OM-LW-01-2015

January 2015

Read this manual carefully before installing,

Commissioning, or operating this product.

Miller Welding Automation, 281 E. Lies Rd., Carol Stream, Il 60188

Telephone: (949) 951-1515 • Fax: (949) 951-9237

Web site: www.jetline.com • E-mail: sales@jetline.com

OPERATION MANUAL

for External Longitudinal Seam

Welders

IMPORTANT

Components or parts manufactured directly by Miller Electric Mfg. Co. are subject to Miller’s True Blue® Warranty set

forth at www.millerwelds.com/support/warranty. Seller does not make any warranties for components or parts not

manufactured directly by Jetline Engineering, Miller Welding Automation, and Panasonic Welding Systems Company;

such components or parts are subject to the warranty terms of the respective manufacturer. Components and parts

manufactured by Jetline Engineering, Miller Welding Automation, and Panasonic Welding Systems Company are

subject to the following warranty terms. Terms and Conditions of Sale Seller warrants to Purchaser that the

components or parts manufactured by Seller or Panasonic Welding Systems Company shall be free from defects in

material and workmanship, and shall conform to the Seller’s specifications for the following periods:

a. 12 months from the date of shipment of the Products for components and equipment manufactured by

Panasonic Welding Systems Company including robot manipulator, controller and connecting cables; external

axis components (external axis base unit, servo amplifiers, motors, connecting cables and pre-engineered

positioners); peripheral devices (high voltage touch sensors, thru arc seam trackers); welding power sources

(internally built into the robot controller cabinet); wire feeders (separated design or integrated design, i.e.

Active Wire Torch/Feeder); or

b. 12 months from date of shipment of the Products for equipment manufactured by Jetline Engineering or

Miller Welding Automation.

In the event of a breach of the warranties set forth above, Seller will, at Seller’s option and as Seller’s sole liability and

Purchaser’s sole remedy, repair, replace or credit Purchaser’s account for, any Product that fails to conform to the

above warranty, provided that (i) during the applicable warranty period Seller is promptly notified in writing upon

discovery of such failure with a detailed explanation of any alleged deficiencies; (ii) Seller is given a reasonable

opportunity to investigate all claims; and (iii) Seller’s examination of such Product confirms the alleged deficiencies and

that the deficiencies were not caused by accident, misuse, neglect, improper installment, unauthorized alteration or

repair or improper testing. No Products may be returned to Seller until inspection and approval by Seller. All warranty

work performed shall be FOB Seller’s facility (Incoterms 2010) and freight for returned Products shall be paid for by

Purchaser. The above warranty against defects does not apply to: (1) consumable components or ordinary wear items

including but not limited to torches; or (2) defects due to (i) failure to install and perform maintenance set forth in

Product documentation, (ii) the use of components, parts, peripherals, attachments, accessories, or perishable tooling

not approved by Seller, (iii) accident, misuse, neglect, abuse, mishandling, misapplication, modification, alteration, acts

of God, or (iv) improper installation, service or maintenance. Purchaser and/or the operator of the Products are in full

control of the weld process. Seller makes no warranty regarding the quality or the success of the welds on the Products

due to factors under Purchaser’s and/or operator’s control including but not limited to welding procedures, material

types, material coatings, joint/part fit, part geometry, metallurgy, welding gases, proper machine/process

maintenance, and operator skill. EXCEPT AS SET FORTH ABOVE, SELLER MAKES NO WARRANTY OR REPRESENTATION

OF ANY KIND, EXPRESS OR IMPLIED (INCLUDING NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY

PARTICULAR PURPOSE).

- See more at: https://www.millerwelds.com/automation-terms-of-sale#sthash.l5oRebWB.dpuf

LIMITED WARRANTY

The installation, operation and maintenance guidelines set out in this manual will enable you to maintain the equipment in peak condition and achieve maximum efficiency with your welding operation. Please read these instructions carefully to become aware of every advantage.

Only experienced personnel familiar with the operation and

safe practice of welding equipment should install and/or

use this equipment.

NOTICE

CAUTION

CONTENTSCONTENTSCONTENTSCONTENTS

SECTION I .......................................................................................................................... 1

SAFETY PRECAUTIONS – READ BEFORE USING (som 2013-09) ...................................... 1

1.1 Symbol Usage ........................................................................................................... 1

1.2 Arc Welding Hazards ................................................................................................ 1

1.3 Additional Symbols for Installation, Operation, And Maintenance ........................ 4

1.4 California Proposition 65 Warnings ........................................................................ 6

1.5 Principal Safety Standards ....................................................................................... 6

1.6 EMF Information ...................................................................................................... 6

SECTION II ......................................................................................................................... 7

INTRODUCTION ............................................................................................................... 7

SECTION III ........................................................................................................................ 8

INITIAL INSPECTION ....................................................................................................... 8

SECTION IV ...................................................................................................................... 10

SPECIFICATIONS ........................................................................................................... 10

A. Input Requirements ........................................................................................... 10

B. Carriage Speed Ranges ....................................................................................... 10

C. Chill Bar Selection – GTAW ................................................................................. 15

D. Chill Bar Selection - GMAW ................................................................................. 16

E. Distance Between Finger Tips ............................................................................ 17

F. Air Regulator Settings ........................................................................................ 17

Section V .......................................................................................................................... 19

Installation ........................................................................................................................ 19

A. System Operating Conditions .............................................................................. 19

B. Mechanical Installation ........................................................................................ 19

C. Electrical Installation ............................................................................................ 22

Section VI ......................................................................................................................... 23

Theory of Operation .......................................................................................................... 23

- 2 -

A. Mechanical Operation ........................................................................................ 23

B. Base Section ........................................................................................................ 23

C. Mainstay .............................................................................................................. 23

D. Mandrel ............................................................................................................... 24

E. Tabletop .............................................................................................................. 24

F. Track ................................................................................................................... 25

G. Carriage Control ................................................................................................. 25

Section VII ........................................................................................................................ 28

Start up and Operation ..................................................................................................... 28

A. Initial Setup .......................................................................................................... 28

B. Operation ............................................................................................................. 28

Section VIII ....................................................................................................................... 30

Troubleshooting ................................................................................................................ 30

A. Fixture ................................................................................................................ 30

B. GTAW Process .................................................................................................... 31

Section IX Mechanical Maitanance ................................................................................... 34

A. Adjustment and Replacement of the Clamping Fingers ....................................... 34

B. Replacement of the Clamping Hoses .................................................................. 35

C. Replacement of the Mandrel................................................................................ 35

D. Adjustment of the Mandrel ................................................................................... 38

E. Adjustment to the Track to the Insert ................................................................... 38

F. Preventative Maintenance ................................................................................... 39

Section X .......................................................................................................................... 40

Parts List ........................................................................................................................... 40

Section XII ........................................................................................................................ 48

Electrical Drawings ........................................................................................................... 48

1

SECTION I

SAFETY PRECAUTIONS – READ BEFORE USING (som 2013-09)

1.1 Symbol Usage

DANGER! − Indicates a hazardous situa$on which, if not avoided, will result in death or serious injury. The possible hazards are shown in the

adjoining symbols or explained in the text.

Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or

explained in the text.

NOTICE − Indicates statements not related to personal injury.

� Indicates special instructions.

This group of symbols means: Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions to avoid the hazards.

1.2 Arc Welding Hazards

The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol,

watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more

complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this unit.

During operation, keep everybody, especially children, away.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is

on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire,

wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded

equipment is a hazard.

• Do not touch live electrical parts.

• Wear dry, hole-free insulating gloves and body protection.

• Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work

or ground.

• Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.

• Use AC output ONLY if required for the welding process.

• If AC output is required, use remote output control if present on unit.

• Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations

or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting,

kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the work piece or ground. For these

conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is

recommended. And, do not work alone!

• Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA

29 CFR 1910.147 (see Safety Standards).

• Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes.

• Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

• When making input connections, attach proper grounding conductor first − double-check connections.

• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.

• Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged – bare

wiring can kill.

• Turn off all equipment when not in use.

• Do not use worn, damaged, undersized, or repaired cables.

Protect yourself and others from injury – read, follow and save these important safety precautions and operating instructions.

ELECTRIC SHOCK can kill.

2

• Do not drape cables over your body.

• If earth grounding of the workpiece is required, ground it directly with a separate cable.

• Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

• Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be

present.

• Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.

• Wear a safety harness if working above floor level.

• Keep all panels and covers securely in place.

• Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.

• Insulate work clamp when not connected to workpiece to prevent contact with any metal object.

• Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use.

• Use GFCI protection when operating auxiliary equipment in damp or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.

• Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before

touching any parts.

• Do not touch hot parts bare handed.

• Allow cooling period before working on equipment.

• To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

• Keep your head out of the fumes. Do not breathe the fumes.

• If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. The recommended way

to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are

exposed.

• If ventilation is poor, wear an approved air-supplied respirator.

• Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners,

consumables, coolants, degreasers, fluxes, and metals.

• Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch-person

nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is

safe.

• Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to

form highly toxic and irritating gases.

• Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area,

the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can

give off toxic fumes if welded.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off

from the weld.

• Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks

when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).

• Wear approved safety glasses with side shields under your helmet.

• Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.

• Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes oil-free

clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

HOT PARTS can burn.

ARC RAYS can burn eyes and skin.

FUMES AND GASES can be hazardous.

3

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying

sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks,

explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

• Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

• Do not weld where flying sparks can strike flammable material.

• Protect yourself and others from flying sparks and hot metal.

• Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

• Watch for fire, and keep a fire extinguisher nearby.

• Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

• Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are

properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).

• Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline).

• Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock, sparks, and fire hazards.

• Do not use welder to thaw frozen pipes.

• Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

• Wear body protection made from durable, flame−resistant material (leather, heavy coMon, wool). Body protecNon includes oil-free

clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

• Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.

• After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.

• Use only correct fuses or circuit breakers. Do not oversize or bypass them.

• Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.

Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables,

coolants, degreasers, fluxes, and metals.

• Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.

• Wear approved safety glasses with side shields even under your welding helmet.

• Shut off compressed gas supply when not in use.

• Always ventilate confined spaces or use approved air-supplied respirator.

• Wearers of Pacemakers and other Implanted Medical Devices should keep away.

• Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating operations.

• Noise from some processes or equipment can damage hearing.

• Wear approved ear protection if noise level is high.

WELDING can cause fire or explosion.

FLYING METAL or DIRT can injure eyes.

BUILDUP OF GAS can injure or kill.

ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices.

NOISE can damage hearing.

4

Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the

welding process, be sure to treat them carefully.

• Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.

• Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.

• Keep cylinders away from any welding or other electrical circuits.

• Never drape a welding torch over a gas cylinder.

• Never allow a welding electrode to touch any cylinder.

• Never weld on a pressurized cylinder − explosion will result.

• Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and

associated parts in good condition.

• Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the

valve.

• Keep protective cap in place over valve except when cylinder is in use or connected for use.

• Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.

• Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication

P-1 listed in Safety Standards.

1.3 Additional Symbols for Installation, Operation, And Maintenance

• Do not install or place unit on, over, or near combustible surfaces.

• Do not install unit near flammables.

• Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.

• Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.

• Use equipment of adequate capacity to lift and support unit.

• If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

• Keep equipment (cables and cords) away from moving vehicles when working from an aerial location.

• Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manually

lifting heavy parts or equipment.

• Allow cooling period; follow rated duty cycle.

• Reduce current or reduce duty cycle before starting to weld again.

• Do not block or filter airflow to unit.

• Wear a face shield to protect eyes and face.

• Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

• Sparks can cause fires — keep flammables away.

• Put on grounded wrist strap BEFORE handling boards or parts.

• Use proper static-proof bags and boxes to store, move, or ship PC boards.

CYLINDERS can explode if damaged.

FIRE OR EXPLOSION hazard.

FALLING EQUIPMENT can injure.

OVERUSE can cause OVERHEATING

FLYING SPARKS can injure.

STATIC (ESD) can damage PC boards.

MOVING PARTS can injure.

5

• Keep away from moving parts.

• Keep away from pinch points such as drive rolls.

• Do not press gun trigger until instructed to do so.

• Do not point gun toward any part of the body, other people, or any metal when threading welding wire.

• Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.

• Keep away from moving parts such as fans.

• Keep all doors, panels, covers, and guards closed and securely in place.

• Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary.

• Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.

• Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety

information at the beginning of the manual and in each section.

• Use only genuine replacement parts from the manufacturer.

• Perform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes.

• High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.

• Have only qualified persons familiar with electronic equipment perform this installation.

• The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

• If notified by the FCC about interference, stop using the equipment at once.

• Have the installation regularly checked and maintained.

• Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

• Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such

as robots.

• Be sure all equipment in the welding area is electromagnetically compatible.

• To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.

• Locate welding operation 100 meters from any sensitive electronic equipment.

• Be sure this welding machine is installed and grounded according to this manual.

• If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line

filters, or shielding the work area.

WELDING WIRE can injure.

BATTERY EXPLOSION can injure.

MOVING PARTS can injure.

READ INSTRUCTIONS.

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

6

1.4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects

and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive

harm. Wash hands after use.

1.5 Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at

http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global

Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global

EngineeringDocuments (phone: 1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:

www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103,

Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way,

Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org).

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25 West

43rd Street, New York, NY 10036 (phone: 212-642-4900, web-site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy,

MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part

1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-

512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd,

Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).

1.6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes

including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields

may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For

example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

1. Keep cables close together by twisting or taping them, or using a cable cover.

2. Do not place your body between welding cables. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep head and trunk as far away from the equipment in the welding circuit as possible.

5. Connect work clamp to workpiece as close to the weld as possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot

welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recom-

mended.

7

SECTION II

INTRODUCTION

Congratulations on your purchase of a Miller

Welding Automation Longitudinal Seam

Welder. Its quality workmanship will bring

many years of dependable service and

consistent high quality seam welds.

The Miller Welding Automation seam welder

uses the chill shunt principle of tooling to

conduct heat away from the part and

minimize burn-through, warping, or

excessive distortion.

Miller Welding Automation seam welders

are designed to clamp a part with a butt-

joint type seam. A motorized carriage on

which a torch is mounted welds the seam.

Variables or factors that determine the

design include type of material to be used,

minimum and maximum material

thicknesses, and type of weld process. The

seam welder can be designed to handle a

variety of shapes and sizes. Seam welders

can accommodate part lengths from 3

inches to 40 feet (76 mm to 12 m),

dependent on the model ordered.

Prior to welding, the part is positioned on

the mandrel insert, clamped, and is then

welded in a stationary position. A welding

torch is mounted to the side beam carriage

with a torch holder and bracket. This allows

the torch and carriage to traverse the entire

length of the part while performing the

weld.

The clamping of the part ensures that the

joint is aligned down the centerline of the

machine. With the part on center and the

torch mounted above the weld joint, in

many applications the welding of a butt-joint

becomes a simple operation without the

necessity of tack welding prior to welding.

Miller Welding Automation longitudinal

seam welders are comprised of several

integral assemblies: a base/mainstay,

mandrel, tabletop, track, carriage, and a

control panel. See Figure 1. These

assemblies combined create an efficient

welding unit. The base is made of tubular

steel and serves as the main support for the

system. The mainstay houses all of the

plumbing and electrical clamping control

boxes. Attached to the mainstay is a

mandrel on which is mounted an insert; this

can be water cooled as an option. The

tabletop is mounted to the top of the

mainstay. This is where the hold down

clamping fingers are mounted.

Mounted directly on the tabletop are two or

three track supports, depending on the

welding length of the tabletop. These track

supports hold up the main track assembly

which extends the entire length of the

tabletop. Riding on the track assembly is a

motorized carriage. The control panel

controlling the carriage speed and weld time

is mounted to the carriage face thus making

the Miller Welding Automation longitudinal

seam welder a well- integrated system.

8

SECTION III

INITIAL INSPECTION

Upon receipt of the equipment, examine the

shipping crate for freight damage. If the

crate appears to have suffered major

damage, the unit should be examined

carefully for possible damage and/or

possible misalignment in the track and

mandrel.

Although Miller Welding Automation has

packaged your equipment well, long and/or

extremely rough shipping can have an

adverse effect on the equipment. As a result,

please spend a few extra minutes to insure

that the assembly pieces are in good order.

The crate in which the seam welder has

arrived will have to be dismantled. Be

careful to dismantle the equipment safely.

Damage to the unit and personal injury can

occur during unpacking, therefore follow all

safety precautions.

Your seam welder was thoroughly tested

and verified it met specifications before

shipping. After receipt, visual inspection of

all adjustment points should be made. See

Figure 1.

