Miller Electric AUTO ARC MW 4150 User manual

AUTO

ARCJ~

May

1991

FORM:OM-113

336D

Effective

With

Serial

No.

KA898403

MODEL:

AUTO

ARCﬁ

4150

AUTO

ARCﬁ

4200

SPW-1

OWNERS

MANUAL

IMPORTANT:

Read

and

understand

the

entire

contents

this

manual,

with

special

emphasis

the

safety

material

throughout

the

manual,

before

MILLER

ELECTRIC

Mfg.

Co.

AMIerGroupLld..Company

installing,

operating,

maintaining

this

equipment.

This

unit

and

these

instructions

are

for

use

only

persons

trained

and

experienced

the

safe

Box

1079

Appleton,

54912

USA

operation

welding

equipment.

not

allow

untrained

persons

Install,

Tel.

414-734-9821

operate,

maintain

this

unit.

Contact

your

distributor

you

not

fully

understand

these

instructions.

SB-087

313D

PRINTED

U.S.A.

ONE

YEAR

LIMITED

WARRANTY

EFFECTIVE:

FEBRUARY

17,

1989

This

warranty

supersedes

all

AUTO

ARC

warranties

and

exclusive

with

other

guarantees

orwarranties

expressed

implied.

COVERAGE



MILLER

Electric

Mfg.

Co.

warrants

the

for

the

purchase

price

(less

reasonable

depreciation

based

buyer

who

purchases

this

AUTO

ARC

Welder

(Welder)

for

upon

actual

use)

upon

return

the

goods

Consumers

risk

personal,

family

household

purposes

(Consumer)

that

this

and

expense.

MILLERs

option

repair

replacement

will

Welderwillbefreefromdefectsinmaterialandworkmanshipfor

FOB.,

Factory

Appleton,

FOB.

MILLER

autho-

period

one

year

from

the

date

purchase.

This

warranty

rized

service

facility,

therefore,

compensation

for

transporta

covers

only

the

original

purchaser

this

Welder.

MILLER

Elec-

tion

costs

any

kind

will

allowed.

Upon

receipt

notice

tric

does

not

authorize

any

party,

including

its

authorized

dis-

apparentdefectorfailure,

MILLER

shall

instructtheclaimanton

tributors,

offer

any

other

warranty

behalf

MILLER

Elec-

the

warranty

claim

procedures

followed.

tric.

Upon

expiration

the

warranty

period,

MILLER

Electric

shall

have

further

liability

the

Welder,

except

THIS

WARRANTY

OFFERED

LIEU

ANY

OTHER

warranty

claims

made

during

the

warranty

period.

warranty

EXPRESS

WARRANTY;

AND,

EXCEPT

THE

EXTENT

made

MILLER

with

respect

engines,

trade

accessories

PROHIBITED

APPLICABLE

LAW,

THE

DURATION

other

items

manufactured

others.

Such

engines,

trade

ac-

ALL

IMPLIED

WARRANTIES,

INCLUDING

BUT

NOT

cessories

and

other

items

are

sold

subject

the

warranties

LIMITED

THE

IMPLIED

WARRANTIES

MERCHAN

their

respective

manufacturers,

any.

All

engines

are

war-

TABILITYAND

FITNESS

FORAPARTICULAR

PURPOSE,

ranted

their

manufacturer

for

two

years

from

date

original

LIMITED

THE

DURATION

THIS

WARRANTY.

purchase,

except

Deutz

engines

which

have

one

year,

2000

hour

warranty.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WARRANTY.

