Miller Travel Master SB-10D Owner's Manual
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Miller Travel Master SB-10D Owner's Manual

Miller Travel Master SB-10D Owner's Manual

Automatic welding sidebeam
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OM-889B
February 1993
Eff. w/Serial Number KC237900
Processes
Automatic Welding
Description
Automatic Welding Sidebeam
Travel Master SB-10D
Visit our website at
www.MillerWelds.com

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  • Page 1 OM-889B February 1993 Eff. w/Serial Number KC237900 Processes Automatic Welding Description Automatic Welding Sidebeam Travel Master SB-10D Visit our website at www.MillerWelds.com...
  • Page 2 Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Section No. Page No. SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. General Information And Safety ....... 1-2.

  • Page 4: Section No

    Section No. Page No. SECTION 7 – SEQUENCE OF OPERATION 7-1. Gas Metal Arc Welding (GMAW) And Flux Cored Arc Welding (FCAW) - Continuous ....... . . 7-2.

  • Page 5: Section 1 - Safety Precautions And Signal Words

    SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. GENERAL INFORMATION AND SAFETY 1-2. SAFETY ALERT SYMBOL AND SIGNAL WORDS A. General The following safety alert symbol and signal words are Information presented in this manual and on various la- used throughout this manual to call attention to and bels, tags, and plates on the unit pertains to equipment identify different levels of hazard and special instruc-...

  • Page 6: Description

    Side View Front View SD-122 295 Side View 40-1/2 6-1/4 Inches Millimeters 25.4 355.6 304.8 406.4 609.6 1028.7 158.8 1371.6 2006.6 * Crossarm can also be mounted at 49-3/4 in. (1263.7 mm) or 58-1/4 in. (1479 mm). Front View 66-3/4 19-1/2 11-1/2 104-1/2 61-3/4 Inches...

  • Page 7: Section 3 - Installation

    SECTION 3 – INSTALLATION 3-1. LOCATION (Figures 2-1 And 3-1) Secure beam mounting post assemblies to floor (hardware must be customer supplied). Select an installation site which provides the following: Install beam onto mounting post assemblies us- Mounting surface capable of supporting weight of ing supplied 1/2-13 x 1-1/4 in.
  • Page 8 Motor Cord And Plug Bearing Bar Motor Release Lever Motor Adjustment Screw And Lock Nut Beam (Be sure beam rests on horizontal Motor surface of mounting post assemblies.) Motor Spring Ring Pinion Gear Motor Mounting 1/2-13 x 1-1/4 in. Bracket Pinion Gear Leveling Screw Guard...

  • Page 9: Carriage Control Meter Display Selection Procedure

    Install supplied pinion gear guard onto bottom If applicable, remove the four screws securing side of motor casing. the Carriage Control to the mounting bracket, and remove the control from the bracket. Adjust position of front two cam rollers on car- Remove the securing screws from control wrap- riage as follows: per, and remove wrapper.

  • Page 10: Electrical Connections

    3-8. ELECTRICAL CONNECTIONS WARNING: ELECTRIC SHOCK can kill. Do not touch live electrical parts. Strain Relief Clamps Shut down Carriage Control and welding power source, and disconnect input power employing lockout/tagging procedures be- fore inspecting, installing, or adjusting. 115 VAC Power Cord And Plug Lockout/tagging procedures consist of remov- ing plug from receptacle, padlocking line discon-...

  • Page 11: Standard Welding Connections

    In normal operation, upon pressing the Carriage Control WORN OR CUT CORD can cause serious personal injury or equipment damage. START button, the unit immediately starts welding, and the carriage immediately starts moving; however, in- Route and secure all cords from welding pow- er source to Carriage Control and Automatic stalling the Carriage Movement Control cord allows the Weld Control over top of beam between car-...

  • Page 12: Diagram 4-1. Connection Diagram For Automatic 1A Weld Control Models

    *Terminals located on either terminal strip 1T or terminal Remove the securing screws from control wrap- strip 2T in weld control. per, and remove wrapper. Loosen upper strain relief clamp on rear of con- To connect cord C to weld control, proceed as fol- lows: trol.

  • Page 13: Diagram 4-2. Connection Diagram For Automatic 1Da Weld Control Models

    AUTOMATIC 1DA Rear View Of Weld Control Carriage Control Carriage Drive Motor 30 ft. (9 m) Voltage Sensing Cord elding Power 5 ft. (1.5 m) Motor Source Control Cord 10 ft. (3 m) Shunt 115 VAC Cord Control Cord And Plug 25 ft.

