Miller AUTO ARC MW 4150 Owner'S Manual Download | Manualshive

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Summary of Contents for AUTO ARC MW 4150

Page 1: ... manual before installing operating or maintaining this equip ment This unit and these instructions are for use only by persons trained and experienced in the safe operation of welding equipment Do not allow un trained persons to install operate or maintain this unit Contact your distributor if you do not fully understand these instructions FORM 113 336B Effective With Serial No JK585798 MODEL AUT...

Page 2: ...SED ON BREACH OF THIS WARRANTY MILLER ELECTRICS NEGLIGENCE OR OTHER TORT OR ON ANY THEORY OF STRICT LIABILITY Some states do not allow the exclusion or limitation of conse quential or incidental damages so the above limitations may not apply to you PROCEDURE FOR OBTAINING WARRANTY PERFORM ANCE As soon as any defect in a Welder becomes known the pur chaser of the Welder must within thirty 30 days n...

Page 3: ...lied retaining rings Amend Figure 4 2 Running Gear Installation Cap Screw Cylinder Bracket Two Front Screw Nut Rack Spreader Bar Cap Screw Casters Nut Wheel Retaining Ring Figure 42 Running Gear installatIon Part No Replaced With TC 049 808 E Quantity Description 50 11 032 524 121 614 RING retaining ext 750 shaft x 082 Effw KA775591 50 13 052 692 135 390 AXLE running gear Eft w KA775591 First digi...

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Page 5: ...ection No Page No SECTION 1 SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1 1 Introduction 1 1 2 General Precautions 1 1 3 Arc Welding 3 1 4 Standards Booklet Index 5 SECTION 2 SAFETY PRECAUTIONS AND SIGNAL WORDS 2 1 General Information And Safety 6 2 2 Safety Alert Symbol And Signal Words 6 SECTION 3 INTRODUCTION 3 1 Volt Ampere Curves 8 3 2 Duty Cycle 8 3 3 Description 8 3 4 Supplied Eq...

Page 6: ... 26 7 6 Overload Protection 27 7 7 Thermal Overload Protection 27 7 8 Printed Circuit Board Replacement 27 7 9 Troubleshooting 27 SECTION 8 ELECTRICAL DIAGRAMS Diagram 8 1 Circuit Diagram 30 Diagram 8 2 Circuit Diagram For SPW 1 Panel 30 SECTION 9 WELDING TECHNIQUES TROUBLESHOOTING 9 1 Gas Metal Arc Welding GMAW Continuous Seam 31 9 2 Gas Metal Arc Welding GMAW Pulsed 32 9 3 Gas Metal Arc Welding ...

Page 7: ...gure 11 6 SPW 1 Spot Panel Optional 48 Figure 11 7 Circuit Card PC5O 49 Figure 11 8 Running Gear 50 LIST OF CHARTS AND TABLES Table 3 1 Specifications 7 Chart 3 1 Volt Ampere Curves 7 Chart 3 2 Duty Cycle 7 Table 3 2 Input Conductor And Fuse Size 17 Table 6 1 Suggested Parameters For Continuous Gas Metal Arc Welding GMAW 21 Table 6 2 Checking Weld Parameters 23 Table 7 1 Maintenance Schedule 23 Ta...

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Page 9: ...r plates protected by clear cover glass This is a MUST for welding or cutting and chipping to protect the eyes from radiant energy and flying metal Replace cover glass when broken pitted or spattered See 1 3A 2 Avoid oily or greasy clothing A spark may Ignite them Hot metal such as electrode stubs and workpleces should never be handled without gloves Medical first aid and eye treatment First aid f...

Page 10: ...ombusti bles solubility followed by purging and inerting with ni trogen or carbon dioxide and using protective equip ment as recommended in A6 O Waterfilling just below working level may substitute for inerting A container with unknown contents should be cleaned see preceding paragraph Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut Hollow castings or containers ...

