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Summary of Contents for Miller PSW-1020ATT
- Page 1 OM-745 201 170A May 2002 Processes Resistance Spot Welding Description PSW-1020ATT, PSW-2020ATT, SSW-1020ATT, SSW-2020ATT, And SSW-2040ATT Visit our website at www.MillerWelds.com...
- Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.
- Page 3 TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1.
- Page 5 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING spotom _nd_11/99 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
- Page 6 MOVING PARTS can cause injury. FUMES can be hazardous. Coatings, cleaners, paints, and platings can pro- The tong tips, tongs, and linkages move during duce fumes when welded. Breathing these fumes operation. can be hazardous to your health. Keep away from moving parts. Do not breathe the fumes.
- Page 7 SECTION 2 – INSTALLATION 2-1. Specifications Rated Output Amperes Rated Output Amperes Input Input Work Work At Listed Tong Length Rated Output Open- Voltage Voltage Capacity Capacity Input At Listed Circuit 50/60 Hz Combined Models Amps 6 in 12 in 18 in Duty Cycle* Voltage...
- Page 8 B. For Portable Models Dimensions 15-5/8 in (397 mm) 14-3/8 in (365 mm) 15-1/8 in (384 mm) 12-1/4 in (311 mm) 19 in (483 mm) 11-7/8 in (302 mm) 19-3/8 in (492 mm) Weight PSW-1020 72 lb (33 kg) PSW-2020 89 lb (40 kg) Control Box 75 lb (34 kg)
- Page 9 2-4. Overview Of System Connections PSW Models Air in Air hose 60 – 100 PSI (see Section 2-10) Air filter/regulator assembly Coolant line (see Section 2-6) Coolant Controller Coolant line* (see Section 2-6) system Coolant line Normally 5/8–18 Input power line (see Section 2-8) left–hand threaded receptacles Start switch lead*...
- Page 10 2-5. Installing Or Cleaning Tongs Y Turn off unit and disconnect input power. Be sure tong ends are clean and not corroded before instal- ling. Clean tongs with fine steel wool. Bottom Tong Installation: Spatter Guard Insulating Strip Check to see that insulating strip is not cracked.
- Page 11 2-6. Coolant Connections Y Turn off power and coolant supply until installation is complete. Tong Coolant Hose Hose Clamp Barbed Fitting Coolant-In Fitting Coolant-Out Tube Coolant Hoses (Customer Supplied) Install hoses as shown. This unit is equipped with a water control pressure switch to insure proper cooling.
- Page 12 2-8. Connecting Input Power Y Disconnect and lockout/tag- out input power before con- necting input conductors from unit. Have only qualified persons make this installation. Remove left side panel. Line Disconnect Device Input And Grounding Conduc- tors Select size and length using Sec- tion 2-9.
- Page 13 2-9. Electrical Service Guide 10 KVA 20 KVA Single Phase Single Phase Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Rating In Amperes Time-Delay Normal Operating 3 Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) (30) (24) (40)
- Page 14 2-11. Adjusting Tong Pressure Y Turn off power before mak- ing adjustments. Top Nut Bottom Nut 13/16 in Top Linkage Bottom Linkage Tongs Tong pressure must be checked and/or set before operation. Correct tong pressure is necessary to create a quality weld and to prevent damage to tips.
- Page 15 SECTION 3 – OPERATION 3-1. Controls First row of LCDs displays actual time set. Second row of LCDs displays squeeze time set or weld time set. 802 751 / Ref. 802 763 / 802 762 / 200 264-A Time Control or Start Switch closes the tongs without Fuse F1 starting weld amperage.
- Page 16 SECTION 4 – MAINTENANCE AND TROUBLESHOOTING 4-1. Maintenance Y Disconnect power before maintaining. During heavy service, maintain monthly. 3 Months Replace Damaged Inspect Oil Unit Or Unreadable Tips Labels 4-2. Overload Protection Y Turn power before checking fuse. Fuse F1 and Power/pilot light/cir- cuit breaker switch S1 protect the control circuitry.
