Miller MSW-41 Technical Manual
  1. Manuals
  2. Brands
  3. Miller Manuals
  4. Welding System
  5. MSW-41
  6. Technical manual
Miller MSW-41 Technical Manual

Miller MSW-41 Technical Manual

Portable resistance spotwelders
Hide thumbs Also See for MSW-41:
Table of Contents

Advertisement

Quick Links

Visit our website at
www.MillerWelds.com
MSW-41, MSW-41T, MSW-42, MSW-42T,
LMSW-52, And LMSW-52T
Portable Resistance Spotwelders
TM-716D
2011−03
Eff. w/Style Number HD-6
Processes
Resistance Spot
Welding
Description
File: Resistance
Spot Welding

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the MSW-41 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Miller MSW-41

Summary of Contents for Miller MSW-41

  • Page 1 TM-716D 2011−03 Eff. w/Style Number HD-6 Processes Resistance Spot Welding Description MSW-41, MSW-41T, MSW-42, MSW-42T, LMSW-52, And LMSW-52T Portable Resistance Spotwelders File: Resistance Spot Welding Visit our website at www.MillerWelds.com...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING ......... Symbol Usage .

  • Page 3: Section 1 − Safety Precautions For Servicing

    SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury — read and follow these precautions. Symbol Usage OM-716H - 2011−12, safety_spottm 2010−03 DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.

  • Page 4: California Proposition 65 Warnings

    California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...

  • Page 5: Section 2 − −Introduction

    (20.4 kg) *Based on 10 second time period; means unit can weld for 5 seconds out of each 10 second time period. ** Not recommended for aluminum or copper alloys. Model MSW-41, 41T LMSW-52, 52T 6 in. 12 in. 18 in.
  • Page 6 B. Dressing The Tips Turn off and unplug welder. New Tip Used Tip Requiring Dressing Dressing Method − Keep top diameter same as a new tip. d = <1/8 in. (3.2 mm) diameter for 1.5 kVA models; 5/32 in. (4 mm) for 2.5 kVA models Tools Needed: Notes...

  • Page 7: Installing Or Cleaning Tongs

    3-2. Installing Or Cleaning Tongs Turn off and unplug welder. Be sure tong ends are clean OSHA and/or local codes may require additional guarding to suit the application. corroded before installing. Clean tongs with fine steel wool. Bottom Tong: Bottom Tong Hole In Spatter Guard Bottom Tong Securing Screws Loosen the four screws.

  • Page 8: Adjusting Tong And Hand Lever Pressure

    3-3. Adjusting Tong And Hand Lever Pressure Tools Needed: 9/16, 11/16 in. Ref. 800 156 splash out around the nugget area. To decrease tong pressure, loosen the rear Turn off and unplug welder. If tong pressure is too weak, parts are nut and turn the front nut up to the pivot cast- Excessive tong pressure can dam- loose when the tongs close, severe arc-...

  • Page 9: Installing Handle

    3-4. Installing Handle MSW 41 And 41T Models MSW 52, And 52T Models Tools Needed: Ref. 802 056-A 7/16, 3/8 in. Install handle onto the spot welder as shown Turn off and unplug welder. above. For 52, and 52T Models, install han- Wooden Handle dle onto either side as desired for either right- Handle Bolt...

  • Page 10: Mounting Control Box

    3-5. Mounting Control Box Push-in slots are provided on rear of box for wall mounting if desired. The slots will fit over 1/4 inch hex- head screws. To mount box, pro- ceed as follows: Control Box Push-In Slots (Not Shown) Use slots as template and install screws at desired locations leaving 1/8 inch stickout.

  • Page 11: Connecting Input Power (Non-T Models)

    3-7. Connecting Input Power (Non-T Models) Input power supply wiring and receptacle must meet National Electrical Code and all other code requirements. Operate spot welder from a sepa- rately fused or circuit breaker pro- tected circuit, and use correct size input conductors.

  • Page 12: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Controls (T Models) Spot Weld Timer And Pilot Light Weld time adjusts from 0 to 5 seconds. The pilot light turns on when the weld cycle begins and off when the cycle ends. Hand Lever Use lever to open and close tongs.

