place.
Item B)
provided in the feet of the slide housing for
purposes.
IMPORTANT:
motor up (on
Mount the slide in the desired
The slide should be mounted with the
top)
to
keep the
and
impede operation (see Figure 3-1, Item C).
3 -2. INTERCONNECTING CABLE INSTALLA
Connect the 11-pin plug from the
TION (Figure 3-1)
cable
to the left-hand receptacle on the
interconnecting
-
remaining 11-socket end to the
corresponding receptacle on the slide. When inserting
plugs into receptacles, align plug keyways with recep
tacle keys, and rotate the threaded collar securely Onto
the receptacle.
control. Connect the
motor and cables free
from heat and weld spatter.
OM-1085 Page 7
5
5/16
x
18
14.3/8
3/4
to bottom of
mounting feet
1
TB-052 314
Figure 3-1. Weld Oscillators Dimensions
3. CONTROL CABLE INSTALLATION (Figure
Connect the 4-pin plug from the control cable to
the center receptacle on the control. Connect the re
maining 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.
3
-
3-1)
-
maining
end to
a
115 volts ac,
single-phase
power sup
ply.
3 -5. REMOTE CONTROL INSTALLATION
This
Oscillator is designed with remote control capability.
When installing any remote control, the following steps
-
must be taken:
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.
a.
b.
Disconnect the power cable from the 115
volts ac power supply.
Remove the outer enclosure from the
con
trol.
c.
Route leads
through cable clamp connector
right-hand side of control front
panel (see Figure 3-1), and up through
plastic clamp by terminal strips (see Figure
on
CENTER OF
GRAVITY
lower
4-2).
(INCHES
FROM
MOUNTING
PLATE)
d.
Make connections
as
instructed to terminal
strips iT and2T (see Figure 3-3).
e.
20
40
80
80
100
3-2.
Torque Curves
3
TA~O52 831
3 -4. POWER CORD INSTALLATION (Figure
Connect the 3-prong, twistlock plug from the
3-1)
power cable to the right-hand receptacle on the control.
Insert the plug and rotate it clockwise. Connect the re
-
OM-1085 Page 8
must be
120
PAYLOAD POUNDS
FIgure
The necessary remote control(s)
supplied by the customer.
6. REMOTE
STALLATION
-
START-STOP
SWITCH
IN
If Remote Start-Stop capability is desired, connect a
normally-closed switch to terminals 21 and 22 on ter
minal strip 2T. For the remote switch to be operational,
switch (S2) must be in the RUN position.
S
~:U~1j
8
53
iT
3
7
54
2
46
45
12
49
13
14
15
16
50
47
48
55
24
56
51
26
52
21
~
2T
22
TA~523i8
Figure
3-3. Terminal Strips
3 -7. REMOTE DWELL ON LEFT CONTROL IN
If Remote Dwell On Left capability is
STALLATION
-
the jumper link across terminals 51 and
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 3-4).
desired,
24
or
multi-Center Posi
potentiometers, switching must be done
wit/i the type of relay that has gold alloy cross bar type
contacts or the
~z41łi1łflfinfiI
i:~iri ~
9
With multi- Travel Width
tion remote
equivalent.
3-10. REMOTE CENTER POSITION CONTROL IN
STALLATION
If Remote Center Position capability is
desired, remove the jumper link across terminals 47 and
48 (on terminal strip 2T) and across 15 and 16 (on ter
minal strip 1 T). Connect a potentiometer (of equal value
to Rio; see Parts List) to terminals 48 and 55 (on ter
minal strip 2T) and terminal 15 (on terminal strip iT).
(See Figure 3-7.)
-
remove
on
24
9
Figure 3-7.
TA-044366
Remote Potentiometer Connections
3-11. REMOTE SPEED TO LEFT CONTROL IN
If Remote Speed To Left capability is
STALLATION
desired, remove the jumper link across terminals 53 and
8 on terminal strip iT, and connect a potentiometer (of
-
Figure 3-4. Remote Potentiometer Connections
3 -8. REMOTE DWELL ON RIGHT CONTROL IN
STALLATION
If Remote Dwell On Right capability is
desired, remove the jumper link across terminals 26 and
to R5; see Parts List) to terminals 53 and 46
terminal strip iT (see Figure 3-8).
equal value
-
on
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 3-5).
