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1991
FORM:OM-113 336D
May
AUTO
ARCJ~
Effective With Serial
No. KA898403
MODEL: AUTOARCfiMW
4150
AUTOARCfiMW
4200
SPW-1
OWNER S
MANUAL
IMPORTANT: Read and understand the entire contents of this with
manual,
MILLER ELECTRIC Co.
Mfg.
before
on the material the
special emphasis safety throughout manual, AMIerGroupLld..Company
or this This unit and these
installing, operating, maintaining
equipment.
Box 1079
instructions for in the safe
are use trained and WI
only by persons experienced Appleton, 54912
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-~~ ONEYEAR LIMITEDWARRANTY EFFECTIVE: FEBRUARY 1989 17, This all AUTOARC warrantiesand is exclusive with no other orwarranties or warrantysupersedes previous guarantees expressed implied. COVERAGE MILLER Electric Co. warrants to the for the reasonable based Mfg. purchase price (less depreciation who this AUTO ARC Welder for actual return of the at Consumer s risk buyer purchases ( Welder ) upon use) upon goods will or household that this and MILLER s of or be personal, family purposes ( Consu
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ERRATASHEET Afterthis manual refinements in occurred. This sheet lists was printed, equipment design exceptions in this manual. to data later appearing AMENDMENTTO SECTION 7 MAINTENANCE & TROUBLESHOOTING Amend Section 7-lA. ROUTINE MAINTENANCE: Fan Motor This unit is with an exhaust fan and relies on forced draft for The fan motor needs equipped adequate cooling. oiling six months SAE 20 oil. using every
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OM-113 3360 5191 RECEIVING-HANDLING Before check carton for dam- Use equipment, the to record the Model unpacking any following spaces Designa that have occurred File tion and Serial Number of unit. age may during shipment. or The infor any Style your claims for loss or with the carrier. mation card is located on the data or the damage delivering nameplate. Assistance for or claims be obtained filing settling may from the distributor and/or the manufactur- equipment Model ______________________
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No. Section No. Page SECTION 5 OPERATOR CONTROLS 19 5-1. Power Switch And Pilot Light Volts Selector 19 5-2. Thickness 5-3. Fine Wire Control 20 Tuning Speed 20 5-4. Fan-On-Demand~ 20 5-5. Panel Controls Optional Spot/Pulse SECTION 6 SEQUENCE OF OPERATION 6-1. Gas Metal Arc And Gas Metal Arc Welding (GMAW)-Continuous Arc 21 (GMAW-P) Welding-Pulsed 6-2. Gas Metal Arc With (GMAW)-Spot (Models Optional Welding SPW-1 Panel 22 Only) 6-3. Down 23 Shutting SECTION 7 MAINTENANCE & TROUBLESHOOTING 24 7
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Section No. No. Page SECTION 11 PARTS LIST 11-1. Main Figure 42 Assembly 11-2. Air Figure Baffle, w/Components 44 11-3. Drive Wire Figure Assembly, 46 11-4. Rear Figure Panel, w/Components 47 11-5. Front Figure Panel, w/Components 48 11-6. SPW 1 Panel Figure Spot (Optional) 50 11-7. Circuit Dual Figure Card, Timer/Pulser P050 51 11-8. Gear Figure Running 52 LIST OF CHARTS AND TABLES Table 3-1. Specifications 7 Chart 3-1. Curves Volt-Ampere 7 Chart 3-2. Duty Cycle 7 Table 4-1. Conductor And Fus
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SECTION 1 SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1. INTRODUCTION or to the welding cutting, (and chipping) protect eyes from radiant and metal. cover energy flying Replace We learn by experience. Learning safety through per when broken, or See 1 -3A.2. glass pitted, spattered. sonal like experience, a child a hot stove is touching harmful, wasteful, and unwise. Letthe ofoth Avoid or A them. experience oily clothing. spark ignite greasy may ers teach you. Hot metal such as ele
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minute amounts of in A6.O. atmospheres even ment as recommended below containing Waterfilling just or level substitute for trichloroethylene perchioroethylene. inerting. working may C. Fire and Prevention A container with unknown contents should be cleaned Explosion DoNOT on sense of (see preceding paragraph). depend Causes of fire and are: combustibles reached explosion smell to determine if it is safe to weld cut. or or sight the hot heated mate by arc, flame, flying sparks, or slag Hollow or
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Prohibited use. Never its use a or contents for outlet from and of cylinder people sources away ignition. Wipe other than its intended NEVER as a with use, or a clean lintless cloth. support roller. Match to Before check regulator cylinder. connecting, Locate or secure so cannot be knocked cylinders they that the label and cylinder and regulator marking area, over. thatthe inletand outlet match.NEVER regulator cylinder CONNECT a for a particular or regulator designed gas and work Passageways are
