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Содержание MW 4150

Страница 1: ...e manual before MILLER ELECTRIC Mfg Co AM IIerGroupLtd Con any Installing operating or maintaining thIs equipment This unit and these Instructions are for use only by persons trained and experienced In the safe P0 Box 1079 A eton WI 54912 USA operation of welding equipment Do not allow untrained persons to install Tel 414 734 9821 operate or maintain this unit Contact your distributor if you do no...

Страница 2: ...Rs breach of warranty or any other duty with respect to the quality of any goods the exclusive remedies therefore shall be at MILLERs option 1 repair or 2 replace mentor where authorized in writing by MILLER in appropriate cases 3 the reasonable cost of repair or replacement at an authorized MILLER service station or 4 payment of or credit for the purchase price less reasonable depreciation based ...

Страница 3: ...ing of 1 45 1 SRi 087660 137 913 RECTIFIER WINDTUNNEL Effw KA898364 MW 4200 model consisting of 1 45 7 057 496 137 912 BRACKET mtg fan motor Eff wIKA898367 MW 4150 model 1 45 7 081 678 137 912 BRACKET mtg fan motor Eff w KA898367 MW 4200 model 1 45 9 125 947 134 982 PANEL rear Eff w KA898364 MW 4150 model 1 47 15 Si 090 328 124 511 SWITCH tgl DPST 40A 600VAC 1 First digit represents page no digits...

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Страница 5: ... 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 Equipment 8...

Страница 6: ...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 For MW4150 Models 30 Diagram 8 2 Circuit Diagram For MW4200 Models 30 Diagram 8 3 Circuit Diagram For SPW 1 Panel 31 SECTION 9WELDING TECHNIQUES TROUBLESHOOTING 9 1 Gas Metal Arc Welding GMAW Continuous Seam 32 9 2 Gas Metal Arc Welding GMAW Pul...

Страница 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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Страница 9: ... 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 workpieces should never be handled without gloves Medical first aid and eye treatment First aid fa...

Страница 10: ...busti bles solubility followed by purging and inerting with ni trogen or carbon dioxide and using protective equip ment as recommended in A6 O Watertilling 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 mu...

Страница 11: ...ith a clean lintless cloth Match regulator to cylinder Before connecting check that the regulator label and cylinder marking area and thatthe regulatorinlet 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 connec...

Страница 12: ...n 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...

Страница 13: ...ting ob ject in contact with the electrode circuit unless the welding power source is off b Equipment without output on off control no contacto r 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 to...

Страница 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 ...

Страница 15: ...Volts DC 60 to 486 ipm 1 5 to 12 3 mpm 023 025 in 0 6 mm 030 in 0 8 mm 035 in 0 9 mm Dimensions Weight A Width 13 1 2 n 343 mm Net Ship B Length 27 in 686 mm 205 lbs 215 lbs C Height 93 kg 98 kg 30 in 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 I a 0 U a 4 V 0 Chart 3 1 Volt Ampere Curves Chart 3 2 Duty Cycle 6 H...

Страница 16: ...DUTY CYCLE RAT INGS will damage the weldIng power source S Do not exceed indicated duty cycles This unit is a single phase constant voltage dc arc weld ing power source and wire feeder system 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...

Страница 17: ... 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 using this welding power source...

Страница 18: ...for supporting the welding power source 2 Shielding gas supply 3 Adequate ventilation and fresh air supply 4 No flammables 5 A clean and dry area 7 Proper airflow around unit a WARNING ELECTRIC SHOCK can kill Do not touch ilve electrical parts Disconnect input power conductors from deenergized supply ilne BEFORE moving weld ing power source FALLING EQUIPMENT can cause serious personal injury and e...

Страница 19: ... 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 source as shown in Figure 4 2 using 1...

Страница 20: ...pment damage Keep cylinders away from any welding or oth 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 Regulator Flowmeter 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...

Страница 21: ...amp handle B Jack Plug Installation Figure 4 6 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 44 mm 3 Place steel tie wire item A Figure 4 ...

Страница 22: ...cedures 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 the gun a...

Страница 23: ...fuse 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 ShIelding 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 flowmeter on the shielding ...

Страница 24: ...ut the hub tension should be sufficient to keep the wire taut and pre vent backlash when the wire feeding ceases If adjust mentis required loosen ortighten the hex nut onthe 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 anddiscon nect input power employing lockout...

Страница 25: ...connect an input white or black con ductor to the ground terminal Do not connect the ground green conductor to an input line 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 Size_ AWG 10...