46
26
Figure 3-8.
Remote Potentiometer Connections
3-12. REMOTE SPEED TO RIGHT CONTROL IN
if Remote Speed To Right capability is
STALLATION
-
Figure 3-5.
Remote Potentiometer Connections
TRAVEL WIDTH CONTROL IN
If Remote Travel Width capability is
desired, remove the jumper link across terminals 13 and
14, and across 12 and 49 on terminal strip iT. Connect
a potentiometer (of equal value to R12; see Parts List)
3
-
9. REMOTE
STALLATION
-
the jumper link across terminals 3 and
terminal strip iT, and connect a potentiometer
(of equal value to R4; see Parts List) to terminals 54 and
45 on terminal strip iT (see Figure 3-9).
desired,
54
remove
on
54
45
terminals 12 and 13 (on terminal strip iT) and ter
minal 9 (on terminal strip 2T). (See Figure 3-6.)
to
12
Figure 3-9.
Remote Potentiometer Connections
If multi-remote speed adjustments (more than
of either left or right) are desired, then an optional
mu/ti-pass circuit card must be installed. (Contact Fec.
S
one
Figure 3-6. Remote Potentiometer Connections
tory Sales Department.)
OM-1086 Page 9
SECTION 4- OPERATOR CONTROLS
Power Cord
(115 volts ac)
TA-052 315
Figure 4-1. Weld Oscillator Controls
4
1. POWER SWITCH (Figure 4-1)
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.
-
-
CAUTION
Placing
__________
position
does
not
the POWER switch in the OFF
power from all of the
4
inspection
or
work inside the unit.
2. PILOT LIGHT (Figure 4-1)
A pilot light is pro
vided on the front panel to indicate that the POWER
switch is ON and that the unit is energized.
-
return
one
direction
capability.
IMPORTANT If
welding is not being performed, do
unit in the STAND BY position for pro
longed periods of time. Instead, shut the unit down by
placing the POWER switch in the OFF position.
_____________
not leave the
C.RUN
This position is the primary working condition of the
unit. All front panel controls are adjustable while
welding in this condition.
-
4 -3. CONDITION SWITCH
A.
(Figure 4-1)
SET-UP
This position permits accurate readjustment of the
CENTER POSITION (without readjusting the other con
trols) by shorting out the TRAVEL WIDTH poten
tiometer thus reducing the TRAVEL WIDTH to zero.
S
The CENTER POSITION control is fully opera
tional in the SET-UP and RUN conditions, but only par
tially opes~tionel in the STAND BY condition.
4. DWELL CONTROLS (FIgure 4-1)
These con
(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
4
-
-
trols
provide from
4
-
B.
STAND-BY
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
Page 10
.1 to 2 seconds of
5. SPEED CONTROLS
adjustment.
(Figure 4-1)
-
These
con
trols (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 other. These controls are
calibrated in percent and provide from 16 to 130 ipm of
adjustment.
is noticed at
unit defect is necessarily
present but rather a below specification speed caused
by manufacturing tolerances. To correct this condition,
LISIl~
minimum
OM-1085
the gun to move, but in
cause
remove
Qscillators internal circuitly. Completely terminate all
electrical power to the Oscillator by removing the 115
volts ac plug from its power supply before attempting
any
rotated, will
only and without
If
erratic
motor
speed settings,
operation
no
slightly increase the speed settings.
4
-
This control
6. TRAVEL WIDTH (Figure 4-1)
of oscillation and is calibrated in per-
regulates the width
-
cent.
1/8
The TRAVEL WIDTH is
factory
housing). See Figure 4-2
adjusting points.
provide
set to
of adjustment. This control may be in
adjusted up to 5 (see Section 4-8).
to 1-1/2
ternally
e.