Page 11: ...h a clean lintless cloth Match regulator to cylinder Before connecting check that the regulator label and cylinder marking area and thatthe regulator inlet and cylinderoutlet match NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas Tighten connections When assembling threaded con nections clean and smooth seats where necessary Tighten If connect...

Page 12: ...open areas sur round the operation with low reflective non combusti ble screens or panels Allow for free air circulation par ticularly at floor level Viewing the weld Provide face shields for all persons who will be looking directly at the weld Others working in area See that all persons are wearing flash goggles Before starting to weld make sure that screen flaps or bay doors are closed B Toxic F...

Page 13: ...ng ob ject in contact with the electrode circuit unless the welding power source is off b Equipment without output on off control no contactor Welding power sources used with shielded metal arc welding SMAW and similar proc esses may not be equipped with welding power output on off control devices With such equip ment the electrode is electrically HOT when the power switch is turned ON Never touch...

Page 14: ...National Standards Institute 1430 Broadway New York NY 10018 SECTION 2 SAFETY PRECAUTIONS AND SIGNAL WORDS 2 1 GENERAL INFORMATION AND SAFETY A General Information presented in this manual and on various la bels tags and plates on the unit pertains to equipment design installation operation maintenance and troubleshooting which should be read understood and followed for the safe and effective use ...

Page 15: ... 1pm 1 5 to 12 3 mpm 023 025 in 0 6 mm 030 in 10 mm 035 in 0 9 mmj Dimensions Weight A Width 13 1 2 in 343 mm B Length 27 in Net Ship 686 mm 205 lbs 215 lbs C Height 30 in 93 kg 98 kg 762 mm Add 2 3 4 lbs 1 25 kg for units with spot Add 5 lbs 2 27 kg for units with spot TB 087 313 C Figure 3 1 Overall Dimensions Chart 3 1 Volt Ampere Curves In J 0 U Chart 3 2 Duty Cycle 1RATED OUTPUT 200 175 150 4...

Page 16: ...DUTY CYCLE RAT INGS wIll damage the weldIng power source Do not exceed indicated duty cycles This unit is a single phase constant voltage dc arc weld ing power source and wire feedersystem This unit is de signed for Gas Metal Arc Welding GMAW with short circuit or spray transfer it is designed primarily for use as a dc Electrode Positive Reverse Polarity machine Rated weld output is 150 amperes 23...

Page 17: ...e from but certain wires are best suited for weld ing thin gauge sheet steel The American Welding Soci ety AWS classification for GMAW wires is usually indi cated on the label of the wire spool Two AWS wire classes recommended are E7OS 6 and E7OS 3 The E7OS 6 provides a more fluid wetter weld puddle and a flatter bead than E7OS 3 Obtain a spool of selected wire E Personal Safety Equipment When usi...

Page 18: ...it over combustible surfaces Maintain at least 18 inches 457 mm of unrestricted space on all sides of unit and keep underside free of obstructions Do not place any filtering device over the in take airpassages that provide airflow for cooling this unit Warranty is void if any type of filtering device is used at intake air passages 4 2 TRANSPORTING METHODS This welding power source is equipped with...

Page 19: ... tour of axle as tightly as possible 5 Install cylinder rack onto welding power source base using 5 16 18 x 3 4 cap screws and associated hardware see Figure 4 2 6 Remove the two front cap screws in top of welding power source wrapper and discard Install running gear handle onto wrapper using 1 4 20 x 3 4 cap screws as shown in Figure 4 2 7 Install cylinder bracket onto rear panel of welding power...

Page 20: ...ipment damage Keep cylinders away from any welding oroth er electrical circuits Never allow a welding electrode to touch any cylinder Always fasten cylinder securely to running gear bracket a wall or other stationary support B Reguiator Fiowmeter Customer Supplied Figure 4 4 1 With the cylinder correctly installed remove cylinder cap see Figure 4 4 Stand to one side of the cylin der valve and open...

