Milweld Auto Arc XLT 165, XLT 135 Owner's Manual
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Milweld Auto Arc XLT 165, XLT 135 Owner's Manual

Arc welding power source and wire feeder
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Auto Arc XLT 135 / 165
For Warranty Claims And Technical Support, Contact:
Milweld Inc., National Distributor
P.O. Box 338, Hortonville, WI 54944-0338
Tel 920-779-0916 Fax 920-779-0924
OM-198 076A
April 2000
Processes
Description
Arc Welding Power Source And
Wire Feeder
R
MIG (GMAW) Welding
Flux Cored (FCAW) Welding

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Summary of Contents for Milweld Auto Arc XLT 165, XLT 135

  • Page 1 Auto Arc XLT 135 / 165 For Warranty Claims And Technical Support, Contact: Milweld Inc., National Distributor P.O. Box 338, Hortonville, WI 54944-0338 Tel 920-779-0916 Fax 920-779-0924 OM-198 076A April 2000 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder...

  • Page 3: Table Of Contents

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage 1-2. Arc Welding Hazards 1-3. Additional Symbols For Installation, Operation, And Maintenance 1-4. Principal Safety Standards WARNING 1-5. EMF Information SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT UTILISATION This product, when used 1-1.

  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. 1-2.
  • Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.

  • Page 8: Emf Information

    1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon committee of the National Research Council concluded that: “The body of evidence, in the committee’...

  • Page 9: Section 1 − Consignes De Securite − Lire Avant Utilisation

    SECTION 1 − CONSIGNES DE SECURITE − LIRE AVANT 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. Signifie NOTA ;...
  • Page 10 LES RAYONS DE L’ARC peuvent pro- voquer des brûlures dans les yeux et sur la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. D Ne pas placer l’appareil sur, au-dessus ou à proxi- mité de surfaces infllammables. D Ne pas installer l’appareil à proximité de produits inflammables D Ne pas surcharger l’installation électrique −...

  • Page 12: Principales Normes De Sécurité

    1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

  • Page 13: Section 2 − Specifications

    SECTION 2 − SPECIFICATIONS 2-1. Specifications A. 115 VAC Model Rated Welding Amperage Output Range 90 A @ 19 Volts DC, 20% Duty Cycle 30 − 135 63 A @ 21 Volts DC, 20% Duty Cycle* Solid/ Stainless Wire Type .023 −...

  • Page 14: Duty Cycle And Overheating

    2-2. Duty Cycle And Overheating A. 115 VAC Model 2 Minutes Welding B. 230 VAC Model 3 Minutes Welding Overheating OM-198 076 Page 10 Duty Cycle % 20% duty cycle at 90 amps 8 Minutes Resting 70 80 Duty Cycle % 30% duty cycle at 130 amps, 60 Hz 20% duty cycle at 130 amps, 50 Hz 7 Minutes Resting...

  • Page 15: Volt-Ampere Curves

    2-3. Volt-Ampere Curves A. 115 VAC Model 30.0 25.0 20.0 15.0 10.0 B. 230 VAC Model 30.0 25.0 20.0 15.0 10.0 Range 4 Range 3 Range 2 Range 1 100 110 120 130 140 150 160 LOAD AMPS 100 110 120 130 140 150 160 170 180 190 200 LOAD AMPS The volt-ampere curves show the minimum and maximum voltage...

  • Page 16: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Installing Welding Gun 3-2. Installing Work Clamp Tools Needed: 3/8, 7/16 in OM-198 076 Page 12 Drive Assembly Gun Securing Thumbscrew Gun End Loosen thumbscrew. Insert gun end through opening until it bottoms against drive assembly. Tighten thumbscrew.

  • Page 17: Process/Polarity Table

    3-3. Process/Polarity Table Process Process GMAW − Solid wire with shield- DCEP − Reverse polarity ing gas FCAW − Self-shielding wire − DCEN − Straight Polarity no shielding gas 3-4. Changing Polarity Polarity Polarity Cable To Gun Connect to positive (+) out- put terminal Connect to negative (−) output terminal...