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1-3. ARC WELDING the weld. Provide face shields for all Viewing persons at who will be the weld. looking directly with in and this precautions 1-1, 1-2, section. Comply Others in area. See that all are Arc is a safe but a working persons wearing Welding, done, properly process, flash careless invites trouble. The carries goggles. operator equipment The is currents at arc high significant voltages. very that Before to weld, make sure screen flaps or starting and hot. fumes rise, ultraviolet and i
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6. ANSI Standard Z49.2, FIRE PREVENTION IN from the Gas Association, 1235 Jef Compressed THE AND USE OF CUTTING WELDINGPROC ferson Davis Suite VA 501, Highway, Arlington, ESSES obtainable from the American 22202. National Standards 1430 New Institute, Broadway, York, 12. CSA Standard CODE FOR SAFETY IN W117.2, NY 10018. WELDING AND CUTTING obtainable from the 7. AWS Standard WELDING A6.0, AND CUTTING Canadian Standards Standards Association, CONTAINERS WHICH HAVE HELD COMBUS 178 Rexdale Sales, B
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HOT current fa used with electrically by stray shock, possibly sources shielded may Welding power DoNOTGROUND tally. to electrical conduit, or to a metal arc and similar pipe welding (SMAW) proc ANY flammable such oil fuel. be with carrying or as or esses not gas liquid may equipped welding power on-off control devices. With such output equip Three-phase connection. Check of phase requirements the electrode is ment HOTwhen the electrically before If equipment is installing. only 3-phase power sw
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SECTION 3 SPECIFICATIONS Table 3-1. SpecificatIons Rated At Rated Load Input Output M Control Electrode Electrode 60 Hz Single-Phase Circuit Wire Wire Ci~cuit Feed At ~ Voltage Diameter Amperes e At Gun Voltag Speed Capability Duty Cycle 200V 230V 460V 575V kva kw 150 60to486 24 Amperes .023/.025 in. (0.6 mm) ipm 26.5 24 At 32 12 9.6 5.5 4.8 Volts in. .030 (0.8 mm) to 12.3 (1.5 DC 23Volts .035 in. (0.9 mm) mpm) DC Dimensions Weight A: Width Net 13-1/2 in. Ship mm) (343 B: Length in. 27 (686 mm)
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3-1. VOLT-AMPERE CURVES 3-3. DESCRIPTION (Chart 3-1) unit This is a constant dc arcweld single-phase voltage RATED OUTPUT and wirefeeder This unit isde source (~3* ing power system. Metal for Gas Arc with short signed Welding (GMAW) circuit transfer. It is for or use as The spray designed primarily curves show the volt-ampere and voltage amper a dc Electrode Positive/Reverse machine. Polarity of the unit. and age output capabilities Voltage amper Rated weld is 150 23 volts dc, at 60% output ampe
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3-5. ADDITIONAL REQUIRED EQUIPMENT C. Gas Hose (Fig ure 3-3) Measure distance from to cylinder gas welding power in. source. Obtain 5/8 outside di The additional good quality (16 mm) to the Gas equipment required complete S.A.E. and install ameter, hose, 5/8-18 Metal Arc be obtained from gas right-hand can Welding (GMAW) setup thread on both ends of hose. local fittings distributor. your welding supplies D. Wire ForGMAW Process Spool A. Gas Cylinder Selection of the correct wire is in Gas weldin
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3-6. OPTIONAL EQUIPMENT 3-7. CONSUMABLE PARTS The can be obtained to extend the following equipment The are towear or in nor following parts subject damage of the basic unit suit capabilities or to special applica mal use: tions: A. SPW-1, Pulse, Continuous Panel Spot, (in A. Contact tubes cludes three installation spot nozzles) (for see Section 4-4) B. Nozzles B. Spool gun C. Gun liner C. Gun cable holder D. ft. 25 cord extension. D. Drive rolls. (7.6 m) power SECTION RELOCATION 4 INSTALLATION
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4-3. RUNNINGGEAR INSTALLATION 5. Install rack (Figure 4-2) onto source cylinder welding power base 5/16-18 x 3/4 screws and asso using cap WARNING: UNCONTROLLED TILTING OR ciated hardware (see Figure 4-2). TIPPING of unit in can result a personal injury or equipment damage. 6. Removethetwo front in screws of cap top welding Use of to liftthe source and discard. Install equipment power run adequate capacity wrapper unit. handle onto 1/4-20 x 3/4 ning gear wrapper using in screws as shown 4-2.
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IMPORTANT: SPW- 1 Panel will PRESSURIZEDCYLINDERS not WARNING: can Spot provide spot serious and for the Retain all hardware rupture causing personal injury capabilities Spool re a gun. loss of FALLING CYLINDERS can cause life; moved this for reinstallation. Alldirec during procedure serious and injury equipment damage. such as left or are with to the tions, right, respect opera- front for the facing panel. from other Keep or cylinders away welding electrical circuits. 1. Remove module cover f
