Академический Документы
Профессиональный Документы
Культура Документы
2010−12
Processes
Resistance Spot
Welding
Description
And LMSW-52T
Mil_Thank 2009−09
TABLE OF CONTENTS
Protect yourself and others from injury — read and follow these precautions.
The symbols shown below are used throughout this manual ELECTRIC SHOCK can kill.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions Touching live electrical parts can cause fatal shocks
to avoid the hazard. The safety information given below is or severe burns. The input power circuit and
only a summary of the more complete safety information machine internal circuits are also live when power is
found in the Safety Standards listed in Section 1-5. Read and on. Incorrectly installed or improperly grounded
follow all Safety Standards. equipment is a hazard.
D Do not touch live electrical parts.
Only qualified persons should install, operate, maintain, and
repair this unit. D Wear dry, hole-free insulating gloves and body protection.
D Additional safety precautions are required when any of the following
During operation, keep everybody, especially children, away. electrically hazardous conditions are present: in damp locations or
while wearing wet clothing; on metal structures such as floors, grat-
ings, or scaffolds; when in cramped positions such as sitting,
SPOT WELDING can cause fire or explosion.
kneeling, or lying; or when there is a high risk of unavoidable or acci-
dental contact with the workpiece or ground. For these conditions,
Sparks can fly off from the welding arc. The flying see ANSI Z49.1 listed in Safety Standards. And, do not work alone!
sparks, hot workpiece, and hot equipment can
D Disconnect input power before installing or servicing this equip-
cause fires and burns. Accidental contact of elec-
trode to metal objects can cause sparks, explosion, ment. Lockout/tagout input power according to OSHA 29 CFR
overheating, or fire. Check and be sure the area is safe before doing 1910.147 (see Safety Standards).
any welding. D Properly install and ground this equipment according to this manual
D Remove all flammables within 35 ft (10.7 m) of the weld. If this is not and national, state, and local codes.
possible, tightly cover them with approved covers. D Always verify the supply ground − check and be sure that input pow-
D Do not spot weld where flying sparks can strike flammable material. er cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
D Protect yourself and others from flying sparks and hot metal.
grounded receptacle outlet.
D Be alert that welding sparks can easily go through small cracks and
D When making input connections, attach the grounding conductor
openings to adjacent areas.
first − double-check connections.
D Watch for fire, and keep a fire extinguisher nearby.
D Keep cords dry, free of oil and grease, and protected from hot metal
D Do not weld on closed containers such as tanks, drums, or pipes, and sparks.
unless they are properly prepared according to AWS F4.1 (see
D Frequently inspect input power cord and ground conductor for dam-
Safety Standards).
age or bare wiring − replace immediately if damaged − bare wiring
D Do not weld where the atmosphere may contain flammable dust, can kill. Check ground conductor for continuity.
gas, or liquid vapors (such as gasoline).
D Turn off all equipment when not in use.
D Remove any combustibles, such as a butane lighter or matches,
D For water-cooled equipment, check and repair or replace any leak-
from your person before doing any welding.
ing hoses or fittings. Do not use any electrical equipment if you are
D After completion of work, inspect area to ensure it is free of sparks, wet or in a wet area.
glowing embers, and flames.
D Use only well-maintained equipment. Repair or replace damaged
D Do not exceed the equipment rated capacity. parts at once.
D Use only correct fuses or circuit breakers. Do not oversize or D Wear a safety harness if working above floor level.
bypass them.
D Keep all panels, covers, and guards securely in place.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
OM-716 Page 1
FLYING SPARKS can injure. FUMES AND GASES can be hazardous.
Very often sparks fly off from the joint area. Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
D Wear approved face shield or safety goggles health.
with side shields.
D Keep your head out of the fumes. Do not breathe the fumes.
D Wear protective garments such as oil-free, flame-resistant leather D If inside, ventilate the area and/or use local forced ventilation at the
gloves, heavy shirt, cuffless trousers, high shoes, and a cap. arc to remove welding fumes and gases.
Synthetic material usually does not provide such protection. D If ventilation is poor, wear an approved air-supplied respirator.