  • Page 14: Diagram 4-4. Connection Diagram For Automatic 2A Weld Control Models

    AUTOMATIC 2A Rear View Of Weld Control Carriage Control Carriage Drive Motor 25 ft. (8 m) Voltage Sensing Cord Welding Power 5 ft. (1.5 m) Motor Source Control Cord 25 ft. (8 m) Electrical 115 VAC Cord Input/Contactor And Plug Control/Voltage Control Cord Automatic...

  • Page 15: Skip Welding Connections

    4-3. SKIP WELDING CONNECTIONS B. Required Equipment The following cords must be obtained by the customer IMPORTANT: Automatic Weld Controls without a digi- for skip weld connections: tal panel are not capable of Skip Welding. A cord of proper type and length to make connec- tions in the Automatic Weld Control.
  • Page 16 Use Figure 4-1 to locate leads 1, 2, and 3 from the Route the four-conductor cord from Step 1 triple-pole, single-throw switch. through the strain relief clamp on the right side of the weld control, and splice one lead from the IMPORTANT: The switch leads are not numbered.

  • Page 17: Remote Start/Stop Connections For Non-Miller Automatic Weld Controls (For Non-Miller Controls Only)

    E. Connections To Sidebeam Carriage Control A. Carriage Control Relay Contact Selection WARNING: Read and follow safety informa- WARNING: Read and follow safety informa- tion at beginning of entire Section 4-4 before tion at beginning of entire Section 4-3 before proceeding.

  • Page 18: Section 5 - Customer-Supplied Remote Control Connections (Optional)

    Reposition and secure control onto mounting switch is closed, or the unit receives a command from an bracket. external weld control. To install the Fixture Delay switch, proceed as follows: Install remaining end of interconnecting cord to Automatic Weld Control according to its Owner’s Remove the four screws securing the Carriage Manual.

  • Page 19: Remote Jog Direction

    IMPORTANT: If the optional Limit Switch is installed, If installing a double-pole double-throw (DPDT) use a momentary-contact switch(es) for remote start switch, install the switch as follows: and stop control (see Step 4). Using a maintained- a. Connect normally-open contact of pole corre- contact (relay) for remote start and stop control will ren- sponding to movement right to terminal E on der the optional Limit Switch inoperative.

  • Page 20: Remote Travel Speed Control

    Travel Right Reinstall and secure control wrapper. Switch Position Connect To Terminal F Reposition and secure control onto mounting On Terminal Strip 2T bracket. Connect To Terminal D 5-5. REMOTE TRAVEL SPEED CONTROL (Figure On Terminal Strip 1T 5-3) Travel Left Switch Position WARNING: Read and follow safety informa- Connect To...

  • Page 21: Section 6 - Operator Controls

    SECTION 6 – OPERATOR CONTROLS Digital Meter Jog Speed Control Fuse F1 (See Section 8-2) Circuit Breaker CB1 (See Section 8-2) Power Switch Optional Delay Start Push Time Control Button Stop Push Button Jog Direction Switch Travel Direction Switch Travel Speed Control SA-122 296 Figure 6-1.

  • Page 22: Travel Speed Control

    CAUTION: CHANGING POSITION OF WELD 6-7. START/STOP PUSH BUTTONS (Figure 6-1) TRAVEL DIRECTION SWITCH while carriage is moving can damage unit. Allow carriage to stop completely before changing travel direction. START Do not change position of TRAVEL DIREC- TION switch (except to center (off) position) while carriage is moving.

  • Page 23: Section 7 - Sequence Of Operation

    SECTION 7 – SEQUENCE OF OPERATION WARNING: ELECTRIC SHOCK can kill; 7-1. GAS METAL ARC WELDING (GMAW) And MOVING PARTS can cause serious injury; FLUX CORED ARC WELDING (FCAW) - CON- IMPROPER AIR FLOW AND EXPOSURE TO TINUOUS ENVIRONMENT can damage internal parts. Do not touch live electrical parts.

  • Page 24: Gas Metal Arc Welding (Gmaw) And Flux Cored Arc Welding (Fcaw) - Spot

    IMPORTANT: If Skip welding function is installed and Energize Automatic Weld Control, and set posi- BURNBACK and CRATER TIME controls are both set tion of its controls and switches as follows: at minimum (0 seconds), unit may not advance at jog a.