If a cable carrier assembly was purchased as

an option, the carrier may have been

removed from the track and packed

separately. Verify that it too has arrived in

good condition before proceeding with its

installation.

The carriage assembly is normally shipped

mounted on the track and requires only the

removal of the temporary mounting bracket.

If the seam welder has an optional riser (for

larger diameters than standard) the carriage

was removed before the seam welder was

shipped. If this is the case, the carriage will

be mounted on the crate deck next to the

seam welder. Verify there is no apparent

damage to it or to the equipment mounted

to it.

After this initial inspection is completed,

installation of the longitudinal seam welder

can begin.

9

Figure 1

Longitudinal Seam Welder

10

SECTION IV

SPECIFICATIONS

A. Input Requirements

Electrical (Standard):

Phase, 50/60 Hz.

115 Volts, Single

Electrical (Optional):

Phase, 50/60 Hz.

230 Volts, Single

Compressed Air: 80 PSI (5.6 kg / sq cm.)

Air pressure will generate up to 5,000 lb/ft

(74.4 kg/cm) of clamping force on the part.

See the air regulator settings chart in this

section to set the correct clamping pressure

for the material thickness being welded.

Welding equipment varies according to

process, manufacturer, and usage. Specific

inputs for shield gas, primary electrical, and

water cooler/ recirculator are contained in

the original manufacturer’s manuals.

B. Carriage Speed Ranges

For seam welders up to 16 ft (4.8 m) long:

The SWCB-3 carriage is rated for 300 lb (136

kg) capacity with the center of gravity out

12” (305 mm) from the face of the carriage.

(See the SWCB-3 Carriage Manual for more

details.)

SWCB-3A: 3 to 135 IPM (75 to 3,450

mm/min)

SWCB-3B: 1.2 to 60 IPM (30 to 1,500

mm/min)

SWCB-3D, Optional: 0.2 to 188 IPM (5 to

4,775 mm/min)

For seam welders over 16 ft (4.8 m) long:

The SWC-6 medium duty carriage is rated for

1000 lb (450 kg) capacity with the center of

gravity out 12” (305 mm) from the face of

the carriage. They are designed for use with

a TKMV style V-way track for structural

integrity. (See the SWC-6 Carriage Manual

for more details.)

SWC-6A: 4 to 165 IPM (102 to 4,191

mm/min)

SWC-6B: 3 to 108 IPM (76 to 2,743

mm/min)

SWC-6C: 2 to 67 IPM (51 to 1,702 mm/min)

SWC-6D: 1 to 45 IPM (25 to 1,143 mm/min)

For LWX Ultra Precision seam welders:

The SWC-4 linear drive carriage is rated for

300 lb (136 kg) capacity with the center of

gravity out 12” (305 mm) from the face of

the carriage. The linear drive provides

smooth, backlash free carriage movement.

SWCA-4A: 4 to 170 IPM (102 to 4,318

mm/min)

SWCA-4B: 2 to 85 IPM (51 to 2,160

mm/min)

11

SWCA-4C, Optional: 0.32 to 160 IPM (8 to

4,060 mm/min)

SWCA-4D, Optional: 0.22 to 106 IPM (5 to

2,700 mm/min)

12

*Model

“A”

Welding

Length

in/mm

“B”

**Min.

Dia Part

in/mm

“C”

***Min.

Dia. Part

in/mm

“D”

Overall

length

in/mm

“E”

Overall

Width

in/mm

“F”

Overall

height

in/mm

Approx.

Ship

Weight

Lb/Kg

LW-24 24/609 2.63/67 32/800 70/1765 40/1003 69/1753 2300/1040

LW-36 36/914 3.5/89 32/800 82/2070 40/1003 69/1753 2600/1180

LW-48 48/1219 4.25/108 32/800 94/2372 40/1003 69/1753 4000/1810

LW-60 60/1524 5.25/133 32/800 106/2677 40/1003 69/1753 4700/2130

LW-72 72/1829 6/152 32/800 118/2981 40/1003 69/1753 5300/2400

LW-84 81/2134 6.87/175 32/800 130/3286 40/1003 69/1753 5900/2680

LW-96 96/2438 7.25/184 32/800 142/3591 40/1003 69/1753 6400/2900

LW-120 120/3048 9.5/241 32/800 176/4470 42/1054 76/1930 12000/5440

LW-144 144/3658 12.25/311 32/800 200/5080 42/1054 76/1930 1300085890

LW-168 168/4267 15.25/387 32/800 224/5689 42/1054 76/1930 14000/6330

LW-192 192/4877 18.5/464 32/800 248/6300 42/1054 76/1930 15000/6780

LW-216 216/5486 21.25/539 32/800 272/6910 42/1054 76/1930 16000/7240

LW-240 240/6096 24.25/616 32/800 296/7518 42/1054 76/1930 17000/7690

Letters “A” through “F” in table above refer to Figure 2.

* Prefix taken from model as noted below.

** Can be modified at any time by purchasing new mandrel.

*** Can be increased to any convenient height by using optional riser block.

LWS Standard Seam Welder

Application: 0.020" to 3/8" (0.5 to 10 mm) – all weldable metals

Travel Accuracy: "0.015" (0.4 mm)

per 10 ft (3 m)

Carriage Drive: Rack and Pinion

13

LWP Precision Seam Welder

Application: 0.005" to 3/8" (0.1 to 10 mm) - all weldable metals

Travel Accuracy: "0.005" (0.1 mm)

per 10 ft (3 m)

Carriage Drive: Rack and Pinion

LWX Ultra-Precision Seam Welder

Application: For critical applications 0.005" to 3/8" (0.1 to 10 mm) - all weldable

metals

Travel Accuracy: "0.005" (0.1 mm)

per 10 ft (3 m)

Carriage Drive: Linear Drive

14

Figure 2

Dimensions - Longitudinal Seam Welder

15

C. Chill Bar Selection – GTAW

TIG-DCSP

GROUP I*

Base Metal:

Steel

Stainless

Aluminum

Magnesium

Copper

TIG-AC

GROUP II**

Base Metal:

Aluminum

Magnesium

TIG-DCSP

GROUP III

Base Metal:

Titanium

Molybdenum

Zircalloy

Tantalum

Rene 41

Hastelloy

Inconel

Haynes 25 .005-.012 Fusion

Filler

.040W .010D

-

-

-

.040W .125D

.013-.0.20 Fusion

Filler

.063W .010D

-

-

-

.125W .100D

.021-.032 Fusion

Filler

.093W .010D

.125W .020D

.093W .010D

.093W .015D

.187W .100D

.033-.040 Fusion

Filler

.125W .020D

.187W .025D

.125W .015D

.125W .020D

.041-.050 Fusion

Filler

.125W .020D

.187W .025D

.156W .015D

.156W .020D

.051-.062 Fusion

Filler

.187W .020D

.250W .040D

.187W .015D

.187W .020D

.063-.072 Fusion

Filler

.187W .020D

.250W .040D

.250W .020D

.250W .025D

.250W .100D

.073-.125 Fusion

Filler

.250W .040D

.312W .040D

.312W .020D

.312W .030D

.126-.250 Fusion

Filler

.312W .020D

.375W .050D

.375W .030D

.375W .040D

.312W .100D

.251-.375 Fusion

Filler

-

-

.375W .030D

.438W .040D

Note: Group III inserts are all copper gas back-up. Part number reflects the groove width and depth in inches (.040W .010D is .040” wide and .010” deep).

16

D. Chill Bar Selection - GMAW

GROUP I*

Base Metal:

Steel

Stainless

Aluminum

Magnesium

Copper

*Copper Chill Bar

GROUP II**

Base Metal:

Aluminum

Magnesium

** Steel or Stainless Insert

.005-.012 MIG

SUB-ARC

-

-

-

-

.013-.020 MIG

SUB-ARC

-

-

-

-

.021-.032 MIG

SUB-ARC

.125W .040D

-

.125W .040D

-

.033-.040 MIG

SUB-ARC

.187W .050D

-

.125W .040D

-

.041-.050 MIG

SUB-ARC

.187W .050D

.125W .035D

.187W .050D

-

.051-.062 MIG

SUB-ARC

.250W .050D

.140W .040D

.250W .050D

-

.063-.072 MIG

SUB-ARC

.250W .050D

.187W .050D

.250W .050D

-

.073-.125 MIG

SUB-ARC

.312W .060D

.375W .055D

.312W .060D

-

.126-.250 MIG

SUB-ARC

.375W .060D

.470W .060D

.375W .060D

-

.251-.375 MIG

SUB-ARC

.437W .080D

.630W .065D

.437W .080D

-

Note: Part number reflects the groove width and depth in inches (.040W .010D is .040” wide & .010” deep).