4
7. CENTER POSITION (Figure 4-1)
This con
trol adjusts the center of oscillation to the right or to the
left. This control is calibrated to provide – 1-1/2 of ad
-
f.
from the actual center of the slide.
g.
-
a.
as
outer enclosure onto
it in
control, and
place.
Connect the power cable to its 115 volts
power
4 -8. TRAVEL WIDTH AND CENTER POSITION
INTERNAL ADJUSTMENTS (Figure 4-2)
To make
internal adjustments, proceed
Replace
secure
-
justment
for location of in
ternal
ac
supply.
Place the POWER switch in the ON position,
and check for satisfactory operation. If it has
not been achieved, repeat Steps A to G until
the desired operation is obtained.
follows:
Place the POWER switch in the OFF position
(Condition Switch should be in the RUN
Terminal Strips
position).
P/acing
CAUTION
__________
position does
not
the POWER switch in the OFF
power from all of the
remove
Oscillators interna/ circuiti~.
Completely terminate all
electrical power to the Oscillator by removing the 115
volts aº p/ug from its power supply before attempting
any inspection or work inside the unit.
b.
Remove the power cable from the 115 volts
ac
c.
power
supply.
Remove the outer enclosure from the
con
trol.
d.
The TRAVEL WIDTH may be internally ad
justed by rotating potentiometer (Ri 3) in a
counterclockwise direction 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 Ri 1, a dual
potentiometer) in a clockwise direction.
(The CENTER POSITION sensitivity must be
decreased so that the slides internal com
ponents do not hit the end(s) of the
SECTION 5
5
-
-
Figure 4-2. Internal Components
SEQUENCE OF OPERATION
4.
1. INITIAL ADJUSTMENTS
Adjust the CENTER POSITION control
the gun is centered
over
the work
as
so
that
desired.
Never, under any circumstances, operate
weld oscillator with any portion of the outer
enclosure removed. In addition to a hazard, improper
cooling may resu4 in damage to the weld oscillator
components. Warranty is void if the weld oscillator is
operated with any portion of the outer enclosure remov
5.
Place the Condition Switch in the RUN
6.
Adjust the TRAVEL WIDTH control for the
ed.
7.
Adjust the Speed Controls for the desired
speeds.
8.
Adjust the Dwell Controls for the desired dwells.
CAUTION
___________
the
1.
2.
Make all necessary connections
Section 3.
Place the POWER switch
on
as
position.
desired travel width.
instructed in
the Oscillator in the
welding, it is imperative that pro
per protective clothing (welding coat end gloves) and
eye protection (glasses and welding helmet) be put on.
Failure to comply may result in serious and even perma
nent bodily damage.
CAUTION
Prior to
___________
ON
3.
position.
Place the Condition Switch in the SET-UP posi
tion.
OM-1085 Page 11
9.
Commence
welding.
5 -2. SHUTTING DOWN
I
When the Condition switch is moved from the
STAND BY position to the RUN position, the s/ide will
afrways start in a direction away from the drive motor.
Place the Condition Switch in the STAND BY
1.
position.
2.
All of the front panel controls may be
I
while
OFF
on
the Oscillator in the
position.
welding.
SECTION 6
-
Placing the POWER switch in the OFF
does
not remove power from all of the
position
Oscillators internal circuitry. Completely terminate all
electrical power to the Oscillator by removing the 115
volts ac plug from its power supply before attempting
CAUTION
__________
any
Place the POWER switch
adjusted
inspection
or
MAINTENANCE
6
POTENTIOMETER (See
5. SLIDE
Parta
If it should become necessary to replace the
slide potentiometer, proceed as follows:
-
LIst)
1.
Remove
drive belt.
cover over
work inside the unit.
2.
Periodically inspect the labels
I
-
on
this unit for
All labels must be maintained in a clearly
readable state and replaced when necessary. See the
Parts List for part number of labels.
Loosen set screws, and
remove
gear from poten
tiometer shaft.
legibility.
6
1. CONTROL
maintenance.