D Protect others in nearby areas by using approved flame-resistant or D Read and understand the Material Safety Data Sheets (MSDSs)
noncombustible fire curtains or shields. Have all nearby persons and the manufacturer’s instructions for metals, consumables, coat-
wear safety glasses with side shields. ings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while wearing
HOT PARTS can burn. an air-supplied respirator. Always have a trained watchperson
nearby. Welding fumes and gases can displace air and lower the
D Do not touch hot parts bare handed. oxygen level causing injury or death. Be sure the breathing air is
D Allow cooling period before working on equip- safe.
ment. D Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
D To handle hot parts, use proper tools and/or wear heavy, insulated
highly toxic and irritating gases.
welding gloves and clothing to prevent burns.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
MOVING PARTS can injure. 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.
The tong tips, tongs, and linkages move during
operation.
OM-716 Page 2
1-4. California Proposition 65 Warnings
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of
Diesel engine exhaust and some of its constituents are
California to cause cancer and birth defects or other
known to the State of California to cause cancer, birth
reproductive harm. Wash hands after handling.
defects, and other reproductive harm.
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.
OM-716 Page 3
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
spotom_2010−03fre
Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
OM-716 Page 4
D Utilisez uniquement un équipement en bonne condition. Réparez D Ne pas s’approcher des points de coincement.
ou remplacez immédiatement toute pièce endommagée. D Ne placez pas les mains entre les électrodes.
D Portez un harnais de sécurité si vous devez travailler au-dessus du D Maintenez en place les panneaux et protections de sécurité.
sol.
D Les applications peuvent nécessiter des protections supplément-
D Maintenez en place les panneaux, couvercles et protections de sé- aires d’après les codes de sécurité locales.
curité.
OM-716 Page 5
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) L’EMPLOI EXCESSIF peut SUR-
peuvent affecter les implants médicaux. CHAUFFER L’ÉQUIPEMENT.
D Les porteurs de stimulateurs cardiaques D Prévoir une période de refroidissement; re-
et autres implants médicaux doivent rester specter le cycle opératoire nominal.
à distance.
D Réduire le facteur de marche avant de pour-
D Les porteurs d’implants médicaux doivent consulter suivre le soudage.
leur médecin et le fabricant du dispositif avant de s’approcher
de la zone où se déroule du soudage à l’arc, du soudage
par points, du gougeage, de la découpe plasma
ou une opération de chauffage par induction.
OM-716 Page 6
SECTION 3 − −INTRODUCTION
3-1. Specifications
AC Input Work Capacity Com- Rated Welder Dimensions Weight
Voltage bined Output At
Model
50/60 Hz Thickness 50% Duty
1-Phase Uncoated Mild Steel Cycle* Height Width Length Net Ship
*Based on 10 second time period; means unit can weld for 5 seconds out of each 10 second time period.
** Not recommended for aluminum or copper alloys.
SECTION 4 − INSTALLATION
1 2 3
OR
Tools Needed:
3
3/16 in.
9/16 in.
OM-716 Page 7
B. Dressing The Tips
Notes
OM-716 Page 8
4-2. Installing Or Cleaning Tongs
! Turn off and unplug welder.
! OSHA and/or local codes may require . Be sure tong ends are clean
additional guarding to suit the application. and not corroded before
installing. Clean tongs with fine
steel wool.
Bottom Tong:
1 Bottom Tong
2 Hole In Spatter Guard
3 Bottom Tong Securing Screws
(4)
Loosen the four screws. If needed,
use a rubber mallet to loosen tong.
Slide tong into bottom tong holder
6 as far as possible, and position so
that tip is pointing straight up.
5
Loosely tighten screws.
Top Tong:
4 Top Tong
4 5 Top Tong Holder/Pivot Casting
6 Top Tong Securing Screws (4)
Loosen the four screws. If needed
for removal, use a rubber mallet to
loosen tong.
2
3 Slide tong into pivot casting as far
as necessary, so that tip mates with
bottom tip when tongs are closed.
7
1
Loosely tighten screws.
7 Tips
Adjust tong positions to line up cen-
ters of tips as shown. Tighten
screws.