Page 21: ...n the work cable over the work clamp handle The supplied jack plugs are used to connect the weld cables to the weld output receptacles Install jack plugs onto weld cables as follows 1 Remove 3 4 in 19 mm of insulation from one end of each weld cable 2 Clamp cable in a vise with the uninsulated end ex tending upward out of vise approximately 1 3 4 in 44mm 3 Place steel tie wire item A Figure 4 6 ap...

Page 22: ...ging procedures before inspecting or installing Lockout tagging procedures consist of removing input power plug from receptacle padlocking line disconnect switch in open position remov ing fuses from fuse box or shutting off and red tagging circuit breaker or other disconnecting device A Gun Feeder Connector InstallatIon FIgure 4 7 And Figure 4 8 IMPORTANT The outlet guide is provided as part of t...

Page 23: ...e box or shutting off and red tagging circuit breaker or other disconnecting device If two guns are connected to this welding power source both electrode wires will be energized when eithergun is operated A Shieiding Gas Connections IMPORTANT Use pure argon shielding gas for alumi num wire welding Connect the shielding gas hose from the Spool Gun to the gas regulator f Iowmeter on the shielding ga...

Page 24: ...e hub tension should be sufficient to keep the wire taut and pre vent backlash when the wire feeding ceases If adjust ment is required loosen or tighten the hex nut on the end of the spindle support shaft accordingly 4 12 ELECTRICAL INPUT CONNECTIONS INPUT a WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Shutdown weldingpowersource and discon nect input power employing lockout ...

Page 25: ...ill Do not connect an input white or black con ductor to the ground terminal Do not connect the ground green conductor to an input ilne terminal Incorrect input connections can result in an elec trically energized welding power source chassis The ground conductor is connected to the weld ing power source chassis and is for grounding purposes only Input Voltage 200V 230V 460V 575V Input Conductor S...

Page 26: ...1 4 in 6 mm out the gun nozzle If wire feeds more than 1 4 in out nozzle cutwire off to 1 4 in 12 Deenergize welding power source 13 Adjust hub tension according to Section 4 11 if nec essary 14 Close and secure access door IMPORTANT For a smoother weld start be sure weld ing wire extends 1 4 in 6 mm out of contact tube and has a sharp end SECTION 5 OPERATOR CONTROLS 5 1 POWER SWITCH AND PILOT LIG...

Page 27: ...P1 and TP2 and relay CR2 control the fan motor 5 5 OPTIONAL SPOT PULSE PANEL CONTROLS FIgure 5 1 IMPORTANT In the PULSE mode the FINE TUNING WIRE SPEED control must be set at 50 percent or less Exceeding the 50 percent control setting may rip the cir cuit breaker in the motor control circuit stopping wire feed A Selector Switch The Selector switch enables the operator to select con tinuous spot or...

Page 28: ...VIRONMENT can damage internal parts Do not touch live electrical parts Keep all covers and panels in place while op erating Warranty is void if the welding power source is operated with any portion of the outer enclosure removed ARC RAYS SPARKS AND HOT SURFACES can burn eyes and skin NOISE can damage hearing Wear correct eye ear and body protection FUMES AND GASES can seriously harm your health Ke...

Page 29: ...tion 5 5 9 Set a voltage condition with the THICKNESS VOLTS selector plug that is appropriate for the base metal thickness and type of shielding gas see Sec tion 5 2 and Table 6 1 IMPORTANT It is important that the selected voltage be appropriate for type of weld and thickness of material Be sure that the weld bead is thoroughly fused with the base metal along the total length of the bead If the w...

Page 30: ...nto lower drive roll and reinstall pressure spring e Close and secure side access door 7 Set spot weld parameters weld voltage wire feed speed spot weld time as follows a Obtain sample pieces of metal the same type but approximately twice the thickness of the fi nal workpiece b Place Selector Switch on optional SPW 1 panel in CONTINUOUS position and set welding volt age and wire feed speed paramet...