-
-
The control
requires
no
periodic
2. DRIVE MOTOR
6
The drive motor requires
initial service nor any periodic maintenance.
-
-
3.
Remove the
tiometer
two
holding the poten
screws
mounting plate.
4.
holding the potentiometer to
slide
mounting plate,
potentiometer out, and
allow it to hang free.
5.
Install
6.
Unsolder wires from old potentiometer, and
resolder wires to the labeled terminals on new
potentiometer as follows: white to slider (S), red
counterclockwise (CCW), and black to
to
clockwise (CW).
Remove the nut
no
new potentiometer (see Parts List) in
mounting plate.
IMPORTANT Do not disassemble the drive motor.
_____________
Synchronous stepping motors will be adversely affected
if taken apart.
The outside of the unit, particularly
8
3. SLIDE
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.
-
-
4. DRIVE BELT
The drive belt is a toothed-type
timing belt and should not need servicing. However,
should adjustment or replacement be required, provi
sions are made for tensioning the belt. Remove cover
6
-
7.
gear onto
set screws
potentiometer shaft, and
(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
and then back it off five turns.
one
extreme,
-
drive belt. Loosen the four bolts in the slotted
motor end.
The belt should be snug, but not overtightened.
over
holes, and slide the belt housing toward the
10.
cover.
Page 12
gear on slide potentiometer with small gear
ball screw.
Align
on
I
A small amount of backlash should be main
tained between these two gears.
11.
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
OM-1085
Reinstall
tighten
Insert screws,
mounting plate.
and
secure
the
potentiometer
SECTION 7
CAUTION Hazardous
ternal
-
TROUBLESHOOTING
voltages are present on the in
circuitry of the weld oscillator as long
as
power is
connected to the unit. Disconnect power before at
tempting any inspection or work on the inside of the
unit. Troubleshooting of internal circuitry should be per
formed by
qua//f/ed personnel only.
The following chart is designed to diagnose and provide
remedies for some of the troubles that may develop in
this weld oscillator.
oscillator has been
ble developed.
functioning properly
until this trou
Use this chart in conjunction with the circuit diagram
while performing troubleshooting procedures. If the
trouble is not remedied after performing these pro
cedures, the nearest Factory Authorized Service Sta
tion should be contacted. In all cases of equipment
recommendations
malfunction, the manufacturers
should be strictly followed.
It is assumed that proper installation has been made, ac
to Section 3 of this manual, and that the weld
cording
TROUBLE
PROBABLE CAUSE
REMEDY
Unit completely inoperative
(pilot light (PL) not on).
Open line fuse.
Replace
Unit completely inoperative
(pilot light (PL) on).
Fuse (Fl) open.
*Replace fuse (Fl).
Plug(s)
Check all plugs, and
Erratic
operation.
not secure in recep-
tacle(s).
Slide
stalled
hums.
.
and
motor
Obstruction
loading.
open line fuse.
ensure
that
they are
secure
in
receptacles.
or
excessive
Remove obstruction and/or reduce loading.
POWER switch (Si) must be turned OFF and then
back ON to restart oscillator.
*lf it becomes necessary to replace any fuse in the Weld Oscillator,
ensure
that
a
fuse of the proper size is used.
OM-1085 Page 13
C541
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Diagram
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-
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00
No.
-
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Diagram
Circuit
1.
-
7
Figure
May 1988
FORM: OM-1085C
Effective With Serial No. JF914709
PARTS
LIST
Fig B
1
7
11
TB-052 310
Figure A
OM-1085 Page
1
-
Main Assembly
Part
No.
Item
No.