Tong Alignment
4 4
7 7
1 1
Tools Needed:
3/16 in.
OM-716 Page 9
4-3. Adjusting Tong And Hand Lever Pressure
Tools Needed:
! Turn off and unplug welder. splash out around the nugget area. To decrease tong pressure, loosen the rear
If tong pressure is too weak, parts are nut and turn the front nut up to the pivot cast-
! Excessive tong pressure can dam- loose when the tongs close, severe arc- ing.
age tips. Do not use tongs as a clamp ing occurs between workpieces, and no
or vice to hold workpiece together. If weld can be made. 6 Machine Screw
the two pieces of material to be
1 Front Nut
welded do not make good contact at The farther down the screw is turned, the far-
the point of the intended weld, clamp 2 Rear Nut ther the hand lever will close. Adjustment of
material to provide good contact be- this screw will determine if the tongs lock on
3 Pivot Casting
tween surfaces. the material, or just pull up tight. Adjust screw
4 Hand Lever to allow lever to be raised easily after the
. Tong pressure is adjustable, and must 5 Tongs weld has been completed.
be checked and/or set before operation.
Correct tong pressure is necessary to To increase tong pressure, loosen front nut. 7 Hex Nut
create a quality weld and to prevent The farther the front nut is turned out, the
damage to tips. greater the pressure on the tips when the To adjust pressure needed to push down
Too much tong pressure causes the hand lever is closed. Turn the rear nut up to hand lever, turn the hex nuts located on each
weld nugget to dimple and material to the pivot casting to lock the position. side of the pivot casting.
OM-716 Page 10
4-4. Installing Handle
1
MSW 41 And 41T Models
2
1
1
2
Tools Needed:
! Turn off and unplug welder. Install handle onto the spot welder as shown
above. For 52, and 52T Models, install han-
1 Wooden Handle
dle onto either side as desired for either right-
2 Handle Bolt hand or left-hand use.
3 Brackets (41 And 41T Models Only)
OM-716 Page 11
4-5. Mounting Control Box
Push-in slots are provided on rear
of box for wall mounting if desired.
The slots will fit over 1/4 inch hex-
head screws. To mount box, pro-
ceed as follows:
1 Control Box
2 Push-In Slots (Not Shown)
Use slots as template and install
screws at desired locations leaving
1
1/8 inch stickout.
2 Push rear slots firmly against screw
heads, and slide box down onto
screws.
OR
800 233-A
OM-716 Page 12
4-7. Connecting Input Power (Non-T Models)
! Input power supply wiring
and receptacle must meet
National Electrical Code and
all other code requirements.
Operate spot welder from a sepa-
rately fused or circuit breaker pro-
tected circuit, and use correct size
5 input conductors.
3 4 1 Rating Label
2 Cord
3 Parallel Plug On 110 Volts AC
Models
Or
4 Tandem Plug On 220 Volts
AC Models
1 2 Do not cut ground terminal off plug.
5 Grounded Receptacle
Connect plug to matching
grounded receptacle.
Notes
OM-716 Page 13
SECTION 5 − OPERATION
5-1. Controls (T Models)
1 Spot Weld Timer And Pilot
Light
Weld time adjusts from 0 to 5
seconds. The pilot light turns on
when the weld cycle begins and off
when the cycle ends.
2 Hand Lever
1
Use lever to open and close tongs.
Close the hand lever during the
welding process to compress the
4 material between the tips. To adjust
tong pressure, see Section 4-3.
3 Start Switch
Move start switch sideways in ei-
ther direction to start weld cycle.
2
When weld cycle time ends, or the
start switch is released, weld output
stops, and the timer resets for
another weld cycle.
4 Power Switch
146 013-B
145 104-A
OM-716 Page 14
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING
6-1. Routine Maintenance
Blow Off
OR Or
Inspect Replace Vacuum
Tips Unreadable Unit
Labels
During Heavy Service,
Clean Monthly
1
2
OM-716 Page 15
6-3. Troubleshooting
Trouble Remedy
No weld output. Check line fuses, and replace if necessary.
For 220 V models, check fuse F1, and replace if necessary (see Section 6-2).
