Dec.1987 IMPORTANT Read and understand the entire FORM: OM-~18 044 Effective With Serial No. JH318063 ______________ manual, with special emphasis on the safety material throughout the manual, before contents of this installing, operating, or maintaining this equip ment. This unit and these instructions are for use only by persons trained and experienced in the safe operation of welding equipment. Do not allow un trained persons to install, operate, or maintain this unit.
ONE YEAR LIMITED WARRANTY Miller Electric Mfg. Co. warrants to the buyer for personal, purchases this Auto Arc Welder (Welder) that this Welder family or household purposes (Consumer) will be free from defects in material and workmanship for a period of one year from the date of purchase. This warranty covers only the original purchaser of this Welder.
ERRATA SHEET After this manual to data was appearing printed, AMEN DMENT TO SECTION 9 Amend P~rts List Dia. as Part No. 13-26 13- Si 087 182 024 253 13-39 13-41 13-45 Ti **First equipment design occurred. This sheet lists exceptions PARTS LIST follows: Mkgs. 12-4 refinements In later in this manual.
TABLE OF CONTENTS Page No. Section No. SECTION 1 SAFETY RULES FOR OPERATION OF PORTABLE RESISTANCE - SPOT WELDING EQUIPMENT 1 1 1 1 1 - - - - - Introduction Installation 1 2. 3. Safety 1 4. Personal Safety Burn Prevention Fumes Fire Prevention Protection Of Others Cords Hoses Maintenance Standardslndex 1. 5. 1 -6. 1 1 - - 7. 8. 1-9. 1-10. 1 -11. 1-12. SECTION 2 2 - - - 3 3 - - - - 4 4 - - - - - 1 1 1 INTRODUCTION 3 3 3 4. 1. 2. 3. 4. 1. 2. 3. 1.
SAFETY RULES FOR OPERATION OF ______ PORTABLE RESISTANCE SPOT WELDING EQUIPMENT SECTION 1 1 - - INTRODUCTION The following safety rules general safe practices which as a minimum should employed when using resistance spot welding equip 1. - cover be ment. from the surface, the area is adequately ventilated, the operator wears an air respirator. 1 7. FIRE PREVENTION Flying sparks can pass through cracks, windows, doors, wall and floor open ings, and along pipes.
4. Documents, U.S. Government Printing Office, Institute, Washington, D.C. 20402. 10018. ANSI Standard Z87.1 Safe Practices For Oc cupation And Educational Eye And Face Protec tion, obtainable from the American National 7. Standard Processes, Protection Standards Institute, 1430 Broadway, New York, NY 10018. Broadway, 51B, New Cutting York, And NY Welding obtainable from the National Fire Association, 470 Atlantic Avenue, Boston, MA 02210. 8. 5.
SECTION 2 - INTRODUCTION Rated Output Voltage Input 50% Open- 60 Hertz Circuit Single-Phase Duty Cycle Voltage 110 Volts AC 1.5 Kva 1.6 Welder Dimensions Without Tongs I Height 6 in. 1152 I Width mm)I 3-1/4 in. (83 Weight Length mm)113 I Ship kg)126 lbs. (12 Net in. (330 mm) 22 lbs. (10 kg) AASW_1510M 12 in. (305 mm) 6 in. Tongs Length (152 mm) 18 in. (457 mm) Secondary 110 Primary Volts Short Circuited I 82 Primary Amps Secondary Amps Figure 2 - 1.
SECTION 3 - INSTALLATION Presure Adjustment Ni Tong Top Tong Holder Pressure Tong Securing Screws (4) Hex-Head Screw Tong TB-900 371-1 115VAC Power Cord With Plug Figure 3 3-1. TONG TIP AND TONG - 1. Resistance Spot Welder Components INSTALLATION - 2. TONG PRESSURE ADJUSTMENT (Figure 3-1) (Figure 3-1) WARNING ELECTRIC SHOCK can kill; HOT burn skin. Do not touch live electrical parts. Disconnect input power cord plug from power supply receptacle before installing tongs or tips.