Figure A
1
009 286
2
3
4
009 266
5
6
7
8
9
10
11
12
13
14
15
16
073 686
039 828
601 469
053 075
075 044
073 139
039 734
073 517
073516
009285
052723
056442
073690
600341
Description
Quantity
Main Assembly
SLIDE, oscillator (Fig B Pg 4)
CABLE, control (consisting of)
PLUG,4socketMS-3106A-14S-2S
CLAMP, cable
CABLE, power-shielded 18 ga 3/c (order by ft)
PLUG, 4 pin MS-3106A-14S-2P
CABLE, interconnecting (consisting of)
CABLE, No. 166/c (order by ft)
CLAMP, cable
PLUG, 11 pin MS-3106A-20-33P
2
1 Oft
loft
2
PLUG 11 socket MS-3106A-20-33S
CONTROL BOX (Fig C Pg 6)
CABLE,
power (consisting of)
CONNECTOR BODY, twistlock-grounded 2P3W 15 amp 277 volts
CAP, straight-grounded 2P3W 15 amp 125 volts
CABLE, No. 163/c (orderbyft)
lOft
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1085
Page
2
TD-05231D
14
18
9
8
23
Oscilator
Slide,
.26
-
B
Figure
35
0 0~ -~
Item
Dia.
Part
No.
Mkgs.
No.
Figure B
009 286
Slide, Oscillator (Fig A Pg 1 Item 1)
090 683
MOUNTING PLATE, drive
COVER
SHAFT, oscillator
2
009 259
3
009 240
4
009 290
5
6
7
8
9
10
11
12
1
HOUSING, drive
INSULATOR, mtg-motor
1
010 116
009 244
19
RC4
RC6
077 175
076 624
20
089 479
21
009 287
009 289
009 262
22
23
24
R8
009 237
25
009 241
26
27
009 253
009 239
28
097 494
29
097 401
009 257
053 452
30
31
32
33
34
35
36
1
PULLEY, gearbelt
17
18
1
009 283
009 264
16
Mot
1
1
2
15
14
Quantity
SHAFT, oscillator
009 291 PILLOW BLOCK, 3/4 shaft
009 256 STRIP, support
053 429 SCREW, drive
009 255 BAR, side
053 451 END PLATE, LH drive
009 252 SPACER, mtg-potentiometer
009 243
009 276
010 142
13
Description
073 240
053 428
009 251
009 250
009 278
601 469
2
1
2
1
2
1
MOTOR
1
CLAMP, 5/16 clamp dia
GROMMET, 3/8 ID x 1/2 mtg hole
PANEL, mtg-connectors receptacle
RECEPTACLE, 11 pin MS-3102A-20-33P
RECEPTACLE, 4 pin MS-3102A-14S-2P
WASHER, shoulder 3/8 OD xO.194 ID
PULLEY, gearbelt
BELT, gear 17 inches long
COVER, drive
POTENTIOMETER, WW 10 turn 1.5 watt 10K ohm
GEAR, potentiometer
GEAR, ball-screw
BRACKET, mtg-potentiometer
MOUNTING, flange-ball nut
BLOCK, carriage
PAN, base
END PLATE, RH drive
RING, retaining-external
2
BEARING, ball
1
CLAMP, retainer-seal
SEAL, clamp-retainer
FOOT, closer-seal
CABLE, power 18 ga 3/c (order by ft)
1
1
1
1
1
4
1
1
1
1
1
1
1
1
1
1
1
2
1
4
1 ft
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1085 Page 4
In
0
0
I.
C
0
Cf
C.)
I.
I-
U.
a
I-
W
C)
F
NW
C)C)
I
C)
N
C)
C.)
2
it
OM-1085
Pages
U.
It)
C)
Item
Dia.
Part
No.
Mkgs.
No.