Check power switch (T models only) and/or start switch. Replace if necessary.
Longer than normal weld time required. Dress or replace tips (see Section 4-1).
Clean workpieces.
Burn through at point of weld. Shorten weld time (see Section 5-1).
Spatter or molten material being ex- Incorrect tip alignment. Dress tips so that they align and are flat on the material (see Section 4-1).
pelled out during welding operation.
Excessive tong pressure. Reduce tong pressure.
Output amperage too high. Reduce amperage setting, if applicable (not available on air-cooled mod-
els).
Poor weld or no weld at tips. Material too thick for spot welding machine. Check that material thickness is within capacity of spot
welding machine.
OM-716 Page 16
SECTION 7 − ELECTRICAL DIAGRAMS
162 466-C
072 065-B
Figure 7-3. Circuit Diagram For 110 And 220 Volts Non-T Models
OM-716 Page 18
Notes
OM-716 Page 19
SECTION 8 − PARTS LIST
17
. Hardware is common and
not available unless listed.
11 10 3 18
10 19
9
12
7 8
6
13
14
15
20
5 48
21 22
46
4
3
31
2 17
1 16 30
32 19
29
28
49
46
3
24
45 27 25
33 26
37
36 35 34
38
42 39
40
41
43
47
44
145 048-E
Quantity
Item Dia. Part Model
No. Mkgs. No. Description 41,41T 52,52T
OM-716 Page 21
Replace Coils At Factory Or Factory Authorized Service Station.
Quantity
Item Part Model
No. No. Description 41,41T 52,52T
Figure 8-2. Transformer, Power Main (Fig 8-1- Item 38) 095 345 095 354
141 482-A
+Item 37 on Figure 8-1 is included when ordering these items as replacement parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and style number required when ordering parts from your local distributor.
OM-716 Page 22
Quantity
Item Dia. Part Model
No. Mkgs. No. Description 115V 230V
Figure 8-3. Timer, Spot (230V Illustrated) 041 081 041 082
3
2 4
12
11
10
9 8
7 146 012-E
OM-716 Page 23
Figure 8-4. Spot Welder Tips
6-1/2” (165 mm) 12” (305 mm) 040 203 Standard Flat
18” (457 mm) 040 204
9-1/2”
(241 mm) 12” (305 mm) 040 205 Standard Flat
18” (457 mm) 040 206
040 211 040 212
TT-9
FF
8” (203 mm) 040 208
FF 040 213
FH
5” (127 mm) 040 209
FH 040 214
S-0550
OM-716 Page 24
Notes
Notes
Effective January 1, 2010
(Equipment with a serial number preface of MA or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions 6. 90 Days — Parts
Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its * Accessory (Kits)
1-800-4-A-MILLER original retail purchaser that new Miller equipment sold after the
effective date of this limited warranty is free of defects in material
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and
for your local and workmanship at the time it is shipped by Miller. THIS
Non-Electronic Controls
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
Miller distributor. WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * M-Guns
WARRANTIES OF MERCHANTABILITY AND FITNESS. * MIG Guns and Subarc (SAW) Guns
* Remote Controls and RFCS-RJ45
Within the warranty periods listed below, Miller will repair or replace
any warranted parts or components that fail due to such defects in * Replacement Parts (No labor)
Your distributor also gives * Roughneck Guns
you ... material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will * Spoolmate Spoolguns
Service provide instructions on the warranty claim procedures to be Miller’s True Blue Limited Warranty shall not apply to:
You always get the fast, followed.