17

E. Distance Between Finger Tips

GROUP I*

Base Metal:

Steel

Stainless

Aluminum

Magnesium

Copper

GROUP II**

Base Metal:

Aluminum

Magnesium

.005-.012" (0.1-0.3 mm) .063" (1.6 mm) -

.013-.024" (0.3-0.6 mm) .100" (2.5 mm) -

.025-.032" (0.6-0.8 mm) .125" (3.2 mm) .312" (8 mm)

.033-.040" (0.8-1.0 mm) .187" (4.8 mm) .375" (10 mm)

.041-.050" (1.0-1.3 mm) .250" (6 mm) .500" (12.7 mm)

.051-.080" (1.3-2.0 mm) .375" (10 mm) .625" (16 mm)

.081-.125" (2.0-3.2 mm) .438" (11 mm) .750" (19 mm)

.126-.250" (3.2-6.3 mm) .500" (12.7 mm) .875" (22 mm)

.251-.375" (6.3-10 mm) .565" (14 mm) 1.0" (25 mm)

F. Air Regulator Settings

Material Thickness Regulator Settings

.005-.012" (0.1-0.3 mm) 10 PSI (4.5 kg/sq mm)

.013-.024" (0.3-0.6 mm) 15 PSI (6.8 kg/sq mm)

.025-.032" (0.6-0.8 mm) 20 PSI (9 kg/sq mm)

.033-.050" (0.8-1.3 mm) 25 PSI (11 kg/sq mm)

.051-.080" (1.3-2.0 mm) 37 PSI (17 kg/sq mm)

.081-.125" (3.2-6.3 mm) 50 PSI (22.7 kg/sq mm)

.126-.250" (3.2-6.3 mm) 75 PSI (34 kg/sq mm)

Use these settings as a guide only. When the material to be welded has been formed to match well and lay flat, less hold-down pressure is required. Always use the least amount necessary.

NOTE

18

19

SECTION V

INSTALLATION

A. System Operating

Conditions Temperature range: 0 to 40C

Humidity: 5 to 95% RH non condensation

Altitude: Up to 1000 meters

Mounting: Secured to reinforced concrete floor

Electrical Input:

Export:

400VAC, 3 phase, 50 Hz nominal

USA: 460 VAC, 3 phase 60 Hz

Export:

Single Phase, 220VAC, 50 Hz

USA: 120VAC, 60 Hz domestic Compressed

Air:

Clean, dry air at 80 PSI (5.6 kg/sq cm) Welding

Gas:

Bottled or bulk supply at 100 PSI (7 kg/sq cm)

minimum pressure

Transportation, Storage:

-20 C Degrees to 60 C Degrees

-4 F Degrees to 140 F Degrees Vibration, Shock:

1G rms 5 to 500 Hz

B. Mechanical Installation Tools Required:

Typically a forklift or overhead crane with at

least 7000 pounds (3125 Kg) capacity. For larger

systems greater capacity lifting is required.

Two lifting straps rated for 4000 pounds (1800

Kb). For larger systems greater capacity lifting is

required.

General hand tools – claw hammer, screw

driver(s), hex keys or allen wrenches, set of box

end wrenches, and adjustable wrench.

Air or electric impact drill if concrete anchoring

bolts needed.

Digital VOM electrical meter.

Installation personnel should be trained and

experienced and locally qualified in moving

heavy loads, setting up electrical/mechanical

systems. Familiarity with local procedures and

standards is necessary. A licensed electrician

should be involved in making primary

connections.

Uncrate the machine, remove the skid and set

the equipment at the desired location. Orient

the seam welder according to your desired

factory floor layout.

20

One of four mounting holes for use with

overhead crane. Two are located at each end of

the tabletop.

CAUTION

When moving the seam welder by fork lift

truck, do not put the forks under the mandrel

or the track. Always move the seam welder by

placing the forks under the base or through the

base structural tubes from the mainstay end of

the machine.

The fixture is free-standing and can be placed

on floor without anchoring it to concrete. The

seam welder base should be secured to

concrete floor if (a) the seamer is integrated

with a conveyor system or (b) a riser is being

used to weld large diameter shells. In these two

cases the seamer base must be secured to

reinforce concrete floor by the use of anchor

bolts/red heads.

After the fixture has been removed and placed

in its location in your factory, it can be anchored

to the floor using 10 mm concrete anchors.

Carriage Installation Procedure

The welding head and carriage are fitted to the

side beam track and require the removal of one

shipping bracket. The shipping bracket is bolted

to the carriage and the track, keeping the

carriage from moving during shipment. The

bracket is located on the top portion of the

track and carriage and is held in place with two

bolts.

Removed this shipping bracket from the

carriage and discard. Look for tag as shown

below.

If the carriage has been removed for shipment,

use the following procedure:

At each end of the track are two mechanical

stops. These stops serve as a safety device to

prevent the carriage from falling off the end of

the track. Remove the carriage angle stops from

the top end of the track. Rotate the cam

handles so that the motor pinion is disengaged.

We recommend using a crane or fork lift truck

to hoist the carriage up to the track (see Figure

1). When lifting the carriage, you will find a ½-

13 tapped hole on top of the carriage. This hole,

along with an eye bolt (not supplied), can be

used for lifting the carriage.

As an alternative, use the lift holes located in

the gussets at either end of the carriage to slide

the carriage onto the track. Refer to Figure 3 to

verify it is correctly aligned.

Once the carriage is mounted on the track,

replace the mechanical stop on the end of the

track to its original position.

21

22

The wire feeder is often removed for shipping

purposes and put in a separate box. The wire

feeder should be installed onto the mounting

brackets located on the carriage.

Make the weld power, electrical, shield gas, air

and water connections to the seam welder

system. A cable channel, which protects welding

gas lines and control cables from the rack and

gears, is provided. The cables are located at the

end of the cable carrier and are marked as to

purpose.

The air supply to the seam welder is ready to be

connected. In order for the seam welder to

operate properly, the shop air supply should be

set at 80 PSI (5.6 kg/sq cm) minimum. The air

supply must be connected before the filter

assembly.

NOTE

DO NOTE BY-PASS THE FILTER. By-passing the filter

assembly when connecting the air supply will allow

moisture to enter the solenoid valves causing the

valves to fail.

Dry run the carriage without welding to be sure the

carriage moves back and forth.

During shipment, bolts and hardware can be shaken

loose. Please check all fasteners to be certain they are

tight before operating the system.

Read and consult welding power source manuals to

insure proper set up, polarity, and that torch

consumables are selected and installed properly.

Perform trial welds on scrap material to test

functioning of system.

C. Electrical Installation The electrical input requirements for the seam welder

are 110-120 VAC, 1 phase, 50/60 Hz, a step-down

transformer can be incorporated into the wiring circuit

to achieve this requirement.

The standard seam welder is supplied with a model

9700T Microprocessor Carriage Control. The control is

normally mounted on the front of the carriage. Refer

to the separate 9700T manual supplied.

Other controls and equipment may have been

purchased and installed on the seam welder carriage.

Individual manuals will be supplied for them. Please

refer to the appropriate manuals for proper

installation guidelines regarding these items.

23

SECTION VI

THEORY OF OPERATION

A. Mechanical Operation

The seam welder is comprised of several main

assemblies. Each assembly is integrated to form

a complete system. The system consists of the

following components: base/mainstay, mandrel,

tabletop, track, carriage, and control panel.

Miller Welding Automation seam welders use

the chill shunt principle of tooling to conduct

heat away from the part. This process minimizes

burn through, warping and excessive distortion

when performing butt- joint welding.

The edges of the part are clamped on the top

centerline of the mandrel and insert. (The inserts

are made of copper, stainless steel or steel,

dependent upon the material type being

welded.) The part is clamped against the insert

by two banks of aluminum clamping fingers,

each bank fitted with copper tips (see Figure 4).