Страница 26: ... 4 in 6 mm out the gun nozzle If wire feeds more than 1 4 in out nozzle cut wire 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...

Страница 27: ... 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 trip 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 pulsed wire feed operation 1 Continuous Position Placing ...

Страница 28: ...NVIRONMENT 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 K...

Страница 29: ...n 5 5 9 Set a voltage condition with the THICKNESS VOLTS selector plug that is appi priate 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 weld...

Страница 30: ...o lower drive roil 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 parameter...

Страница 31: ...l 2 Shut down welding power source 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 Frequenc...

Страница 32: ...ng the drive roll assembly It is necessary to remove the drive rolls for proper clean ing of the wire grooves see Section 7 2 for removal and installation instructions Use a wire brush to clean rolls 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 GU...

Страница 33: ... Reinstall self locking nut onto drive roll shaft c Adjust horizontal position of lower drive roll 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 dr...

Страница 34: ...MBLY FIgure 7 2 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 turni...

Страница 35: ...olts 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 ove...

Страница 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 51 Replace Si Switch control relay CR1 Replace CR1 No weld output wire feeds THICKNESSNOLTS plug not secure in receptacle Secure conn...

Страница 37: ...ts 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 models with 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 Fact...

Страница 38: ...S _ A C B 5 PLG2 POSITIVE NEGATIVE Circuit Diagram No B 121 827 Diagram 8 1 CIrcuit Diagram For MW 4150 Models AC B POSITIVE NEGATIVE Circuit Diagram No B 137 373 2 3 4 Diagram 8 2 Circuit Diagram For MW 4200 Modeis 113336 Page 30 ...

Страница 39: ...PLG5 Circuit Diagram No A 090 568 A Diagram 8 3 Circuit Diagram For SPW 1 Panel CON T SPOT PULSE 7 B 8 B N PC55 62 56 113 336 Page 31 ...

Страница 40: ...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 6 mm beyond the gun nozzle and placed on the seam before lowering the helmet and pressing the gun trigger TA 057 469 119 The gun can be moved along the seam in a steady movement known as t...

Страница 41: ...nd the gun trig ger is depressed the welding wire feeds through the gun forthe 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 trigger is released The pulse option provid...

Страница 42: ... 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 arcwillbe maintainedforthefull length of time seton 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 bottom s...

Страница 43: ...e 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 1 Inadequate shielding gas coverage Corrective Actions Remove spatter from the gun nozzle Check gas hoses for leaks Eliminate drafts from fans open doors etc blowing into the welding arc Place nozzle 1 4 to 5 1...

Страница 44: ... on the side walis 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 Possible 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 ...

Страница 45: ...ible Causes Corrective Actions 1 lmproper joint preparation Material too thick Joint preparation and design must be adequate to provide access to the bottom of the groove while maintaining proper welding wire extension and arc character istics 2 Heat shrin input too high causing excessive kage and distortion Select lower voltage range and reduce wire speed Increase travel speed G Wavinessof Bead F...

Страница 46: ...ould be cleaned for applying body filler af ter welding is completed 2 Remove damaged metal using hand cutters shears or a power hand grinder equipped with a cutting 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 113 336 Page 38 4 Clamp the new metal in place and prepare to spot weld 5 Place the VOLTA...

Страница 47: ...nel 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 care...

Страница 48: ...I I C SECTION 11 PARTS LIST r E 0 Cl I C U U C LI a 1 Cd C IC CD 1 I 113336 Page 40 ...

Страница 49: ...CREW slftpg type F filh 8 32 1 1 21 026 978 INSULATOR jack plug blk 1 1 22 101 219 PLUG jack 5 8 x 2 5 8 1 1 23 602 178 SCREW set stl sch 250 20 2 2 24 010521 WlRE tiebagi6ga 1 1 25 019 833 STRIP cop 010 x 2 500 x 750 1 1 26 MWG 160 GUN 1 26 MWG 200 GUN 1 27 115522 PANEL side 1 1 122 679 LABEL instruction 1 135 358 LABEL instruction 1 28 089 899 LATCH slide flush style 2 2 Fig 11 8 RUNNING GEAR 1 ...

Страница 50: ...Figure 11 2 Baffle Air w Components 11 _ SC 132 243 7 9 31 17 18 90 Fig 11 3 25 27 11 113 336 Page 42 ...