GUARANTY

REPRE

MILLER

shall

required

honor

warranty

claims

war-

SENTATION

PERFORMANCE,

AND

ANY

REMEDY

ranted

Equipment

the

event

failure

resulting

from

defect

FOR

BREACH

CONTRACT

WHICH,

BUT

FOR

THIS

within

the

following

periods

from

the

date

delivery

Equip-

PROVISION,

MIGHT

ARISE

IMPLICATION,

OPERATION

ment

the

original

user:

LAW,

CUSTOM

TRADE

COURSE

DEALING,

INCLUDING

ANY

IMPLIED

WARRANTY

MERCHANT-

2

ers,

power

sources,

comporien

year

ABILITY

FITNESS

FOR

PARTICULAR

PURPOSE,

Ibr

rnai

power

iers

years

WITH

RESPECT

ANY

AND

ALL

EQUIPMENT

FUR

welding

guns,

feeder/guns

and

torches

days

NISHED

MILLER

EXCLUDED

AND

DISCLAIMED

Replacement

repair

parts,

exclusive

labor

days

LLE

Batteries

months

. 

Some

states

not

allow

limitations

how

long

implied

provided

that

MILLER

notified

writing

within

thirty

(30)

days

warranty

lasts,

the

above

limitation

may

not

apply

you.

such

failure.

This

warranty

gives

you

specific

legal

rights,

and

you

may

also

have

other

rights

which

vary

from

state

state.

WHAT

NOT

COVERED



This

warranty

does

not

extend

any

Welder

subjected

misuse,

neglect,

accident,

in-

THE

PURCHASERS

REMEDIES

FOR

DEFECTIVE

warranty

repair

anyone

except

MILLER

Electric

its

autho-

WELDER,

THE

EXTENT

PERMITTED

APPLICABLE



rized

service

stations.

Further,

thiswarranty

only

extends

the

LAW,

ARE

LIMITED

THE

REMEDY

PROVIDED

THIS

original

purchaser

this

Welder.

WARRANTY.

THE

EXTENT

ENFORCEABLE

UNDER

APPLICABLE

LAW,

MILLER

ELECTRIC

SHALL

the

case

MILLERs

breach

warranty

any

other

duty

EVENT

LIABLE

FOR

CONSEQUENTIAL,

INCIDENTAL

with

respect

the

quality

any

goods,

the

exclusive

remedies

SPECIAL

DAMAGES

ARISING

OUT

THE

USE

OF,

therefore

shall

be,

MILLERs

option

(1)

repair

(2)

replace-

INABILITY

USE,

THE

WELDER,

WHETHER

BASED

ment

or,

where

authorized

writing

MILLER

appropriate

BREACH

THIS

WARRANTY,

MILLER

ELECTRICS

NEG



cases,

(3)

the

reasonable

cost

repair

replacement

LIGENCE

OTHER

TORT,

ANY

THEORY

authorized

MILLER

service

station

(4)

payment

credit

STRICT

LIABILITY.

ERRATA

SHEET

After

this

manual

was

printed,

refinements

equipment

design

occurred. This

sheet

lists

exceptions

data

appearing

later

this

manual.

AMENDMENT

SECTION

7

MAINTENANCE

TROUBLESHOOTING

Amend

Section

7-lA.

ROUTINE

MAINTENANCE:

Fan

Motor

This

unit

equipped

with

exhaust

fan

and

relies

forced

draft

for

adequate

cooling.

The

fan

motor

needs

oiling

every

six

months

using

SAE

oil.

OM-113

3360

5191

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

dam-

Use

the

following

spaces

record

the

Model

Designa

age

that

may

have

occurred

during

shipment.

File

any

tion

and

Serial

Style

Number

your

unit.

The

infor

claims

for

loss

damage

with

the

delivering

carrier.

mation

located

the

data

card

the

nameplate.

Assistance

for

filing

settling

claims

may

obtained

from

the

distributor

and/or

the

equipment

manufactur-

Model

________________________________

ers

Transportation

Department.

Serial

Style

No.

____________________

When

requesting

information

about

this

equipment,

ways

provide

the

Model

Description

and

Serial

Style

Date

Purchase

_____________________

Number.

TABLE

CONTENTS

Section

No.

Page

No.

SECTION



SAFETY

RULES

FOR

OPERATION

ARC

WELDING

POWER

SOURCE

1-1.

Introduction

1-2.