This clamping concept allows the seam to be

welded but restricts the heat from passing

through the part. The heat is absorbed by the

fingers and the mandrel. The seam welder

maintains sufficient force to hold parts with a

wall thickness up to 0.375" (10 mm). However,

dependent upon the welding process used, edge

preparation may be required and, on thicker

materials, multi-pass welds may be required as

well.

Optional designs to handle thicker parts are

available. For welding of material above .375”

(10 mm), the application needs to be

communicated before manufacture of the seam

welder.

The LWS, LWP and LWX seam welders are

designed to perform butt-joint welds by arc

welding on all conventional metals. Some of the

arc welding processes include Gas Tungsten Arc

Welding (GTAW), Gas Metal Arc Welding (GMAW),

Shielded Metal Arc Welding

(SMAW), Submerged Arc Welding (SAW) and Plasma

Arc Welding (PAW). Materials that can be welded

include stainless steel, weldable aluminum,

magnesium alloys, zirconium, molybdenum,

titanium, mild steel and low carbon steels. Some of

these metals require a preparatory edge process in

order to be welded successfully.

Part configurations which the seam welder can

handle are cylinders, cones, truncated cones, open

ended boxes, double bowl sinks, flat plates and

sheets.

B. Base Section The base is made from a rigid tube steel structure

which provides stability and safety during

operation. The base is equipped with mounting

holes to ensure stability of the equipment on

uneven surfaces.

The base houses the electrical toe-touch clamping

switches. These switches run the entire length of

the base. When facing the front of the seam welder,

the switch closest to the operator controls the front

bank of clamping fingers. The switch next in line

controls the rear bank of clamping fingers. The third

switch controls the rear clamping fingers only. To

activate one of the switches, merely touch the

switch with your toe. This will either clamp or

unclamp a bank of clamping fingers.

C. Mainstay The primary purpose for the mainstay is to support

the tabletop. On the standard seam welder, the

mainstay is high enough to accommodate an

approximate 32" (800 mm) diameter part. As an

option a riser can be made for diameters greater than

32" (800 mm).

The mainstay also houses the control box (FCP- 10B)

for the toe-touch switches, the pneumatic valves,

24

water lines if applicable, and electrical solenoids

which operate the pressure hose assemblies.

The air hose connection, filter, ground lug and

electrical box are located on the back side of the

mainstay. If a need for 460 volts is required, a

step down transformer will be mounted on the

mainstay as well.

D. Mandrel The mandrel is mounted to the mainstay and is

typically round, but can be designed to meet the

demands of the application. The mandrel must

support the part’s weight, along with supporting

the clamping forces exerted by the clamping

fingers. In most cases, the mandrel is designed to

be supported at the mainstay and at the latch

end.

The mandrel is designed to support a back-up

insert and may have optional water cooling

capability. Depending on the thickness of the

material to be welded and the welding process,

the insert will have a specific groove dimension

(width and depth) machined into it. When several

different thicknesses of materials are to be

welded on the same seam welder, additional

inserts may be required to obtain a quality weld.

The inserts may also be designed to provide gas

back-up to the part. This option provides backing

gas to the penetration side (bottom) of the weld.

Backing gas is required for welding refractory

metals and is recommended for stainless steel

materials.

In high production environments, and/or when

welding with high current, an optional water-

cooled mandrel is required. The water-cooled

mandrel provides cooling of the insert using a

separate water circulator. This helps to maintain a

consistent temperature and weld throughout the

production run.

E. Tabletop The tabletop houses the two banks of clamping

fingers, and supports the side beam track and

carriage.

One of the most outstanding features of the tabletop

design is the ability to view the weld in progress via

the naked eye (with weld shield) or with a video

camera.

The two banks of clamping fingers are set and

mounted within the tabletop. The tabletop section will

differ in size and weight as the welding length of the

seam welder increases. The tabletop is designed to

withstand the clamping forces generated by the

clamping fingers.

On both sides of the tabletop are adjusting screws

used to adjust the finger spacing (see Figure 4). There

are several screws that are used to adjust the location

of the fingers relative to the insert groove. These

screws should be adjusted symmetrically to the

groove to provide an even chilling effect.

The finger spacing as a standard depends largely on

the material thickness being welded. See Section IV

for Miller Welding Automation’s recommendation. As

a safety note, after the adjustments have been

completed, there should not be a gap greater than

1/8" (3.2 mm) between fingertip and part when the

bank of fingers is in its unclamped state. This

adjustment is made to minimize a pinch point

condition between the fingers and part being welded.

The fingers on a Miller Welding Automation seam

welder are 3" (75 mm) wide and are made of

aluminum. At the end of each finger is a copper or

optional stainless steel fingertip screwed to the

aluminum finger

body. These tips are reversible and should be changed

if damaged or worn.

The latch assembly is mounted on the opposite end of

the mainstay. The latch must be closed during the

clamping of the fingers, thus securing and supporting

the mandrel. If the clamping forces are exerted on the

mandrel without the latch support, there is a potential

for mandrel damage. As a result, we have installed a

safety switch which prevents clamping without the

latch being closed.

25

WARNING

This safety switch should not be by-passed.

F. Track

Two or three track supports, depending on the

welding length of the seam welder, are mounted

to the tabletop. The side beam track is bolted

securely and mounted to these track supports.

There are no supports in the welding area of the

seam welder. The track is positioned in such a

way that it is suspended over the welding area.

See Figure 5.

Typically a TKSA style track is adequate to span

distances under 192" (4875 mm) of weld length.

For longer distances, the TKMV medium duty

track is used. These Miller Welding Automation

tracks ensure a tracking accuracy of the carriage

along the track of "0.015" (0.4 mm) in both

planes.

G. Carriage Control

The carriage is driven by the 9700T

Microprocessor Control which is designed for

automatic sequencing of carriage travel and

power supply starting and stopping. The control

is equipped with a two line display which guides

the operator through setup and displays travel

speed during the weld procedure. The separate

9700T manual contains complete operating

instructions.

For more advanced systems, a 9900 Computer

Controller is used to control the weld process

and carriage travel.

Carriage Layout with 9600 travel control and GMAW gear

GTAW Carriage Layout with 9900 Computer Controller

GTAW Carriage Layout with standard 9700 Series Controls – travel, wire, alc

26

Carriage Layout with 9600 travel control and Sub-Arc gear

27

Figure 5

Track Support Assembly

28

SECTION VII

START UP AND OPERATION

A. Initial Setup 1. Edge Preparation

It is important that the part edges are

prepared so that when they are brought

together in the seam welder any

resulting joint gap is less than 10% of

the part’s thickness. Ideally, when using

the GTAW or PAW process, the edges

are as tight together as possible at the

beginning of the weld to minimize burn

through.

2. Finger Pressure

The finger pressure should be set based

on material thickness and the actual

application. The Specifications section

of this manual gives some

recommended pressures for different

material thicknesses.

3. Back-up Insert

Your back-up insert is designed

specifically for certain material types

and material thickness ranges. The

backup inserts can weld a variety of

material types and material thickness

spans. Welding a wide range of material

types and thicknesses will require

additional inserts. The Specifications

section of this manual gives

recommendations for back-up inserts.

These inserts are readily available from

Miller Welding Automation.

The back-up insert, sitting inside the

mandrel, should be parallel to the track.

Refer to Section X.

4. Distance Between Fingers

The distance between the front and

rear banks of fingers is adjustable. Only

adjust when fingers are in the up

position. It is best to adjust each screw

an equal distance and then to close the

fingers to inspect the finger distance

from the insert groove. One full turn of

each screw will move the fingers 1/16"

(1.6 mm). Each bank of fingers should

be an equal distance from the

centerline of the back-up insert.

The closer that the fingers are to the

groove of the back-up insert, the more

chilling effect they wills are apart, the

less chilling effect is provided. Fingers

that are adjusted close to the groove

can increase the control of welding heat

input, while wider spaced fingers can

tend to give increased travel speeds.

Therefore, it is important to set the

finger distance based on your specific

part.

The chart in the Specifications section

gives initial recommendations for finger

spacing.

B. Operation

NOTE

The latch should be completely closed before

welding.

1. Begin with both sets of fingers in the

unclamped (up) position. (Seam

welders that utilize any automatic

loading or centering may need to be

cycled in order to start at the beginning

of a cycle.)

2. The centering devices should be pushed

down and toggled over. Check to make

sure that the blade is located over the

center of the back-up insert. The back

side of the centering device blades

should be located on the centerline of

the back-up insert. (Or very slightly to

the front of center).