- Page 17 4-3. Installing Or Dressing Tips A. Installing Tips Y Turn off power before re- moving tips. Telescoping Tube Removal: Tips have a Morse Taper and a press fit. Use a vice grip pliers to rotate and loosen tips. Once loose, pull tips straight out.
- Page 18 4-4. Troubleshooting Trouble Remedy No weld output; pilot light Off. Check line fuses, and replace if necessary (see Section 2-8). Check fuse F1 and/or Power/pilot light/circuit breaker switch S1, and replace if necessary (see Section 4-2). Turn On Power/pilot light/circuit breaker switch S1. No weld output, pilot light on.
- Page 19 SECTION 5 – ELECTRICAL DIAGRAMS 199 203 Figure 5-1. Circuit Diagram For Portable Models 199 202 Figure 5-2. Circuit Diagram For Stationary Models OM-745 Page 15...
- Page 20 200 302-A Figure 5-3. Circuit Diagram For Foot Control OM-745 Page 16...
- Page 21 SECTION 6 – PARTS LIST Hardware is common and not available unless listed. Fig 6-2 Fig 6-4 & 6-5 Fig 6-6 Fig 6-3 802 764 Figure 6-1. Main Assembly Quantity Model PSW- SSW- Part 1020 ATT 1020ATT 2020ATT Description 2020ATT 2040ATT Figure 6-1.
- Page 22 Hardware is common and not available unless listed. 802 774 Figure 6-2. Resistance Spot Welder, Air OM-745 Page 18...
- Page 23 Quantity Model PSW- SSW- Item Dia. Part 1020ATT 2020ATT 1020ATT 2020ATT Description Mkgs. 2040ATT Figure 6-2. Resistance Spot Welder, Air (Fig 6-1) ..000 365 . . . RING, rtng ext .390 shaft grv x .042 E .
- Page 24 Quantity Model PSW- SSW- Item Dia. Part 1020ATT 2020ATT 1020ATT 2020ATT Description Mkgs. 2040ATT Figure 6-2. Resistance Spot Welder, Air (Fig 6-1) (Continued) ..010 739 . . . SHIELD, tube coolant .
- Page 25 Item Dia. Part Description Mkgs. Quantity Figure 6-3. RFSW-10/20 (Fig 6-1) ... . 185 929 . . . PEDAL/HOUSING/BOTTOM PLATE ........
- Page 26 Hardware is common and not available unless listed. 802 765 Figure 6-4. Pedestal, Air Operated (SSW Models) OM-745 Page 22...
- Page 27 193 776 . . . LABEL, MILLER 6.093 x 2.593 horizontal .......
- Page 28 Hardware is common and not available unless listed. 802 773 Figure 6-5. Control Box OM-745 Page 24...
- Page 29 ... . 193 776 LABEL, MILLER 6.093 x 2.593 horizontal ......
- Page 30 Hardware is common and not available unless listed. 027 777-A Figure 6-6. Tongs OM-745 Page 26...
- Page 31 Quantity Holder No. 1 Morse Taper No. 2 Morse Taper 45 or 90 Item Part Description 6” 12” 18” 6” 12” 18” Figure 6-6. Tongs (Optional) 027 778 TONG, 6 in (consisting of) ....90 deg .
- Page 32 Tongs and Tips (Must be ordered separately from spot welders. One pair of tips are supplied with each set of tongs.) Notes for tongs and tips: TONG LENGTH TIPS INCLUDED Tongs and tips shown to the 6 in 12 in 18 in TONGS (150 mm)
- Page 33 Notes...
- Page 34 Notes...
- Page 35 Effective January 1, 2002 (Equipment with a serial number preface of “LC” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other Warranty Questions? guarantees or warranties expressed or implied. Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT &...
- Page 36 Distributor Address City State For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories...
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