General

Precautions

1-3.

Arc

Welding

1-4.

Standards

Booklet

Index

SECTION

SAFETY

PRECAUTIONS

AND

SIGNAL

WORDS

2-1.

General

Information

And

Safety

2-2.

Safety

Alert

Symbol

And

Signal

Words

SECTION

3SPECIFICATIONS

3-1.

Volt-Ampere

Curves

3-2.

Duty

Cycle

3-3.

Description

3-4.

Supplied

Equipment

3-5.

Additional

Required

Equipment

3-6.

Optional

Equipment

3-7.

Consumable

Parts

SECTION

4INSTALLATION

RELOCATION

4-1.

Site

Selection

4-2.

Transporting

Methods

4-3.

Running

Gear

Installation

4-4.

Optional

SPW-1

Panel

Installation

4-5.

Shielding

Gas

Installation

4-6.

Work

Cable

Assembly

4-7.

Weld

Polarity

Selection

4-8.

MWG-200

Welding

Gun

Connections

4-9.

Installation

Optional

Spool

Gun

4-10.

Welding

Wire

Spool

Installation

4-11.

Hub

Tension

Adjustment

4-12.

Electrical

Input

Connections

4-13.

Welding

Wire

Threading

Section

No.

Page

No.

SECTION

5OPERATOR

CONTROLS

5-1.

Power

Switch

And

Pilot

Light

5-2.

Thickness

Volts

Selector

5-3.

Fine

Tuning

Wire

Speed

Control

5-4.

Fan-On-Demand~

5-5.

Optional

Spot/Pulse

Panel

Controls

SECTION

6

SEQUENCE

OPERATION

6-1.

Gas

Metal

Arc

Welding

(GMAW)-Continuous

And

Gas

Metal

Arc

Welding-Pulsed

Arc

(GMAW-P)

6-2.

Gas

Metal

Arc

Welding

(GMAW)-Spot

(Models

With

Optional

SPW-1

Panel

Only)

6-3.

Shutting

Down

SECTION

7

MAINTENANCE

TROUBLESHOOTING

7-1.

Routine

Maintenance

7-2.

Replacing

Drive

Roll

And

Wire

Inlet

Guide

7-3.

Drive

Housing Realignment

7-4.

Replacing

Hub

Assembly

7-5.

Inspecting

And

Replacing

Motor

Brushes

7-6.

Overload

Protection

7-7.

Thermal

Overload

Protection

7-8.

Printed

Circuit

Board

Replacement

7-9.

Troubleshooting

SECTION

8

ELECTRICAL

DIAGRAMS

Diagram

8-1.

Circuit

Diagram

For

4150

Models

Diagram

8-2.

Circuit

Diagram

For

4200

Models

Diagram

8-3.

Circuit

Diagram

For

SPW-1

Panel

Diagram

8-4.

Wiring

Diagram

For

SPW-1

Panel

Diagram

8-5.

Circuit

Diagram

For

SPW-1

Panel

Dual

Timer/Pulser

Board

PC5O

SECTION

9

WELDING

TECHNIQUES

TROUBLESHOOTING

9-1.

Gas

Metal

Arc

Welding

(GMAW)



Continuous

Seam

9-2.

Gas

Metal

Arc

Welding

(GMAW)-Pulsed

9-3.

Gas

Metal

Arc

Welding

(GMAW)-Spot

9-4.

Plug

Welds

9-5.

Skip

Welding

9-6.

Troubleshooting

The

Gas

Metal

Arc

Welding

Process

SECTION

10

AUTO

BODY

REPAIR

APPLICATION

10-1.

Pointers

For

Welding

Auto

Body

Sheet

Metal

10-2.

Procedure

For

Welding

Mild

Steels

10-3.

Procedures

For

Welding

Door

Panels

10-4.

How

Prevent

Glass

Breakage

And

Spatter

Windows

10-5.

Procedures

For

Welding

Fenders

And

Quarter

Panels

10-6.