If the seam welder is equipped with

more than two centering devices, use

only two, preferably spaced as far apart

as possible for your particular part.

29

3. The part should be loaded into the rear

of the seam welder first. Push the edge

of the part up against the centering

device blades. Once you are sure that

the part is located properly, depress the

rear finger toe touch strip. This will

cause the rear pressure hose to fill,

clamping the rear bank of fingers and

securing the part in the seam welder.

Try to space the part in the seam

welder so that the ends of the part are

at least half covered by a finger at each

end. If the end is being covered by less

than half of a finger, then the finger

could tilt and result in insufficient chill.

If there is difficulty with burn through at

the beginning or end of the part, this

could be the cause. To solve the

problem simply move the part so that

the finger coverage is correct or insert a

small tab underneath the troublesome

finger so the finger bridges evenly

between the end of your part and the

small tab.

4. Now retract the centering devices.

5. Load the front side (edge) of the part

and butt it up against the edge of the

part that is already clamped by the rear

finger bank. Be sure that the ends are

even.

6. Depress the front fingers’ toe touch

strip and clamp the front fingers on the

part. The front fingers should always be

closed last because these are the “push-

in” fingers. These fingers push in slightly

as clamping pressure is applied,

ensuring a good fit at the joint.

7. Now that the part is loaded, you can

prepare to weld.

8. If limit switches are used to determine

the start and stop points of the weld, it

is best to set up on a practice part.

Move the carriage and torch at the

desired starting point, then slide the

“home” limit switch cam until it

contacts the “home” limit switch. Now

test this starting point by jogging the

carriage forward (12 or more inches if

possible) and then returning the

carriage to the “home” position. This

will indicate the true starting point.

To set the end of weld limit switch, use

a similar process. First manually set the

contact location, then test it by

reversing travel, then moving the

carriage to the end of weld.

9. Welding

Each and every welding application

requires its own unique set of welding

parameters. Wire speeds, voltages,

travel speeds, gas types, flow rates,

back-up bar size, type, finger spacing,

clamping pressures, material type,

material thickness and joint preparation

are some of the many variables that

need to be adjusted in order to provide

the most robust welding procedure for

a particular application.

Weld development is the sole responsibility of

the owner of the equipment and not the

responsibility of Miller Welding Automation.

10. Once the seam has been welded

successfully, release both sets of

fingers, open the latch if needed, and

carefully remove the part.

30

SECTION VIII TROUBLESHOOTING

A. Fixture Problem Cause and Correction

1. Misalignment of torch to the weld joint

(insert groove centerline).

a. The track and carriage not aligned parallel to

inside groove; readjust as per Section X

b. Alignment devices not adjusted to centerline of

insert. Clamp a straight edge or a length of

material over centerline of insert groove and

adjust the alignment devices by loosening the

locking nut on the Allen adjusting screw at the

top of the telescoping arm. Adjust the Allen

screw so that the device blades contact the

straight edge and tighten the lock nut.

c. The part is not against the two alignment device

blades when the part is clamped by the fingers.

Unclamp, align, and clamp.

d. Gibbs loose on the weld head cross seam slide;

adjust as needed.

e. If an arc length control is incorporated on the

fixture, check the ways and wheels in the drive

(actuator) for play and adjust.

2. Carriage will not travel a. The main items to check are:

- Input power to carriage control

- Control fuse

- Check the drive motor brushes, brush

springs and caps.

- Be sure the clutch is engaged.

- Fiber gear in gear head motor may be

stripped.

b. Refer to the supplied carriage control manual for

wiring.

3. Travel speed readout with optional

tach generator fluctuates.

a. Check the belt that connects the carriage drive

motor shaft to the tach generator. Replace the

belt if worn or loose.

b. Check for binding between the carriage wheels

and the rails on the track. Readjust the wheels if

required; see supplied carriage manual.

c. Refer to supplied control manual for wiring

information.

4. Clamping fingers will not clamp. a. Check air supply to fixture.

b. Check clamping pressure air regulator for proper

pressure (see Section IV).

c. Check fuse in the FCP-10B toe-touch panel.

d. Check toe-touch strip for short. If shorted,

31

replace with new.

e. Check relays and transformer and toe-touch

panel.

f. Shop line pressure is too low to actuate the pilot

actuated air solenoid valve.

5. Can hear air leaking in the vertical riser. Open hinge door and check:

a. White poly flow tubing for leaks.

b. Internal air hoses for leaks.

c. Clamping hoses for leaks.

6. Cannot establish tight, even butt-up of

final sheared parts.

a. When worn or misaligned, the shear knives can

produce a concave cut, convex cut, or shear drag

(burr). Once the cut-off shear blades are

readjusted, sharpened, or replaced, the

straightness of the part should be checked

against a straight edge.

B. GTAW Process

Problem Cause and Correction

1. Cannot initiate an arc when using

GTAW welding equipment.

a. Remove the torch cap which retains the collet

and electrode. If the weld tip of the electrode is

blue or contaminated, sharpen it or replace with

a new sharpened electrode. If the bore of the

collet is worn or does not provide a tight grip of

the electrode when installed in the torch,

replace collet with a new one.

b. A blue finish to the surface of the tungsten

implies oxygen contamination. This can be

caused by too short of a post flow time, a loose

gas fitting, a contaminated gas supply, air

turbulence at the weld zone, too small a shield

cup on the torch, or too low of a flow rate of

gas.

c. Check shield gas pressure (PSI) at the regulator

and flow (CFH) at the flowmeter. The PSI should

not be less than 50 and the CFH should coincide

with established welding parameters.

d. Make sure the “high frequency” control at the

power supply is switched to the proper mode of

“start” for D.C.S.P. welding or continuous for

A.C.H.F. welding.

2. If an arc still will not establish, check

the following steps.

a. Increase the high frequency intensity

potentiometer on the power source.

b. Amperage setting at the power supply may be

too low to initiate an arc. Raise the amperage

setting.

c. Material to be welded may contain coated or

32

scaled surface. Remove coating or scale by using

a fine emery cloth.

3. Electrode sticks to part when using

GTAW welding equipment.

a. This condition usually occurs at the start of the

weld cycle.

- Shut the welder off and stop carriage from

traversing.

- Raise the torch head to free the electrode.

- If that fails, unscrew the tube assembly of

the torch head and pull the tube, collet, and

electrode out.

- As a last resort, make sure that the weld

mode is in the “off” position, then cut the

tungsten electrode with wire cutters.

4. Arc voltage raises or lowers during the

weld a. cycle when using GTAW

welding equipment.

a. Check the insert and travel carriage for

parallelism. If a variation exists, adjust the track

and/or mandrel.

b. Make sure all drive gearing, roundways and cam

followers are clean.

c. If an arc length control (AVC) is used with the

fixture, check to see if it is correcting for

variations in the arc length (check trouble

shooting section in the ALC manual).

5. White smoke appears during GTAW

welding process.

a. Check the shield gas bottle for pressure.

b. Check the shield gas flow at the flowmeter.

c. Check the electrode stick-out. Maximum stick-

out is 1/4" (6.35 mm) with standard collets, ½"

(12.7 mm) with gas lens collet bodies.

d. Inspect the torch nozzle for tightness and/or

cracking. A loosely fitted or defective nozzle

permits aspiration. Check for too small a nozzle

orifice for size of tungsten.

6. Black smoke appears during GTAW

weld cycle.

a. The electrode is contaminated from use or has

been ground on a contaminated grinding wheel.

Replace or re-grind the electrode.

b. The torch head is overheating. The coolant line

(if so equipped) “to” and “from” the torch may

have insufficient water flow.

c. Gas is not flowing.

7. Butted parts rise when welding light

gauge material.

a. Adjust the clamping pressure to eliminate any

deformation of the butt joint once the parts are

butted and clamped.

b. Fingertip distance is too far apart (see chart,

Section IV).

c. Welding amperage setting may be too high and

the carriage speed too slow. Adjust amperage

first, then carriage speed if needed.

33

8. Incomplete penetration. a. Check the welding parameters for material being

welded.

b. If the parameter is not listed, try the following

steps:

- Increase the amperage on the power supply.

- Once penetration is attained, adjust the

carriage speed at the carriage control to

assure uniformity of the weld bead. Rule of

thumb is never try to over-penetrate. If

over- penetration occurs, increase the

carriage speed or decrease the amperage.