1. Consumable components; such as contact tips,
reliable response you Miller shall honor warranty claims on warranted equipment listed cutting nozzles, contactors, brushes, relays, work
need. Most replacement below in the event of such a failure within the warranty time station table tops and welding curtains, or parts that
parts can be in your periods. All warranty time periods start on the delivery date of the fail due to normal wear. (Exception: brushes and
hands in 24 hours. equipment to the original end-user purchaser, and not to exceed relays are covered on all engine-driven products.)
one year after the equipment is shipped to a North American 2. Items furnished by Miller, but manufactured by others,
Support distributor or eighteen months after the equipment is shipped to an
Need fast answers to the such as engines or trade accessories. These items are
International distributor.
covered by the manufacturer’s warranty, if any.
tough welding questions? 1. 5 Years Parts — 3 Years Labor
Contact your distributor. 3. Equipment that has been modified by any party other than
* Original main power rectifiers only to include SCRs, Miller, or equipment that has been improperly installed,
The expertise of the diodes, and discrete rectifier modules improperly operated or misused based upon industry
distributor and Miller is standards, or equipment which has not had reasonable
2. 3 Years — Parts and Labor
there to help you, every and necessary maintenance, or equipment which has
* Engine Driven Welding Generators
step of the way. been used for operation outside of the specifications for
(NOTE: Engines are warranted separately by the
engine manufacturer.) the equipment.
* Inverter Power Sources (Unless Otherwise Stated) MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Plasma Arc Cutting Power Sources USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
* Process Controllers TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders
* Smith 30 Series Flowgauge and Flowmeter In the event of a warranty claim covered by this warranty, the
Regulators (No Labor) exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
* Transformer/Rectifier Power Sources appropriate cases, (3) the reasonable cost of repair or
* Water Coolant Systems (Integrated) replacement at an authorized Miller service station; or (4) payment
3. 2 Years — Parts of or credit for the purchase price (less reasonable depreciation
* Auto-Darkening Helmet Lenses (No Labor) based upon actual use) upon return of the goods at customer’s risk
and expense. Miller’s option of repair or replacement will be F.O.B.,
4. 1 Year — Parts and Labor Unless Specified Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized
* Automatic Motion Devices service facility as determined by Miller. Therefore no
* CoolBelt and CoolBand Blower Unit (No Labor) compensation or reimbursement for transportation costs of any
* External Monitoring Equipment and Sensors kind will be allowed.
* Field Options TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
(NOTE: Field options are covered for the remaining PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
warranty period of the product they are installed in, or REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
for a minimum of one year — whichever is greater.) DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Flowgauge and Flowmeter Regulators (No Labor)
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
* RFCS Foot Controls (Except RFCS-RJ45) OTHER LEGAL THEORY.
* Fume Extractors
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* HF Units ANY IMPLIED WARRANTY, GUARANTY OR
* ICE Plasma Cutting Torches (No Labor) REPRESENTATION AS TO PERFORMANCE, AND ANY
* Induction Heating Power Sources, Coolers, and REMEDY FOR BREACH OF CONTRACT TORT OR ANY
Electronic Controls/Recorders OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION,
* Load Banks MIGHT ARISE BY IMPLICATION, OPERATION OF LAW,
* Motor Driven Guns (w/exception of Spoolmate CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING
Spoolguns) ANY IMPLIED WARRANTY OF MERCHANTABILITY OR
FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO
* PAPR Blower Unit (No Labor) ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS
* Positioners and Controllers EXCLUDED AND DISCLAIMED BY MILLER.
* Racks
Some states in the U.S.A. do not allow limitations of how long an
* Running Gear/Trailers implied warranty lasts, or the exclusion of incidental, indirect,
* Spot Welders special or consequential damages, so the above limitation or
* Subarc Wire Drive Assemblies exclusion may not apply to you. This warranty provides specific
* Water Coolant Systems (Non-Integrated) legal rights, and other rights may be available, but may vary from
* Weldcraft-Branded TIG Torches (No Labor) state to state.
* Work Stations/Weld Tables (No Labor) In Canada, legislation in some provinces provides for certain
5. 6 Months — Parts additional warranties or remedies other than as stated herein, and
to the extent that they may not be waived, the limitations and
* Batteries exclusions set out above may not apply. This Limited Warranty
* Bernard Guns (No Labor) provides specific legal rights, and other rights may be available,
* Tregaskiss Guns (No Labor) but may vary from province to province.
miller_warr 2010−01
Owner’s Record
Please complete and retain with your personal records.
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier to: 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.
ORIGINAL INSTRUCTIONS − PRINTED IN USA 2010 Miller Electric Mfg. Co. 2010−01