  • Page 18: Installing Gas Supply

    3-5. Installing Gas Supply OM-198 076 Page 14 Tools Needed: 5/8, 1-1/8 in Argon Gas Obtain gas cylinder and chain to running gear, wall, or other station- ary support so cylinder cannot fall and break off valve. Cylinder Valve Remove cap, stand to side of valve, and open valve slightly.

  • Page 19: Selecting A Location And Connecting Input Power For 115 Vac Model

    3-6. Selecting A Location And Connecting Input Power For 115 VAC Model 18 in (460 mm) Rating Label Grounded Receptacle A 115 volt, 20 ampere individual 18 in branch circuit protected by time-de- (460 mm) lay fuses or circuit breaker is re- quired.

  • Page 20: Selecting A Location And Connecting Input Power For 230 Vac Model

    3-7. Selecting A Location And Connecting Input Power For 230 VAC Model 18 in (457 mm) of space for airflow Y Always connect grounding conductor first. = GND/PE OM-198 076 Page 16 Y Do not move or operate unit where it could tip. Rating Label Supply correct input power.

  • Page 21: Electrical Service Guide For 230 Vac Model

    3-8. Electrical Service Guide For 230 VAC Model Input Voltage Input Amperes At Rated Output Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes Min Input Conductor Size In AWG/Kcmil Max Recommended Input Conductor Length In Feet (Meters) Min Grounding Conductor Size In AWG/Kcmil Reference: 1996 National Electrical Code (NEC) 3-9.

  • Page 22: Threading Welding Wire

    3-10. Threading Welding Wire Tools Needed: Open pressure assembly. Tighten Close and tighten pressure assembly, and let go of wire. Press gun trigger until wire comes out of gun. OM-198 076 Page 18 Hold wire tightly to keep it from unraveling. 6 in (150 mm) Pull and hold wire;...

  • Page 23: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Controls Voltage Switch The higher the selected number, the thicker the material that can be welded (see weld setting label in welding power source or Sections 4-2 and 4-3, as applicable). Do not switch under load. Voltage Switch - Purge “0”...

  • Page 24: Weld Parameters For 115 Vac Model

    4-2. Weld Parameters For 115 VAC Model 196 052 OM-198 076 Page 20...

  • Page 25: Weld Parameters For 230 Vac Model

    4-3. Weld Parameters For 230 VAC Model 196 081-A OM-198 076 Page 21...

  • Page 26: Section 5 − Maintenance &Troubleshooting

    SECTION 5 − MAINTENANCE &TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. 5-2. Overload Protection 5-3. Drive Motor Protection Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, release gun trigger and wait until protection circuit resets allowing drive motor to feed wire again.

  • Page 27: Changing Drive Roll Or Wire Inlet Guide

    5-4. Changing Drive Roll Or Wire Inlet Guide Tools Needed: 5-5. Replacing Gun Contact Tip Tools Needed: Inlet Wire Guide Securing Screw Inlet Wire Guide Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. Drive Roll The drive roll consists of two differ- ent sized grooves.

  • Page 28: Cleaning Or Replacing Gun Liner

    5-6. Cleaning Or Replacing Gun Liner Head Tube Lay gun cable out straight before installing new liner. OM-198 076 Page 24 Y Disconnect gun from unit. Remove nozzle, contact tip, adapter, gas diffuser, and wire outlet guide. 8 mm Blow out gun casing. Tools Needed: 8 mm / 10mm 10 mm...

  • Page 29: Replacing Switch And/Or Head Tube

    5-7. Replacing Switch And/Or Head Tube Remove handle locking nut. Secure head tube in vice. Loosen jam nut. Remove from vice and turn head tube out by hand. Hand-tighten head tube into cable connector. Tools Needed: 19 mm Y Turn Off welding power source /wire feeder and disconnect gun.