Figure C
2
R6,7
R4,5
3
RiO
4
S2
SRi
1
5
6
7
8
RC2,3
9
PCi
10
009 285
PC2
009339
12
C3
073 453
13
Ri
030 836
15
+072 402
047 497
Si
011 233
1,21
000368
009292
22
23
R9,ii
24
25
26
R13
27
Ci,2
Ti
009258
29
072 400
30
010610
074 188
PL1
.012617
32
33
Fl
*012 663
097 922
34
35
36
RC1
2
2
1
1
1
1
6
2
1
2
1
1
1
2
2
1
1
1
1
ac
1
1
1
1
1
000479 POTENTIOMETER, carbon 1 turn 2 watt 25K ohm
009 234 TRANSFORMER, kva 1/3 115-18
006 426 CLAMP, capacitor 2 inch
009344 CAPACITOR, electrolytic 9000 uf 35 volts
28
31
1 Item 12)
POTENTIOMETER, carbon 1 turn2wattl0K/iOK ohm
17
20
21
Pg
039462
009 248
19
A
010 146
009 247
030640
16
18
(Fig
CIRCUIT CARD, control-motor
CAPACITOR, electrolytic 10 uf 150 volts
RESISTOR, WW adj 10 watt 1000 ohm
GROMMET, 1/4 ID x 3/8 mtg hole
RESISTOR, WW adj 100 watt 5 ohm
SHIELD, resistor
COVER, top-control box
LABEL, general precautionary
SWITCH, toggle SPDT 10 amp 250 volts
LINK, jumper
BLOCK, terminalS amp 14 pole
CLAMP, 5/8 clamp dia
BRACKET, mtg-componerits
604311
R2,3
Control Box
005 577 POTENTIOMETER, carbon 1 turn 2 watt 200K ohm
039 463 POTENTIOMETER, carbon 1 turn2watt lOOK ohm
009 156 POTENTIOMETER, carbon 1 turn 2 watt 2.5K ohm
009 342 SWITCH, rotary 3 position
035914 RECTIFIER, integrated 30 amp 400 volts
009 254 HEAT SINK, rectifier
009 335 STAND-OFF, No. 4-40 x 5/8
073 730 TERMINAL, header 22 pin
009 340 CIRCUIT CAR D;control-logic (Fig Cl Pg 8)
009 267 CLAMP, circuit card
11
14
Quantity
Description
056 665
056 442
37
PC4
009 296
38
PC3
009 294
39
R12
035 897
SKID, base
CHASSIS, control box
CONNECTOR, clamp-cable 1/2 inch
LIGHT, incandescent-red lens
HOLDER, fuse
FUSE, miniature-glass sb bbo 3 amp
KNOB, pointer
NAMEPLATE (order by model and serial number)
RECEPTACLE, twistlockflanged grounded 2P3W 15
CONNECTOR BODY, Arrow Hart 4780 (RC1)
CIRCUIT CARD, HF filter (Fig C2 Pg 9)
CIRCUIT CARD, HF filter (Fig C3 Pg 9)
POTENTIOMETER, carbon 1 turn2 watt 1000 ohm
1
1
2
2
2
1
1
1
1
1
7
1
1
amp
*Recommended Spare Parts.
+ When ordering a component originally displaying a precautionary label, the label should also be ordered;
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-1085 Pagee
1
059
182
0
01
0
0
0
181
0
0
0
179
0
1C52
+
C57
0
RiO
185
+
C60
c.4
0
~~C56
U
V
C61
10I
+
C54
In
V
0
177
In
C55
195
U
0
\
176
I
0
U
I
R 70
D57
194
C58
C52
193
0
+
051
R98
I;
f4-
169
0
~
164/
056
0
-;I
I
0
+
~153
1
053
050
0
155
I
I
I
R50
~4
171
R68
1107
057
D62
R67
166
CI,
0
061
Ic,
0
I0
165
In
In
In
C50
p
U
In
0
II~b
R57
O
~
t
OM-1085
Page
7
Otto
~
Olr
2
~
C65
051
R56
C.)
0
/
C66
I
I
1102
+
U
I
TO
I
173
4-
Ic,
I
054
C.)
C.)
C53+
0
C.)
.~
.~R72
CM
-
0
0
I
In
C 67
I
I
154
0
0
1162 ~
C51
0
0
IC50~
01
180
0
Dia.
Part
Mkgs.
No.