Welding

Frames

And

High

Strength

(HSS)

Steels

Section

No.

Page

No.

SECTION



PARTS

LIST

Figure

11-1.

Main

Assembly

Figure

11-2.

Baffle,

Air

w/Components

Figure

11-3.

Drive

Assembly,

Wire

Figure

11-4.

Panel,

Rear

w/Components

Figure

11-5.

Panel,

Front

w/Components

Figure

11-6.

SPW

Spot

Panel

(Optional)

Figure

11-7.

Circuit

Card,

Dual

Timer/Pulser

P050

Figure

11-8.

Running

Gear

LIST

CHARTS

AND

TABLES

Table

3-1.

Specifications

Chart

3-1.

Volt-Ampere

Curves

Chart

3-2.

Duty

Cycle

Table

4-1.

Input

Conductor

And

Fuse

Size

Table

6-1.

Suggested

Parameters

For

Continuous

Gas

Metal

Arc

Welding

(GMAW)

Table

6-2.

Checking

Weld

Parameters

Table

7-1.

Maintenance

Schedule

Table

7-2.

Troubleshooting

SECTION



SAFETY

RULES

FOR

OPERATION

ARC

WELDING

POWER

SOURCE

1-1.

INTRODUCTION

learn

experience.

Learning

safety

through

per

sonal

experience,

child

touching

hot

stove

harmful,

wasteful,

and

unwise.

Let

the

experience

oth

ers

teach

you.

Safe

practices

developed

from

experience

the

use

welding

and

cutting

are

described

this

manual.

search,

development,

and

field

experience

have

evolved

reliable

equipment

and

safe

installation,

opera

tion,

and

servicing

practices.

Accidents

occur

when

equipment

improperly

used

maintained.

The

rea

son

for

the

safe

practices

may

not

always

given.

Some

are

based

common

sense,

others

may

require

technical

volumes

explain.

wiser

the

rules.

Read

and

understand

these

safe

practices

before

tempting

install,

operate,

service

the

equipment.

Comply

with

these

procedures

applicable

the

par

ticular

equipment

used

and

their

instruction

manuals,

for

personal

safety

and

for

the

safety

others.

Failure

observe

these

safe

practices

may

cause

seri

ous

injury

death.

When

safety

becomes

habit,

the

equipment

can

used

with

confidence.

These

safe

practices

are

divided

into

two

Sections:

1-General

Precautions,

common

arc

welding

and

cut

ting;

and

2-Arc

Welding

(and

Cutting)

(only).

Reference

standards:

Published

Standards

safety

are

also

available

for

additional

and

complete

pro

cedures

than

those

given

this

manual.

They

are

listed

the

Standards

Index

this

manual.

ANSI

Z49.1

the

most

complete.

The

National

Electrical

Code,

Occupational

Safety

and

Health

Administration,

local

industrial

codes,

and

local

inspection

requirements

also

provide

basis

for

equip

ment

installation,

use,

and

service.

1-2.

GENERAL

PRECAUTIONS

Difterent

arc

welding

processes,

electrode

alloys,

and

fluxes

can

produce

difterent

fumes,

gases,

and

radiation

levels.

addition

the

information

this

manual,

sure

consult

flux

and

electrode

manu

facturers

Material

Safety

Data

Sheets

(MSDS5)

for

specific

technical

data

and

precautionary

measures

concerning

their

material.

Burn

Prevention

Wear

protective

clothing-gauntlet

gloves

designed

for

use

welding,

hat,

and

high

safety-toe

shoes.

Button

shirt

collar

and

pocket

flaps,

and

wear

cuffless

trousers

avoid

entry

sparks

and

slag.

Wear

helmet

with

safety

goggles

and

glasses

with

side

shields

underneath,

appropriate

filter

lenses

plates

(protected

clear

cover

glass).

This

MUST

for

welding

cutting,

(and

chipping)

protect

the

eyes

from

radiant

energy

and

flying

metal.

Replace

cover

glass

when

broken,

pitted,

spattered.