Page 31: ...LDING GAS can harm health or kIll Shut off gas supply when not in use SECTION 7 MAINTENANCE TROUBLESHOOTING 7 1 ROUTINE MAINTENANCE IMPORTANT Every six months inspect the labels on this unit for legibility All precautionary labels must be maintained in a clearly readable state and replaced when necessary See Parts List for part numberofpre cautionary labels Table 7 1 MaIntenance Schedule Frequency...

Page 32: ...g the drive roll assembly It is necessary to remove the drive roiis for proper clean ing of the wire grooves see Section 7 2 for removal and instaliation instructions Use a wire brush to clean roiis IMPORTANT Failure to properly maintain the drive rolls can result in a buildup of wire particles which decreases the efficiency of the wire feeding operation 7 2 REPLACING DRIVE ROLL AND WIRE INLET GUI...

Page 33: ... in or out as necessary To move the drive roll in to wards the motor insulator rotate the self lock ing nut clockwise To move the drive roll out away from the center panel of the unit rotate the nut counterclockwise IMPORTANT Be sure that upper and lower drive roll gears are properly meshed and the drive roll grooves are aligned when adjusting horizonta position of lowerdrive roll d Reengage press...

Page 34: ...If it should become necessary to replace part or all of the hub assembly reinstall the new hub assembly as fol lows 1 Slide the following items onto the single support shaft in order given a Fiber Washer c Hub d Brake Washer e Fiber Washer f Keyed Washer g Spring h Flat Washer 2 Rotate hex nut onto support shaft Hex nut should be rotated only until a slight drag is felt while turning hub 3 Install...

Page 35: ...lts ac winding of transformer Ti from overload CB2 is located under the access door Should CB2 open the contactor W coil would open thereby stopping all output from the welding power source If CB2 opens manually reset the breaker 7 7 THERMAL OVERLOAD PROTECTION Rectifier SRi is protected from overheating by a normal ly closed thermostat TP3 wired in series with contactor W coil circuit Should over...

Page 36: ...osition See Section 4 12 for proper jumper link position Line fuse s open Check and replace open line fuses Main rectifier SRi overheating thermal shutdown Allow rectifier to cool down see Section 7 7 Gun switch or gun switch leads See gun Owners Manual POWER switch Si Replace Si Switch control relay CR1 Replace CR1 No weld output wire feeds THICKNESSNOLTS plug not secure in receptacle Secure conn...

Page 37: ...ints Contact nearest Factory Authorized Service Station Gun switch See gun Owners Manual Transformer Ti Contact nearest Factory Authorized Service Station Plug PLG2 not secure in recep tacle RC55 modelswith option al Spot Weld Panel only Secure PLG2 into RC55 Wire does not feed open circuit voltage normal Circuit breaker CB1 or CB2 Reset CB1 or CB2 see Section 7 6 Rectifier SR2 Contact nearest Fac...

Page 38: ...CTRICAL DIAGRAMS A C B Circuit Diagram No A 090 568 A DIagram 8 2 CircuIt Diagram For SPW 1 Panel 54 2 3 4 DIagram 8 1 CircuIt Diagram NEGATIVE Circuit Diagram No B 121 827 CONT SPOT PC5O 7 9 8 62 56 113336 Page 30 ...

Page 39: ...ack from the seam when the arc starts as this will create a long wire extension and result in a poor weld The welding wire is not energized until the trigger is pressed Therefore the welding wire can be extended 1 4 inch 6mm beyond the gun nozzle and placed on the seam before lowering the helmet and pressing the gun trigger Figure 9 2 Gun Position TA 057469 IIB The gun can be moved along the seam ...

Page 40: ...tch is placed in the PULSE position and the gun trig ger is depressed the welding wire feeds through the gun for the length of time set on the SPOT TIME PULSE ON TIME control At the end of the pulse on time the welding wire stops feeding for the length of time set on the PULSE OFF TIME control This on and off sequence continues for the amount of time selected on the time control untilthe gun trigg...