- Check the insert selection chart (Section IV)

to be sure that the insert is manufactured

from the correct material and that the

groove in the insert is the correct width and

depth for the thickness of material to be

welded.

34

SECTION IX

MECHANICAL MAITANANCE

Once a month, check all the hoses and fittings for

leaks or deterioration. A leaking hose can cause

loss of clamping pressure and result in poor quality

work. Blow out water from the air filter on the side

of the mainstay by opening the drain valve at the

bottom of the filter while the shop air is

connected. See Figure 1.

Re-machine or replace, if necessary, the copper

finger tips or continuous strips when they become

marred by dents or excessive impression marks.

Both the finger tips and the continuous strips are

reversible for extended life.

A. Adjustment and Replacement

of the Clamping Fingers Both left and right banks of fingers can be adjusted

in or out by means of screws located on each side

of the tabletop. Each screw applies pressure to the

finger adjusting bar which applies proportional

pressure against the finger bank assembly.

Each finger bank must be adjusted parallel to the

insert groove. The distance from the groove to the

finger tips must be the same on each side. Always

start adjustment with the screws located at the

center of the machine. Turn the screws a

maximum of one revolution at a time, working

towards both ends. Repeat until proper setting is

reached.

To remove a finger assembly, first loosen the

slotted flat head screw from the bottom side of the

finger. Once the screw is loose in the countersink,

move it towards the front of the finger and pass

the head of the screw through the clearance hole.

The finger can now be removed from the fixture.

Avoid removing the screw completely from the

spring and nut assembly.

CAUTION

Do not inter-exchange the front fingers with the

rear fingers, as they are of a different design.

When all the fingers are removed, the clamping

hose will hang loose from the tabletop; this is

normal.

To replace the fingers, start at the mainstay and

work toward the latch end of the seam welder.

Fasten a “C” clamp onto the nesting bar to keep

the finger adjusting bar from rolling out of the

nesting bar when the fingers are removed. See

Figure 4.

Install the aluminum only end of the finger into the

nesting bar. Guide the finger adjusting screw

through the clearance hole in the finger and pull

the screw back until it seats into the countersink.

Tighten the screw until the finger contacts the lip

of the tabletop. Continue to install the fingers in

the above manner until all are in place. The screw

in the last finger can be guided through the finger

with a screwdriver. Tighten all the fingers

proportionately so that they all return against the

tabletop lip when the air is exhausted from the

hoses.

The aluminum fingers are three inches wide and

have replaceable, reversible copper finger tips. (As

an option, they are available made from 300 series

stainless steel.) The copper finger tips, in addition

to clamping the part against the back-up insert,

also act as a heat sink to absorb heat created by

the welding process. If a fingertip is subject to

nicks or gouges at the point it contacts the part, it

can affect its ability to act as a heat sink and should

be dressed or replaced.

To remove a fingertip from the finger body,

remove the two Allen head screws which hold it to

the finger. These screws are located on the bottom

of the finger tip. Place the fingertip in a vice and,

using a flat file, draw the file over the clamping

surface of the finger tip. The maximum which can

be filed off the tip is 0.05" (1.3 mm). The tip is

reversible and, if the tip cannot be dressed, replace

the tip using the opposing side. When both sides

are beyond dressing, replace the tip.

35

B. Replacement of the Clamping

Hoses The clamping movement of the fingers is caused by

inflating the pressure hose located between the

tabletop and the upper surface of the fingers. Over

a period of time, the hose may become damaged

from extreme heat, weld spatter or deterioration

of the rubber in the hose. Should this happen, the

hose cannot be repaired but must be replaced.

To replace the hose, use the following procedure:

Disconnect the 115 volts AC and air supply to the

seam welder. Remove the finger adjusting

channels which are located at the latch end of the

machine. The channels are located between the

left and right first finger assemblies and the front

plate. Once the finger adjusting channel is

removed, the end of the pneumatic hose and hose

clamps will be exposed. The three hose clamp bolts

serve two purposes. They clamp the ends of the

hoses together and attach the ends of the hoses to

the tabletop. Remove the three bolts from each

clamp and remove the clamps from the hoses. Tie

an electrician’s fish tape to this end of one of the

hoses.

At the opposite end of the machine, open the

hinged door at the rear of the mainstay. On the

interior of the door is mounted the FCP-10B foot

control panel. The hoses and controls for the

clamping system are located inside the mainstay.

Remove the small white vinyl high pressure tube

from the tee by pushing the tube locking collet and

remove the tube from the collet. Remove the

larger pneumatic hose from the air solenoid valves.

(See Figure 6.) Pull the pressure hose out of the

tabletop from the mainstay, making sure the fish

tape is pulled through the tabletop. If there is an

orange spatter shield around the hose, pull it out

with the hose.

ut a new pressure hose the same length as the old.

Pre-drill the three holes in the end of the new hose

for the hose clamp. Re-install the round plug using

two new H40 worm drive clamps. Use No. 2

Permatex as a sealant for both ends of the hose

when assembling.

Pull the fish tape and the new hose through the

tabletop from the latch end of the machine. If

there is a spatter shield to be installed, it must be

pulled through with the hose. The seam of the

spatter shield must be either on the top or bottom

surface of the hose. The clamping fingers may have

to be loosened when installing hose with a spatter

shield.

Reconnect the high pressure tube and pneumatic

hoses. Be sure to allow the Permatex to set up

before connecting to the shop air. Pressurize the

hoses and check for air leaks. Replace the finger

adjusting channels and, using the set screws,

adjust the channels for proper clearance and

spacing.

C. Replacement of the Mandrel To ease installation of a mandrel in a Miller

Welding Automation Longitudinal Seam Welder, it

is recommended that a Miller Welding Automation

Mandrel Cart be used. Installing the mandrel can

also be done using a suitable lifting device such as

a fork lift truck.

Before doing the installation, a number of actions

must be done first.

On one end of the mandrel there is the mounting

plate which has four tapped holes and a number of

slots. In the four tapped holes there are four

square head bolts, used as “jacking screws”.

Welded on the front of mainstay, are two vertical

bars and one horizontal bar. One vertical bar and

the horizontal bar have adjusting screws. These

screws must be backed off to allow clearance for

the mandrel plate to fit between them. Ensure that

the nuts and washers have been removed from the

mandrel anchor bars which protrude through the

front face of the mainstay. Raise the latch

assembly.

36

Using either the mandrel cart or fork lift truck,

move the mandrel mounting plate close to the

ends of the anchor bar screws that protrude

through the mainstay. Align the slots in the

mandrel mounting plate with the anchor bar

screws and push the mandrel over them and up to

the mainstay front face.

Replace the washers and nuts onto the anchor bar

screws. Lightly tighten them to hold the mandrel

against the mainstay face so that the mandrel

plate lies between the two vertical bars and above

the horizontal bar. The cart, or similar device, can

now be removed.

37

Figure 6

Pneumatic System

38

D. Adjustment of the Mandrel Once the mandrel has been fitted to the seam

welder, it then has to be adjusted to be positioned

correctly relative to the fingers and tabletop

assembly. The adjustment procedure is made

easier by having the insert installed in its machined

groove in the top of the mandrel.

With the mandrel anchor bar nuts slightly loose,

the first adjustment is to make the mandrel and

insert parallel with the underside of the clamping

fingers. Based upon welding a 1/8" material

thickness (or less) as an example for adjusting the

machine, first, use the horizontal bar with 1" screw

to coarse adjust the mandrel vertically. Using a

scale, adjust the mandrel up until there is an

approximate 3/16" space between the finger tips

and the highest point of the insert. Use the square

head “jacking screws” in the mandrel plate to pitch

the mandrel until its full length is parallel with the

clamping finger tips. View the mandrel from the

side and using a scale measure the gap at the

mainstay end and the latch end. Both

measurements should be equal.

Next, adjust the insert groove parallel with the

centerline of the tabletop. Viewing from above the

tabletop, first measure and determine the

centerline distance between the formed tabletop

edges. Starting at the mainstay end of the

mandrel, use the two screws in the vertical bar

that is welded to the front of the mainstay to move

the mandrel until the insert groove is on centerline

of the formed tabletop. Then use a combination of

the four square head “jacking screws” to move the

latch end of the insert groove to centerline as well

as maintain parallelism to the finger tips.