Страница 51: ...uf 35VDC 6 15 082 902 STRIP mtg center capacitor 1 16 082 875 ANGLE mtg LH capacitor 1 17 CR1 072817 RELAY encI24VACDPDT 1 18 052704 CL1P springmtgresistor 2 19 R5 006 537 RESISTOR WWfxd 12W 51 ohm 1 20 605 741 CLIP mtg resistor 6 21 R3 059642 RESISTOR WWfxd 25W 10 ohm 1 22 038 620 LINK jumper term blk 30A 1 23 TEl 026 189 BLOCK term 30A 3P 1 24 034 260 LINK connecting contactor terminal 2 25 W 03...

Страница 52: ...t No Description Quantity SPRING pressure drive roll GUIDE wire inlet HOUSING drive roll feeder PIN cotter hair 042 x 937 NUT sti slflkg hex thin 312 24 GEAR drive roll V groove 030 035 wire top WASHER flat sti spr 375 INSULATOR motor KEY woodruff 062 x 250 MOTOR gear PM 12V 1 25hp consisting of BRUSH SPRING SCREW SCREW cap stl hex hd slflkg 375 16 WASHER lock sti split 375 WASHER flat stl SAE 375...

Страница 53: ...ntl tooth 750 2 4 605 884 NUT stl hex half 750 16 4 4 C1 4 031 689 CAPACITOR rectifier 4 4 C14 17 031 689 CAPACITOR rectifier 4 5 D1 2 037305 DlODE recti50A300VSP 2 5 D6 8 037 956 DIODE rect 275A 300V SP 2 6 TP3 086 323 THERMOSTAT NO 1 1 7 057 496 BRACKET mtg fan motor 1 7 081 678 BRACKET mtg fan motor 1 8 032 662 BLADE fan lOin 5wg 1 1 9 125947 PANEL rear 1 9 134982 PANEL rear 1 10 605 227 NUT ny...

Страница 54: ... 11 1 14 15 17 2 16 Figure 11 5 Panel Front w Components SC 1 1 148 A 113 336 Page 46 ...

Страница 55: ...o Arc open module 1 13 RC1 048 282 RECEPTACLE W SOCKET consisting of 1 079 534 TERMINAL female lskt 18 14 wire 4 14 Ri 605828 RHEOSTAT WW5OW1 5ohm 1 15 Si 090 328 SWITCH tgl DPST 40A 600VAC 1 16 PL1 048 573 LIGHT md red lens 28V 1 17 023 084 CABLE PLUG jack consisting of 1 17 044 943 CABLE PLUG jack consisting of 1 18 600 318 CABLE weld cop strd No 3 order by ft As Reqd 19 039 878 PLUG jack yellow...

Страница 56: ...W fxd 15W 25 ohm GROMMET scrNo 8 10 HOUSING PLUG SOCKETS consisting of TERMINAL contact hdr24 18 wire HOUSING term header 13 pin TERMINAL contact hdr 24 18 wire CIRCUIT CARD dual timer pulser Fig 11 7 HOUSING PLUG PINS consisting of TERMINAL male 1 pin PANEL spot timer SKP 35 NAMEPLATE order by model serial number KNOB pointer S Figure 11 6 SPW 1 Spot Panel Optional 12 SC 086 924D BE SURE TO PROVI...

Страница 57: ...LAY end 24VDC SPOT SPRING hold down relay SOCKET relay l4skt 1 1 1 D50 54 57 66 026 202 DIODE rect 1A 400V SP 15 056 037 449 DIODE zener 15V 1W SP 1 Q50 51 037 200 TRANSISTOR NPN 200MA 40V 2 Q52 073535 TRANSISTOR NPN 100MA6OV 1 R50 030018 RESISTOR ClW82Oohm 1 R51 035 823 RESISTOR CF 25W 100 ohm 1 R52 71 035884 RESISTOR CF 25WlOOKohm 2 R53 57 61 68 70 039 331 RESISTOR CF 25W 4 7K ohm 5 R54 56 59 60...

Страница 58: ...lunt 1 1 2 in CHAIN weldless 2 0 x 27 in SNAP chain WHEEL rubolene 10 in dia WASHER flat sti SAE 750 RACK cylinder AXLE running gear consisting of RING retaining ext 750 shaft x 082 SCREW cap stl hex hd 312 18 WASHER lock stl split 312 NUT sti hex jam 312 18 CASTER plastic swvl 4 in dia ANGLE spreader cyl rack WASHER lock stl split 375 NUT stl hex jam 375 16 FIgure 11 8 RunnIng Gear BE SURE TO PRO...

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