Page 41: ...weld is made by placing the welding gun directly on the top sheet and holding it motionless as shown in Figure 9 8 When the gun trigger is depressed the elec trode wire and shielding gas will be continuously fed The arc will be maintained forthe lull length of time set on the SPOT TIME PULSE ON TIME control and it will con tinue to penetrate in one place until the top sheet is welded with the bott...

Page 42: ...me the spot timer times out Skip welds on sample material should be made so that proper parameters can be set 9 6 TROUBLESHOOTING THE GAS METAL ARC WELDING PROCESS A Porosity Possible Causes Corrective Actions 1 inadequate shielding gas coverage Remove spatter from the gun nozzle Check gas hoses for leaks Eiminate drafts from fans open doors etc blowing into the welding arc Place nozzle 1 4 to 5 1...

Page 43: ... on the side walls of the groove Provide improved access at root of joints Keep electrode directed at the leading edge of the puddle Provide proper gun angle D Lack of Fusion Figure 9 11 Lack of Penetration Poss ibie Causes Corrective Actions 1 Improper joint preparation Material too thick Joint preparation and design must be adequate to provide access to the bottom of the groove while maintaining...

Page 44: ...r weiding wire extension and arc character istics 2 Heat input too high causing excessive shrinkage and distortion Select lower voltage range and reduce wire speed Increase travel speed G Waviness of Bead Figure 9 13 Waviness of Bead Possible Causes Corrective Actions 1 Welding wire extends too far out of nozzle Welding wire should extend 1 4 in 6 mm out of nozzle 2 Unsteady hand Support hand on s...

Page 45: ... area should be cleaned for applying body filler afterweld ing is completed 2 Remove damaged metal using hand cutters shears or a power hand grinder equipped with a cut ting wheel 3 Fit a new piece of sheet steel over the section which was removed The new material should overlap the cut away section by one inch 25 mm 4 Clamp the new metal in place and prepare to spot weld 5 Set the weld timer at 3...

Page 46: ...isto be replaced the old panel must be removed by cutting along the weld if welded by continu ous seam or by drilling out the spot welds if it is spot welded in place Car and body manufacturers have the panels welded in different places so it will be necessary to inspect the body to determine where the welds are lo cated in each case After the old panel is removed the inner panels must be carefull...

Page 47: ...SECTION 11 PARTS LIST 113 336 Page 39 ...

Page 48: ...For Parts List of Gun See Form 112 934 33 JFI 13 9 10 11 12 23 22 17 TD 072507 J 16 0 0 0 0 CD 0 1 Figll 2 Figll 4 5 6 Figure 11 1 MaIn Assembly ...

Page 49: ...i sec 1 19 083175 SKID base 2 20 Fig 11 5 PANEL front w components 1 21 023 100 CABLE interconnecting ground 1 22 026 843 INSULATOR vinyl blk 43 2 23 010 368 CLAMP ground 100A 1 24 039 901 PLUG jack bik consisting of i 25 602 160 SCREW slftpg type F filh 8 32 1 26 026 978 INSULATOR jack plug blk 1 27 101 219 PLUG jack 5 8 x 2 5 8 i 28 602 178 SCREW set sti sch 250 20 2 29 010 521 WIRE tie bag i6ga...

Page 50: ...113336 Page 42 FIgure 11 2 Baffle Air W Components TD 072 509 F ...

Page 51: ... 072817 RELAY enc124VACDPDT 1 13 083147 GROMMET scr8 10 6 14 082 907 ANGLE mtg RH capacitor 1 15 C6 031 728 CAPACITOR elctIt 20000uf 35VDC 6 16 082 902 STRIP mtg center capacitor 1 17 082 875 ANGLE mtg LH capacitor 1 18 034 260 LINK connecting contactor terminal 2 19 W 035 519 024 493 CONTACTOR def prp 40A 3P 24V consisting of COIL cntor 24VAC 40A 1 1 20 038 620 LINK jumper term blk 30A I 21 TEl 0...