The seam welder is designed to accommodate

different material thicknesses and the actual

vertical position of the mandrel is governed by

this. For the machine to work efficiently, the gap

between the fingers and insert should be the

material thickness plus 1/16" (3 mm).

After these adjustments have been made, the

mandrel anchor nuts can now be tightened. After

tightening the nuts, check and readjust as

required.

E. Adjustment to the Track to

the Insert Once the back-up mandrel and insert have been

adjusted to the tabletop, the track will require

adjustment relative to the insert groove and face.

The vertical distance between the insert face and

the welding torch (mounted on the travel carriage)

should vary no more than 0.08" (2 mm) at full

clamping pressure. The tracking accuracy (track to

insert groove) should be ".015" (0.4 mm) per 10 ft

(3 m) of track length for the standard machine. For

the precision machines (LWP, LWX), tracking

accuracy (track to insert groove) should be ".005"

(0.13 mm) per 10 ft (3 m) of track length.

To check the vertical height accuracy, move the

carriage to the end of its travel, towards the

mainstay end of the machine. Actuate and clamp

both finger banks at 40 PSI against the backup

insert. Mount a machinist’s dial indicator to the

travel carriage and align the stem against the face

of the back-up insert. Set the indicator dial at zero,

and then manually move the carriage towards the

latch of the machine. Correct adjustment of the

track is obtained when the indicator also reads

zero at the latch end of the machine. If the

indicator does not read zero, vertical track

adjustment is required. Note that it is typical for

the mandrel to deflect approximately 0.040" (1

mm) between each end due to the clamping

pressure exerted.

1. Vertical Track Adjustment

If vertical adjustment of the track is

required, only make adjustment at the

latch end of the machine. Loosen the four

3/4" track mounting bolts that are located

at the backside of the track. The track

39

mounting bracket is slotted allowing

vertical adjustment using the lever arm

mounted on its side.

Using an Allen wrench, turn the vertical

adjusting bolt counter-clockwise to lower

the track (clockwise to raise). The amount

of adjustment is determined by watching

the dial indicator mounted on the carriage,

trying to “match” the zero reading from

the mainstay end of the machine. After the

track is adjusted, tighten the four 3/4"

bolts on the track bracket.

2. Horizontal Adjustment

Using the ground torch electrode or the

welding wire as a pointer, adjust either so

that it just clears the upper surface of the

insert. Adjust the pointer horizontally so

that it is right over the tangent point

where the edge of the machined groove

meets the flat surface on the insert. The

machined edge of the groove will be used

as the reference point for the electrode or

wire to track the insert groove. Starting at

the mainstay end of the machine, manually

traverse the carriage along the track and

stop at the latch end of the machine.

Observe if the track requires adjustment

and if so, which direction the pointer must

move in relation to the machined edge of

the insert.

On the mounting bracket above the

vertical adjusting lever are four 3/4" bolts.

For adjustment, loosen the four bolts

noting that the bracket is slotted in the

horizontal direction. At the rear of the

bracket is a single 3/4" adjustment screw.

When the adjustment screw is rotated

clockwise, the track will move away from

the insert centerline. Rotating counter

clockwise will move the track towards the

insert centerline. Once the track is

adjusted parallel to the machined edge of

the insert, tighten the four 3/4" bolts.

F. Preventative Maintenance 1. Daily Mechanical

a. Inspect roundway or v-way rails of the

track, clean and coat with WD-40 or

equal.

b. Inspect finger tips for excess weld

spatter. Remove by wire brushing.

c. Inspect inserts for oxides and foreign

matter. Clear with wire brush, MEK or

Acetone.

d. Drain the air filter at the rear of the

mainstay by turning the valve at the

bottom of the bowl.

2. Weekly Mechanical

a. Inspect track and mandrel alignment

for accuracy.

b. Check v-way wheels on SWC-6 series

carriage for proper adjustment (see

SWC-6 operation manual).

3. Monthly Mechanical

a. Check all bolts and components of the

alignment devices to be sure that they

are tight.

b. Check coolant level in torch water

recirculator.

c. Check all hoses, gas, water, and air for

leaks and deterioration.

4. Bi-annual Mechanical

a. Check oil level on SWC-6 series

carriage gear box (see SWC-6

operators manual).

5. Quarterly Mechanical

a. Check all welding and exposed cables.

b. Check carriage motor brushes.

6. Bi-annual Electrical

a. Check welding power source for dust

and dirt.

b. Check all pushbutton emergency

switches.

40

SECTION X

PARTS LIST

The following pages provide a detailed parts list of

all the elements of the longitudinal seam welder.

They are arranged so the parts list on the right

hand page corresponds to the assembly illustrated

on the left hand page. Item numbers shown in the

parts list refer to those numbers contained in the

balloon in the drawing. The quantities shown are

the number of items used in that particular

assembly.

Two columns are included in the list to show the

spare parts which are recommended to be stocked

by the user. The two levels can be defined as

follows:

Level 1 These are the spares recommended for US

domestic users whose use of the product does not

exceed 2000 hours per year.

Level 2 These are the spares recommended for

international use of the product or for US domestic

users who will use the product in excess of 2000

hours per year.

The following parts lists are included in this

manual. Their appropriate page numbers are

listed:

Longitudinal Seam Welder ....................... 46/47

Foot Control.............................................. 48/49

Retractable Centering Device ................... 50/51

Common Spare Parts 52

41

42

Longitudinal Seam Welder

Recommended Item Part Level Level

No. No. Description Qty I II

1

Track ................................................................................ 1

2 Track Arm ........................................................................ 2

3 Pressure Gauge ............................................................... 1

4 Tabletop .......................................................................... 1

5 Mainstay .......................................................................... 1

6 Base ................................................................................. 1

7 Electrical Cord, 116 VAC .................................................. 1

8 Switch, Finger Actuation ................................................. 3

9 CBS Mandrel ........................................................................... 1

10 Latch Assembly................................................................ 1

11 Mounting Plate Nuts ....................................................... 4

12 Mandrel Plate Adjustment Screws .................................. 4

13 Finger Adjustment Screws .............................. as required

14 Air Filter ........................................................................... 1

15 SWCB-3 Carriage Assembly, standard .......................................... 1

16 9700T Control Panel Assembly, standard .................................. 1

43

44

Retractable Centering Device

CLW-110A

Item

Part

Recommende

d Level Level

No. No. Description Qty I II

2

CL-200 End Piece ......................................................................... 1

3 CL-201 Pivot Stop, regular and thin ....................................... 1 ea

4 CL-202 Pivot Block ....................................................................... 1

5 CL-203 Spacer Plate ..................................................................... 1

6 CL-204 Guide Block ..................................................................... 1

7 CL-205A Extension Arm ................................................................. 1

8 3/8-16x3/4 Button Head Screw ......................................................... 1

9 3/8-16x1 Socket Set Screw ............................................................. 1

10 3/8-16x2 Hex Head Cap Screw ....................................................... 2

11 3/8-16,5-10LB Ball Plunger ..................................................................... 1

12 3/8-16,2-4LB Ball Plunger ..................................................................... 1

13 3/8-16 Hex Jam Nut .................................................................... 1

14 3/8x3/4 Socket Head Shoulder Screw .......................................... 1

15 3/16x1/2 Roll Pin ............................................................................ 2

16 5/16x3/4 Brass Socket Set Screw .................................................... 2

45

46

Foot Control Panel

FCP-10B

Recommended

Item No. Part No. Description Qty Level I Level II

2 A10N84 Nema I Enclosure 1

3 FCP-10B=3 Foot Control PCB 1 1

4 RY2LS-120A 120 VAC Latch Relay 2 1 1

5 RY2S-U-24A 24 VAC DPDT Latch Relay 2 1 1

6 RY2S-U-120A 120 VAC DPDT Latch Relay 2 1 1

7 J74 202A Jumper 1

8 SYSF-51F1 LR1, LR2, Spring Hold 1

9 SYSF-02F1 CR1,2,3,4/CR2, Spring Hold 6

10 28F027 Fuse Holder 1

11 GGC-3 Fuse, 3A 1 1 1

47

48

SECTION XII

ELECTRICAL DRAWINGS

Each longitudinal seam welder made by Miller Welding

Automation has an electrical control schematic. These

drawings are identified by job number and are part of

the document package shipped with your system.

49

50