Figure Cl
Quantity
Description
009 340
Circuit Card,
073
005
031
028
031
009
009
026
Control-Logic (Fig
C
P9 6 Item 9)
D63
074 440
1C50-52
009 159
Q50,51 ,56,57,60,61
Q52,53
Q54,55,58,59
R50,51 ,63,64,80,81 ,91 ,92
037 200
073 529
037 201
R52,53
074 026
CAPACITOR, tantalum 0.15 uf 35 volts
CAPACITOR, tantalum 2.2 uf 20 volts
CAPACITOR, ceramic 0.01 uf 500 volts dc
CAPACITOR, electrolytic 1 uf 25 volts dc
CAPACITOR, tantalum 6.5 uf 35 volts dc
RELAY, reed 3 amp 24 volts dc
RELAY, reed 2 amp 18 volts dc
DIODE, lamp 400 volts SP
DIODE, zener4.7 volts 1 watt
DIODE, zener 15 volts 1 watt
DIODE, zener 6 volts 1 watt
IC, linear 358
TRANSISTOR, 200MA40 volts NPN
TRANSISTOR, unijunction 2 amp 35 volts
TRANSISTOR, 200MA 40 volts PNP
RESISTOR, carbon 0.25 watt 10K ohm
RESISTOR, carbon 0.25 watt 150 ohm
R54,57
605 919
RESISTOR, carbon 0.25
R55,56,68,69
R58,59
R60,65
R61,66
R62,67
R70,71 ,73,75,76,79,90,95
R72,74,93
605 912
077 310
C50,51
C52,53
C54,58-65
C55,66,67
C56 ,57
CR1
CR2
050-60,64
713
023
643
290
677
157
158
202
D6 1
D62
037 084
037 449
R77
R78,82
R83,85
R84
R86-89
R94,96
R97-102,104,105
Ri 06
Ri 07
Ri 08
605 gil
2
2
9
3
2
12
3
6
2
4
8
2
2
4
watt 47 ohm
RESISTOR, carbon 0.25 watt 4700 ohm
POTENTIOMETER, WW 1 turn 0.5 watt 10K ohm
605 915 RESISTOR, carbon 0.25 watt 2200 ohm
074 041 RESISTOR, carbon 0.25 watt 47K ohm
605 908 RESISTOR, carbon 0.25 watt 33K ohm
074 043 RESISTOR, carbon 0.25 watt lOOK ohm
605 916 RESISTOR, carbon 0.25 watt 1K ohm
074 039 RESISTOR, carbon 0.25 watt 27K ohm
074 027 RESISTOR, carbon 0.25 watt 220 ohm
074 044 RESISTOR, carbon 0.25 watt 1 meg ohm
035 887 RESISTOR, carbon film 0.25 watt 3300 ohm
038 584 RESISTOR, carbon 0.25 watt 470K ohm
089 174 RESISTOR, metal film 0.25 watt lOOK ohm
030 044 RESISTOR, metal film 0.25 watt lOOK ohm
039 328 RESISTOR, carbon film 0.25 watt 1 .5K ohm
030 033 RESISTOR, carbon 0.5 watt 470 ohm
074 099 RESISTOR, carbon 1 watt 150 ohm
2
2
2
2
8
2
4
2
8
1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM1
085
Page 8
Dia.
Part
Mkgs.
No.
Figure C2
C91 ,92
C90
RC5
Quantity
Description
009 296
Circuit Card, HF Filter
000 340
CAPACITOR, ceramic 0.01 uf 50 volts
CAPACITOR, ceramic 0.001 uf 1000 volts
RECEPTACLE, 4 socket MS-3102A-14S-2S
031 646
073 687
(Fig
C
Pg
6 Item 37)
2
0
AG
QD
BQ
QC
TA-052 316
Figure C2
-
Circuit Card, HF Filter
0
~K
AC
BO
O~
CM
CL
CO
OH
0
D~
-
TA-052
Figure C3
Dia.
Part
Mkgs.
No.
Figure C3
C80-85
RC7
-
Description
009 294
Circuit Card, HF Filter (Fig C Pg 6 Item 38)
000 340
073 515
CAPACITOR, ceramic 0.01 uf 50 volts
RECEPTACLE, 11 socket MS-3102A-20-35S
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-lO85Page9
316
Circuit Card, HF Filter
Quantity
6