Page 52: ...GEAR drive roil no groove 024 wire 1 13 010929 WASHER fiatstlspr 375 1 14 M 119 040 MOTOR gear PM 12V 1 25hp consisting of 1 15 130820 BRUSH SPRlNG 2 16 057432 SCREW 2 17 079 624 SCREW cap sti hexhd slflkg 375 16 1 18 602 213 WASHER lock stl split 375 2 19 010910 WASHER flatstlSAE 375 1 20 044 994 INSULATOR motor 1 21 601 838 NUT brs hex 375 16 1 22 079 633 FITTING hose brs barbed nipple 3 16TBG 1...

Page 53: ...VAC1500RPM 1 2 032 662 BLADE fan lOin 5wg 1 3 125947 PANEL rear 1 4 SRi 089 733 RECTIFIER si diode consisting of 1 5 057 496 BRACKET mtg fan motor 1 6 037 306 DIODE rect 150A 300V RP 2 7 TP3 086 323 THERMOSTAT NO 1 8 037 305 DIODE rect 150A 300V SP 2 9 Cl 4 080 894 CAPACITOR cer disc 01 uf I 000VDC 4 10 TP1 604515 THERMOSTAT NC 1 3 2 1 Figure 11 4 Panel Rear W Components TD 072 508 B 113 336 Page ...

Page 54: ...113 336 Page 46 Figure 11 5 Panel Front W Components TB 131 148 ...

Page 55: ... 924 KNOB pointer 1 21 057 608 RECEPTACLE jack plug yellow consisting of 6 22 601 881 NUT stl hex jam 500 20 1 23 605 787 WASHER lock stl Intl tooth 500 1 24 604 668 NUT stl slf 1kg hex med fnsh 500 20 2 25 010 291 WASHER flat nylafil 625 ID 1 26 072 334 RECEPTACLE NUT jack plug yellow 1 27 023 084 CABLE PLUG jack consisting of i 28 039 878 PLUG ASSEMBLY consisting of 1 29 602 160 SCREW slftpg 8 3...

Page 56: ...350K ohm 1 4 550 086 895 SWITCH rotary 3 position I 5 073 914 WASHER centering 437 dia 2 6 R53 605 890 RESISTOR WW fxd 15W 25 ohm I 7 080509 GROMMET scrNo 8 10 3 8 PLG5I 072 669 HOUSING term header 9 pin 1 9 PLG5O 079 798 HOUSING term header 13 pin 1 10 PC5O 097 897 CIRCUIT CARD dual timer pulser Fig 11 7 I 11 RC55 008 072 058 971 HOUSING PLUG PINS consisting of TERMINAL male 1 8 12 086650 PANEL s...

Page 57: ...11 7 CIrcuit Card PC5O Not part of circuit card BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS Dia Part Mkgs No Description 097 897 CIrcuit Card Fig 11 6 item 10 Quantity 009 159 039482 032 820 073 714 073 739 090 573 027810 099 019 099 018 079844 091 861 026202 037449 037200 073 535 030018 035823 035884 039331 035 827 035 886 039 333 039 327 035 887 092 648 079 795 072...

Page 58: ...7 602 387 CHAIN weldless 2 0 x 27in 1 8 602 384 SNAP chain 1 9 052 693 RACK cylinder 1 10 602 250 WASHER flat stl SAE 750 4 11 032524 PIN cotter 187x 1 500 2 12 070 799 WHEEL rubolene lOin dia 2 13 052 692 AXLE running gear 1 14 601 944 SCREW cap stl hexhd 312 18 4 15 602 211 WASHER lock stl split 312 4 16 601 869 NUT sti hex jam 312 18 4 17 008 999 CASTER plastic swvl 4in dia 2 18 052 691 ANGLE s...

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