See

-3A.2.

Avoid

oily

greasy

clothing.

spark

may

ignite

them.

Hot

metal

such

electrode

stubs

and

workpieces

should

never

handled

without

gloves.

Medical

first

aid

and

eye

treatment.

First

aid

facilities

and

qualified

first

aid

person

should

available

for

each

shift

unless

medical

facilities

are

for

immediate

treatment

flash

burns

the

eyes

and

skin

burns.

Ear

plugs

should

worn

when

working

overhead

confined

space.

hard

hat

should

worn

when

others

work

overhead.

Flammable

hair

preparations

should

not

used

per

sons

intending

weld

cut.

Toxic

Fume

Prevention

Severe

discomfort,

illness

death

can

result

from

fumes,

vapors,

heat,

oxygen

enrichment

depletion

that

welding

(or

cutting)

may

produce.

Prevent

them

with

adequate

ventilation

described

ANSI

Standard

Z49.1

listed

Standards

Index.

NEVER

ventilate

with

oxygen.

Lead

cadmium

-,zinc-,

mercury-,

and

beryllium-bear

ing

and

similar

materials,

when

welded

(or

cut)

may

pro

duce

harmful

concentrations

toxic

fumes.

Adequate

local

exhaust

ventilation

must

used,

each

person

the

area

well

the

operator

must

wear

air-sup

plied

respirator.

For

beryllium,

both

must

used.

Metals

coated

with

containing

materials

that

emit

toxic

fumes

should

not

heated

unless

coating

removed

from

the

work

surface,

the

area

well

ventilated

and,

necessary,

while

wearing

air-supplied

respirator.

Work

confined

space

only

while

being

ventilated

and,

necessary,

while

wearing

air-supplied

respira

tor.

Gas

leaks

confined

space

should

avoided.

Leaked

gas

large

quantities

can

change

oxygen

con

centration

dangerously.

not

bring

gas

cylinders

into

confined

space.

Leaving

confined

space,

shut

OFF

gas

supply

source

prevent

possible

accumulation

gases

the

space

downstream

valves

have

been

accidentally

opened

left

open.

Check

sure

that

the

space

safe

before

re-entering

it.

Vapors

from

chlorinated

solvents

can

decomposed

the

heat

the

arc

(or

flame)

form

PHOSGENE,

highly

toxic

gas,

and

other

lung

and

eye

irritating

prod

ucts.

The

ultraviolet

(radiant)

energy

the

arc

can

also

decompose

trichloroethylene

and

perchloroethylene

pors

form

phosgene.

NOT

WELD

cut

where

sol

vent

vapors

can

drawn

into

the

welding

cutting

mosphere

where

the

radiant

energy

can

penetrate

OM-113

336

Page

atmospheres

containing

even

minute

amounts

trichloroethylene

perchioroethylene.

Fire

and

Explosion

Prevention

Causes

fire

and

explosion

are:

combustibles

reached

the

arc,

flame,

flying

sparks,

hot

slag

heated

mate

rial;

misuse

compressed

gases

and

cylinders;

and

short

circuits.

AWARE

THAT

flying

sparks

falling

slag

can

pass

through

cracks,

along

pipes,

through

windows

doors,

and

through

wall

floor

openings,

out

sight

the

goggled

operator.

Sparks

and

slag

can

fly

feet.

prevent

fires

and

explosion:

Keep

equipment

clean

and

operable,

free

oil,

grease,

and

(in

electrical

parts)

metallic

particles

that

can

cause

short

circuits.

combustibles

are

area,

NOT

weld

cut.

Move

the

work

practicable,

area

free

combustibles.

Avoid

paint

spray

rooms,

dip

tanks,

storage

areas,

venti

lators.

the

work

cannot

moved,

move

combustibles

least

feet

away

out

reach

sparks

and

heat;

protect

against

ignition

with

suitable

and

snug-fitting,

fire-resistant

covers

shields.

