Miller Electric OM-1102 User Manual

Page 1
OM-1102 113 214A
July 1995
Processes
Multiprocess Welding
Description
Semiautomatic Welding Platform
Swingpak 12 & 16
www.MillerWelds.com
Page 2
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.
Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you
Miller is the first welding equipment manufacturer in the U.S.A. to be registered to the ISO 9001 Quality System Standard.
Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web.
figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided.
Working as hard as you do – every power source from Miller is backed by the most hassle-free warranty in the business.
Miller offers a Technical Manual which provides more detailed service and parts information for your unit. T o obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMA W-P.
Page 3
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. General Information And Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Safety Alert Symbol And Signal Words 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Description 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION OR RELOCATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Location 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Installation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – PARTS LIST 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
Page 4
Page 5
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 ef fective use of this equipment.
B. Safety
The installation, operation, maintenance, and trouble­shooting of arc welding equipment requires practices and procedures which ensure personal safety and the safety of others. Therefore, this equipment is to be in­stalled, operated, and maintained only by qualified per­sons in accordance with this manual and all safety pre­cautions in the welding power source Owners Manual.
SECTION 2 – SPECIFICATIONS
Gas Cylinder Support Bracket Located
Here (SWINGPAK-12 Models Only)
1-2. SAFETY ALERT SYMBOL AND SIGNAL
WORDS
The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instruc­tions.
This safety alert symbol is used with the signal words WARNING and CAUTION to call atten­tion to the safety statements.
WARNING statements identify procedures or practices which must be followed to avoid seri­ous personal injury or loss of life.
CAUTION statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment.
IMPORTANT statements identify special instructions necessary for the most efficient operation of this equip­ment.
Coolant System
(Mounted Onto
SWINGPAK
Locker)
Resistance
Grid
(Mounted Onto
SWINGPAK
Locker)
**65 in. (1651 mm)
*66-7/8 in. (1699 mm) Swingpak-16
**79 in. (2007 mm) Swingpak-16
Figure 2-1. Overall Dimensions, Mounting Hole Layout, And Component Locations
Flux
Tank
Boom
Support
Base
Swingpak-12
Welding
Power
Source
K G
H
J
FRONT
*50-7/8 in.
(1292 mm)
Swingpak-12
C
L
B
A
D
F
E
S-0458-A
Inches Millimeters
A
28
B
30
C
31
D
32-3/4
E
37
F
39
G
14-1/2
H
16-3/4
J
20 K 12-3/8 314 L 24-1/16 611
711 762 787 831 940 991 368 415 508
OM-1102 Page 1
Page 6
2-1. DESCRIPTION
The SWINGPAK-12 and SWINGPAK-16 provide a di­rect mounting facility for several welding power sources (refer to welding power source Owners Manual for base mounting hole layout), SWINGARC wire feeder or CB boom, RADIATOR 1A or RADIATOR 2A coolant sys­tem, MPG-395B resistance grid, AFT-100 flux tank, and shielding gas cylinder. If equipment other than that listed is to be used, mounting hole locations may have to be modified to accommodate equipment. A SWINGPAK locker and brackets for mounting a disconnect switch to the SWINGARC post support are also supplied.
SECTION 3 – INSTALLATION OR RELOCATION
Additional space is available on the base for mounting customer supplied accessories.
Table 2-1. Specifications
Weight
Net Ship
SWINGPAK-12
SWINGPAK-16
412 lbs.
(187 kg)
504 lbs.
(229 kg)
418 lbs.
(190 kg)
510 lbs.
(231 kg)
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Disconnect equipment input power conduc-
tors from deenergized supply line BEFORE moving unit.
3-1. LOCATION
When installing this unit, be sure to allow room for the boom to swing horizontally in the desired arc, and to piv­ot upward to the desired angle. The location should al­low room to remove panels of associated equipment for installation, inspection, maintenance, and repair proce­dures. Consider the input power requirements as well a s coolant (water) needs of optional equipment when choosing a location.
The service life and efficiency of this unit and associated equipment will be reduced if they are subjected to high levels of dust, dirt, moisture, corrosive vapors, and ex­treme heat.