  • Page 25: Section 8 - Maintenance & Troubleshooting

    SECTION 8 – MAINTENANCE & TROUBLESHOOTING IMPORTANT: Every six months inspect the labels on Lockout/tagging procedures consist of remov- ing input plug from receptacle, padlocking line the unit for legibility. All precautionary labels must be disconnect switch in open position, removing maintained in a clearly readable state and replaced fuses from fuse box, or shutting off and red-tag- when necessary.

  • Page 26: Brush Inspection And Replacement

    If it should become necessary to replace part or all of the CAUTION: DISASSEMBLY OF MOTOR FIELD MAGNETS can result in personal in- hub assembly, reinstall the new hub assembly as fol- jury and equipment damage. lows: Limit drive motor repairs to brush replace- Remove wire spool from hub.

  • Page 27: Troubleshooting

    Long-Nose Lockout/tagging procedures consist of remov- Pliers Spring Assembly ing input plug from receptacle, padlocking line disconnect switch in open position, removing Brush fuses from fuse box, or shutting off and red-tag- Brush ging circuit breaker or other disconnecting de- vice.
  • Page 28 Table 8-1. Troubleshooting (Continued) TROUBLE PROBABLE CAUSE REMEDY Carriage and auxiliary equip- Improper jumper connections. Check and correct jumper connections accord- ment (if applicable) do not ing to Section 5 or the circuit diagram. start when START button PB1 is pressed. Relay CR1.
  • Page 29 Notes OM-889 Page 25...

  • Page 30: Section 9 - Electrical Diagrams

    SECTION 9 – ELECTRICAL DIAGRAMS Diagram 9-1. Circuit Diagram OM-889 Page 26...
  • Page 31 Circuit Diagram No. SD-128 724 OM-889 Page 27...

  • Page 32: Diagram 9-2. Wiring Diagram

    OM-889 Page 28...

  • Page 33: Diagram 9-3. Circuit Diagram For Motor Control Board Pc1

    OM-889 Page 29...

  • Page 34: Diagram 9-4. Circuit Diagram For Timer Board Pc2

    OM-889 Page 30...

  • Page 35: Diagram 9-5. Circuit Diagram For Tachometer Board Pc3

    Circuit Diagram No. SA-094 456-A Diagram 9-5. Circuit Diagram For Tachometer Board PC3 Circuit Diagram No. SA-119 758 Diagram 9-6. Circuit Diagram For Optional Remote Pendant Control RP-SB-10D OM-889 Page 31...

  • Page 36: Section 10 - Parts List

    SECTION 10 – PARTS LIST Hardware is common and not available unless listed. OM-889 Page 32...

  • Page 37: Figure 10-1. Main Assembly (Section A)

    Item Dia. Part Description Quantity Mkgs. Figure 10-1. Main Assembly (Section A) ....128 972 CONTROL BOX, (Fig 10-2) ........
  • Page 38 Item Dia. Part Description Quantity Mkgs. Figure 10-1. Main Assembly (Section A) (Continued) ....120 821 SCREW, set stl sch .375-16 x .750 ....... . .

  • Page 39: Figure 10-1. Main Assembly (Section B)

    Item Part Description Quantity Figure 10-1. Main Assembly (Section B) ....119 736 END CAP, beam ........... .
  • Page 40 Hardware is common and not available unless listed. OM-889 Page 36...

  • Page 41: Figure 10-2. Control Box

    Item Dia. Part Description Quantity Mkgs. 128 972 Figure 10-2. Control Box (Fig 10-1 Item 1) ....123 154 LABEL, warning general precautionary ......
  • Page 42 Item Dia. Part Description Quantity Mkgs. 128 972 Figure 10-2. Control Box (Fig 10-1 Item 1) (Continued) ....115 940 CASE SECTION, front/bottom/rear ....... . .
  • Page 43 Call LIMITED WARRANTY – Subject to the terms and conditions APT, ZIPCUT & PLAZCUT Model Plasma Cutting below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants Torches 1-800-4-A-MILLER to its original retail purchaser that new Miller equipment sold...
  • Page 44 FAX: 44 (0) 1204-598066 www.MillerWelds.com Contact the Delivering Carrier for: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00...

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