Walls

touching

combustibles

opposite

sides

should

not

welded

(or

cut).

Walls,

ceilings,

and

floor

near

work

should

protected

heat-resistant

covers

shields.

Fire

watcher

must

standing

with

suitable

fire

extin

guishing

equipment

during

and

for

some

time

after

weld

ing

cutting

if:

appreciable

combustibles

(including

building

construction)

are

within

feet

appreciable

combustibles

are

further

than

feet

but

can

ignited

sparks

openings

(concealed

visible)

floors

walls

within

feet

may

expose

combustibles

sparks

combustibles

adjacent

walls,

ceilings,

roofs,

metal

partitions

can

ignited

radiant

conducted

heat.

Hot

work

permit

should

obtained

before

operation

ensure

supervisors

approval

that

adequate

precautions

have

been

taken.

After

work

done,

check

that

area

free

sparks,

glowing

embers,

and

flames.

empty

container

that

held

combustibles,

that

can

produce

flammable

toxic

vapors

when

heated,

must

never

welded

cut,

unless

container

has

first

been

cleaned

described

AWS

Standard

A6.O,

listed

Standards

Index.

This

includes:

thorough

steam

caustic

cleaning

(or

solvent

water

washing,

depending

the

combusti

bles

solubility)

followed

purging

and

inerting

with

trogen

carbon

dioxide,

and

using

protective

equip-

ment

recommended

A6.O.

Waterfilling

just

below

working

level

may

substitute

for

inerting.

container

with

unknown

contents

should

cleaned

(see

preceding

paragraph).

NOT

depend

sense

smell

sight

determine

safe

weld

cut.

Hollow

castings

containers

must

vented

before

welding

cutting.

They

can

explode.

Explosive

atmospheres.

Never

weld

cut

where

the

air

may

contain

flammable

dust,

gas,

liquid

vapors

(such

gasoline).

Compressed

Gas

Equipment

Standard

precautions.

Comply

with

precautions

this

manual,

and

those

detailed

CGA

Standard

P-i,

SAFE

HANDLING

COMPRESSED

GASES

CYLIN

DERS,

listed

Standards

Index.

Pressure

Regulators

Regulator

relief

valve

designed

protect

only

the

regulator

from

overpressure;

not

intended

protect

any

downstream

equipment.

Provide

such

protection

with

one

relief

devices.

Never

connect

regulator

cylinder

containing

gas

other

than

that

for

which

the

regulator

was

designed.

Remove

faulty

regulator

from

service

immediately

for

pair

(first

cylinder

valve).

The

following

symptoms

indicate

faulty

regulator:

Leaks-if

gas

leaks

externally.

Excessive

Creep-if

delivery

pressure

continues

rise

with

downstream

valve

closed.

Faulty

Gauge-if

gauge

pointer

does

not

move

off

stop

when

pressurized,

nor

returns

stop

after

pressure

release.

Repair.

NOT

attempt

repair.

Send

faulty

regulators

for

repair

manufacturers

designated

repair

center,

where

special

techniques

and

tools

are

used

trained

personnel.

Cylinders

must

handled

carefully

prevent

leaks

and

damage

their

walls,

valves,

safety

devices:

Avoid

electrical

circuit

contact

with

cylinders

including

third

rails,

electrical

wires,

welding

circuits.

They

can

produce

short

circuit

arcs

that

may

lead

serious

acci

dent.

(See

1-3C.)

ICC

DOT

marking

must

each

cylinder.

assurance

safety

when

the

cylinder

properly

han

dled.

Identifying

gas

content.

Use

only

cylinders

with

name

gas

marked

them;

not

rely

color

identify

gas

content.

Notify

supplier

unmarked.

NEVER

DEFACE

alter

name,

number,

other

markings

cylinder.

illegal

and

hazardous.

Empties:

Keep

valves

closed,

replace

caps

securely;

mark

MT;

keep

them

separate

from

FULLS

and

return

promptly.

OM-113

336

Page

This manual suits for next models

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