  • Page 30: Troubleshooting Table

    5-8. Troubleshooting Table Trouble Secure power cord plug in receptacle (see Section 3-6). No weld output; wire does not feed; fan does not run does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 4-1). Reset welding power source circuit breaker if open.

  • Page 31: Section 6 − Electrical Diagram

    SECTION 6 − ELECTRICAL DIAGRAM 194 324 Figure 6-1. Circuit Diagram For 115 VAC Model OM-198 076 Page 27...
  • Page 32 194 325 Figure 6-2. Circuit Diagram For 230 VAC Model OM-198 076 Page 28...

  • Page 33: Section 7 − Mig Welding (Gmaw) Guidelines

    SECTION 7 − MIG WELDING (GMAW) GUIDELINES 7-1. Typical MIG Process Connections Regulator/ Flowmeter Shielding Gas Wire Feeder/ Power Source Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.

  • Page 34: Typical Mig Process Control Settings

    7-2. Typical MIG Process Control Settings NOTE These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. .035 in Wire Recommendation Size...

  • Page 35: Holding And Positioning Welding Gun

    7-3. Holding And Positioning Welding Gun NOTE Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. End View Of Work Angle End View Of Work Angle 0 -15...

  • Page 36: Conditions That Affect Weld Bead Shape

    7-4. Conditions That Affect Weld Bead Shape NOTE Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. Short Short FILLET WELD ELECTRODE EXTENSIONS (STICKOUT) Slow OM-198 076 Page 32 Push...

  • Page 37: Gun Movement During Welding

    7-5. Gun Movement During Welding NOTE Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. 7-6. Poor Weld Bead Characteristics 7-7.

  • Page 38: Troubleshooting − Excessive Spatter

    7-8. Troubleshooting − Excessive Spatter Possible Causes Wire feed speed too high. Voltage too high. Electrode extension (stickout) too long. Workpiece dirty. Insufficient shielding gas at welding arc. Dirty welding wire. 7-9. Troubleshooting − Porosity Possible Causes Insufficient shielding gas at welding arc. Wrong gas.

  • Page 39: Troubleshooting − Lack Of Penetration

    7-11. Troubleshooting − Lack Of Penetration Lack of Penetration Good Penetration Possible Causes Improper joint preparation. Improper weld technique. Insufficient heat input. 7-12. Troubleshooting − Incomplete Fusion Possible Causes Workpiece dirty. Insufficient heat input. Improper welding technique. 7-13. Troubleshooting − Burn-Through Possible Causes Excessive heat input.

  • Page 40: Troubleshooting − Waviness Of Bead

    7-14. Troubleshooting − Waviness Of Bead Possible Causes Welding wire extends too far out of nozzle. Unsteady hand. 7-15. Troubleshooting − Distortion Base metal moves in the direction of the weld bead. Possible Causes Excessive heat input. OM-198 076 Page 36 Waviness Of Bead −...

  • Page 41: Common Mig Shielding Gases

    7-16. Common MIG Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table.

  • Page 42: Section 8 − Parts List

    SECTION 8 − PARTS LIST Hardware is common and not available unless listed. 802 449-A Figure 8-1. Main Assembly OM-198 076 Page 38...
  • Page 43 Item Dia. Part Mkgs..... . 195 999 ..... 196 000 .
  • Page 44 Item Dia. Part Mkgs..... . 111 443 ..... 116 996 .
  • Page 45 Item Part 042 053 ..... 130 789 ....130 792 .
  • Page 46 Notes...

  • Page 47: Warranty

    Warranty Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, warrants to its original retail purchaser that new equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is...

  • Page 48: Owner's Record

    Owner’s Record Please complete and retain with your personal records. Model Name Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Resources Available Always provide Model Name and Serial/Style Number. Contact your Distributor for: Contact the Delivering Carrier for: For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department.

This manual is also suitable for:

Xlt 135, xlt 165Auto arc xlt 165, auto arc xlt 135

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