IMPORTANT ______________ Tong pressure is adjustable, and must adjusted before operation. be checked and/or To adjust tong A. pressure, proceed as The hand lever can 1. Loosen the screw at Loosen nut 2. Tighten so that the tongs lock so that the tongs depending upon locking the rear nut on the hex-head machine of the handle (see Figure 3-1). front of top tong holder. on 2. Adjust the screw up per tong closing. Be of top tong holder until both snug against top tong holder.
1. Install and connect unit according OVERHEATING CAUTION resistance spot welder. Do not spot weld mild can 3. to Section 3. damage Close hand lever to with the workpiece. stainless steel in. (3.2 mm) combined thickness, or two over into contact the CAUTION ARCING or bring tong tips can damage tong tips. Do not release hand lever while the Start switch is 1/8 closed. pieces of heavier than 20 gauge (1.8 mm) galvanized metal. Do not exceed 50% duty cycle. 4.
It is assumed that the unit was properly installed accor Section 3 of this manual, the operator is familiar with the function of controls, the resistance spot welder was working properly, and that the trouble is not related ding to to the process. The following chart is designed to and provide remedies for some of the troubles Use this chart in conjunction with the circuit diagram performing troubleshooting procedures.
SECTION 6 6 1. SAFETY TRODUCTION - - RESISTANCE SPOT WELDING PROCESS FUNDAMENTALS REQUIREMENTS AND IN the cross-sectional area of the welding tip contact sur faces. The pressure exerted by the tongs and electrode tips, through which the ELECTRIC SHOCK WARNING: can kill. Do not touch live electrical parts. according to Section 3 and all ap plicable codes. current flows, holds be welded in intimate contact before, the welding current time cycle.
The resistances are in series and each point of resistance will retard current flow. The amount of resistance at point 3, the interface of the workpieces, will depend on the heat transfer capabilities of the material, its electrical resistance, and the combined thickness of the materials at the weld joint. It is at this part of the circuit that the nugget of the weld is formed.
Investigations the weld on have shown that high pressures exerted decrease the resistance at the point of joint contact between the electrode The surface. the greater tip and the workpiece pressure, the lower the With magnetic materials such as mild steel, the current through the weld can vary substantially depending on how much of the magnetic material is within the tong loop. The tong loop is sometimes called the throat for resistance factor. the resistance spot weld unit.
cause long sleeve shirts and protective working with coated or plated steels. irritation. Wear face shields when Other coated material, such as terne plate (lead-coated) may have varying degrees of toxicity. Adequate ventila tion is mandatory when working with these materials. resistance PROCEDURES The spot weld should have shear strength equal to the base metal shear strength and should exceed the strength of a rivet or a fusion plug weld of the same cross sectional 6 - 4. TESTING - area.
~~I69 mm) ~__~ 6 (152 mm) 042 169 12 (305 mm) 042 160 STANDARD Standard Flat 042162 042161 1 TD-900 371-6 Figure *Recommended When ordering A - Main Assembly Spare Parts. 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.
Item Dia. Part No. Mkgs. No.
Replace Coils At Factory Or Factory Authorized Service Station. Item Dia. Part No. Mkgs. No. Figure B 026 765 3 4 5 6 095 347 Transformer, Power-Main 026 601 026 772 1 2 Ti 7 8 9 10 Description (Fig A Quantity Pg l3Item 39) INSULATION, coil (consisting of) STRIP, 0.015 x 4-5/8 x 8 1 2 . .TUBING,1-1/4x1-7/8long 026 774 STRIP, 0.015 x 1-5/8 x 1-3/4 026 770 STRIP, 0.015x5/8x7-7/8 **095 312 COIL, primary 026 764 STRIP, 0.015x1-3/4x2-i/2 010 157 STUD, No.