Mounting holes are provided in the SWINGPAK base for installing equipment.
3-2. INSTALLATION (Figures 2-1 And 4-1)
IMPROPER LIFTING OR INSTALLING OF EQUIPMENT can cause personal injury and equipment damage.
Use equipment of adequate capacity to lift
components.
Use bolts and fasteners of adequate capacity
to assemble and install unit.
IMPORTANT: Refer to Figures 2-1 and 4-1 during as­sembly as necessary.
Mounting hardw a r e i s p a c k e d i n l o c k e r f o r s h i p p i n g p u r ­poses. Remove hardware kit from locker and proceed as follows:
1. Install boom support base onto SWINGPAK base using supplied 1/2-13 x 1-1/2 inch cap screws (Item 23, Figure 4-1) and associated hardware (see Figure 2-1 for mounting location).
2. Locate appropriate mounting holes on SWING­PAK base for welding power source, and install power source onto SWINGPAK base using supplied 3/8-16 x 1-1/4 inch cap screws (Item 20, Figure 4-1).
3. Install boom into boom support base following procedure outlined in appropriate Owners Manu­al.
WARNING: OVERTURNING BASE can result in serious injury and equipment damage.
Mount the welding power source on SWING-
PAK base before mounting SWINGARC wire feeder into SWINGARC support base.
Do not install or operate on an incline.
Do not lift the SWINGPAK base with a fork lift
from the sides unless the lift forks extend far enough under the base to ensure against tip­ping.
OM-1102 Page 2
4. If applicable, install AFT-100 flux tank onto SWINGPAK base using supplied 5/16-18 x 1 inch cap screws (Item 13, Figure 4-1) and associated hardware.
5. Install SWINGPAK locker onto SWINGPAK base using supplied 1/4-20 x 3/4 inch self-threading screws (item 16, Figure 4-1).
6. If applicable, install coolant system mounting brackets onto SWINGPAK locker using supplied 1/4-20 x 1inch cap screws (Item 7, Figure 4-1).
Page 7
IMPORTANT: If cooling system has mounting holes i n base, do not install mounting brackets onto SWINGPAK locker. Instead, install coolant system directly onto lock­er using supplied hardware.
7. If applicable, install grid onto SWINGPAK locker using supplied 1/4-20 x 1 inch cap screws (Item 7, Figure 4-1) and associated hardware.
8. If applicable, install gas cylinder support bracket onto SWINGPAK locker using supplied 5/16-18 x 3/4 inch self-threading screws (item 12, Figure 4-1).
9. Install cylinder support bracket to SWINGPAK locker using supplied 1/4-20 x 1 inch cap screws and associated hardware. Secure gas cylinder in bracket using supplied cylinder chain.
10. If applicable, install disconnect switch mounting brackets onto disconnect switch (customer must supply mounting hardware).
WARNING: ELECTRIC SHOCK can kill.
Do not touch live electrical parts.
Be sure input power is disconnected and
welding power source is shut down before making connections to disconnect switch.
1 1. Install disconnect switch onto boom support, and
secure using supplied disconnect switch mount­ing clamps (Item 2, Figure 4-1) and 3/8-16 nuts (Item 5) and associated hardware.
12. Make electrical input connections from welding power source to disconnect switch according to welding power source Owner’s Manual.
13. To make electrical connections from line discon­nect switch to source of input power, consult local electric utility or certified electrician.
OM-1102 Page 3
Page 8
. Hardware i s common and
not available unless listed.
SECTION 4 – PARTS LIST
AFT-100
Flux Tank
13
14
SD-113 627-A
Coolant System
RADIATOR 1 Or RADIAT OR 2
MPG-395B
Resistance Grid
Gas
Cylinder
8
Coolant System
7
6
7
6
5
4
3
2
10
Support
Cylinder
9
Mounting Bracket
Locker
SWINGPAK
Bracket
11
12
7
6
15
Gas Bottle
Support Bracket
16
17
Base
SWINGPAK
Figure 4-1. Complete Assembly
Wire Feeder
SWINGARC Digital
OM-1102 Page 4
1
Disconnect Switch
Mounting Brackets
Disconnect
Switch
Base
232221
Boom Support
201918
Page 9
Quantity
Item
No.
Part
No.
Description
Model
12 16
Figure 4-1. Complete Assembly
1 086 752 BRACKET, mtg disconnect switch 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 086 739 CLAMP, mtg disconnect switch 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 010 910 WASHER, flat SAE .375 8 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 602 213 WASHER, lock split .375 8 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 601 872 NUT, hex full .375-16 8 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 602 207 WASHER, lock split .250 10 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 604 631 SCREW, hexhd .250-20 x 1.000 10 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 099 038 BRACKET, mtg coolant system 2 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 085 940 LOCKER 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
085 840 DOOR 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 169 654 BRACKET, support tank 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 602 387 CHAIN, weldless 2/0 x 27 bright zinc pld 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 602 159 SCREW, hexwhd .312-18 x .75 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 601 948 SCREW, hexhd-pln .312-18 x 1.000 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 602 211 WASHER, lock split .312 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 087 876 BRACKET, support gas bottle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 604 224 SCREW, hexwhd .50D .250-20 x .750 8 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 085 939 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 086 736 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 602 241 WASHER, flat stl SAE .250 (used w/Maxtron) 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 602 207 WASHER, lock split .250 (used w/Maxtron) 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 601 927 SCREW, cap stl hexhd .250-20 x .750 (used w/Maxtron) 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 010 910 WASHER, flat SAE .375 (all models except Maxtron 450) 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 602 213 WASHER, lock split .375 (all models except Maxtron 450) 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 604 657 SCREW, hexhd-pln .375-16 x 1.250 (all models except Maxtron 450) 4 4. . . . . . . . . . . . . . . . . . .
21 602 246 WASHER, flat .500 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 602 216 WASHER, lock split .500 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 604 467 SCREW, hexhd-pln .500-13 x 1.500 4 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To maintain the factory original performance of your equipment, use only Manufacturers Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-1102 Page 5
Page 10
Notes
Page 11
Warranty Questions?
Call 1-800-4-A-MILLER for your local Miller distributor.
Y our distributor also gives you ...
Service
Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.
Support
Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way.
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
LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor.
1. 5 Years Parts – 3 Years Labor
* Original main power rectifiers * Inverters (input and output rectifiers only)
2. 3 Years — Parts and Labor
* Transformer/Rectifier Power Sources * Plasma Arc Cutting Power Sources * Semi-Automatic and Automatic Wire Feeders * Inverter Power Supplies * Intellitig * Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the engine manufacturer .)
3. 1 Year — Parts and Labor
* DS-2 Wire Feeder * Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250) * Process Controllers * Positioners and Controllers * Automatic Motion Devices * RFCS Foot Controls * Induction Heating Power Sources * Water Coolant Systems * HF Units * Grids * Maxstar 140 * Spot Welders * Load Banks * Miller Cyclomatic Equipment * Running Gear/Trailers * Plasma Cutting Torches (except APT & SAF
Models) * Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year whichever is greater.)
4. 6 Months — Batteries
5. 90 Days — Parts
* MIG Guns/TIG Torches * Induction Heating Coils and Blankets
guarantees or warranties expressed or implied.
* APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches * Remote Controls * Accessory Kits * Replacement Parts (No labor) * Spoolmate 185 & Spoolmate 250 * Canvas Covers
Millers True Blue Limited Warranty shall not apply to:
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear.
2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturers warranty, if any.
3. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Millers option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation bas e d u p o n a c tual use) upon return of the goods at customers risk and expense. Millers option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. I N N O EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.
In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.
miller_warr 7/00
Page 12
Owners 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.
Contact your Distributor for:
Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information
and Parts) Circuit Diagrams Welding Process Handbooks
Miller Electric Mfg. Co.
An Ill inoi s Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA
International Headquarters–USA
USA Phone: 920-735-4505 Auto-At t ended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125
European Headquarters – United Kingdom
Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066
www.MillerWelds.com
Contact the Delivering Carrier for:
For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.
PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00
File a claim for loss or damage during shipment.
Loading...