  • Page 13: Section 5 − Theory Of Operation

    SECTION 5 − THEORY OF OPERATION Input Power Plug PLG1 Provides connection for line input power. 110 Volts Model With A Timer Power Switch S1 Single-Phase Turns unit On/Off. Line Input Control Transformer T2 Power Input Power (220 V Models) Power Switch Supplies power to spot timer control...
  • Page 14 For Models Without A Timer Single-Phase Input Power Plug Line Input Provides connection for line input Power Input Main power. Start Power Transformer Switch Start Switch S1 Plug Turns weld current On/Off. Main Transformer T1 Supplies power to weld output cir- cuit.

  • Page 15: Section 6 − Troubleshooting

    6-1. Troubleshooting Table See Sections 6-2, 6-3 and 6-4 for test points and val- ues and Section 9 for parts location. Use Miller Testing Booklet (Part No. 150 853) when servicing this unit. See the Miller Extranet for service memos that may aid in the repair of this product.
  • Page 16 Tips arcing on material. Not enough tong pressure. Increase tong pressure. Tips not aligned correctly. Realign tips or dress tips to proper diameter (see Section 3-1). Base material may be welded to tips causing high resistance and poor electrical current flow. Clean or dress tips (see Section 3-1).

  • Page 17: Troubleshooting Circuit Diagram For 1.5 Kva (110 Or 220V) And 2.5 Kva (220V) Models

    6-2. Troubleshooting Circuit Diagram For 1.5 KVA (110 Or 220V) And 2.5 KVA (220V) Models Resistance Values Voltage Readings Tolerance − 10% unless specified Tolerance − 10% unless specified   Turn Off unit and disconnect plug Reference − as indicated before checking resistance Wiring Diagram −...

  • Page 18: Troubleshooting Circuit Diagram For 1.5 Kva, 110 Volts Model

    6-3. Troubleshooting Circuit Diagram For 1.5 KVA, 110 Volts Model Resistance Values Voltage Readings Tolerance − 10% unless specified Tolerance − 10% unless specified   Turn Off unit and disconnect plug Reference − as indicated before checking resistance Wiring Diagram − see Section 8 0.4 ohms 115 volts AC 115 volts AC with S1 closed...

  • Page 19: Troubleshooting Circuit Diagram For 1.5 And 2.5 Kva, 220 Volts Models

    6-4. Troubleshooting Circuit Diagram For 1.5 And 2.5 KVA, 220 Volts Models Voltage Readings Resistance Values Tolerance −  10% unless specified Tolerance − 10% unless specified  Reference − as indicated Turn Off unit and disconnect plug before checking resistance Wiring Diagram −...

  • Page 20: Waveforms For Sections 6-2, 6-3 And

    6-5. Waveforms For Sections 6-2, 6-3 And 6-4 5 ms 2 V 5 ms 2 V A. AC Open-Circuit Voltage For 1.5 KVA B. AC Open-Circuit Voltage For 2.5 KVA Models Model Test Equipment Needed: TM-716 Page 18 MSW And LMSW Series...

  • Page 21: Section 7 − Maintenance

    SECTION 7 − MAINTENANCE 7-1. Routine Maintenance Disconnect power before maintaining. Every Use 3 Months 6 Months Blow Off Vacuum Replace Inspect Unit Unreadable Tips Labels During Heavy Service, Clean Monthly 7-2. Overload Protection For 220 Volts Model Turn Off unit and disconnect input power.

  • Page 22: Section 8 − Electrical Diagrams

    162 466-C MSW-42T & LMSW-52T HD-6 thru JA-40 048 101-A JA-41 and following 072 065-C 162 467-B Figure 8-1. Circuit Diagram For MSW-41, MSW-42, And LMSW-52 Effective With Style No. KD-53 And Following TM-716 Page 20 MSW And LMSW Series...
  • Page 23 162 466-C Figure 8-2. Circuit Diagram For MSW-41T Effective With Style No. HD-6 And Following 048 101-A Figure 8-3. Circuit Diagram For MSW-42T And LMSW-52T Effective With Style No. HD-6 Thru JA-40 MSW And LMSW Series TM-716 Page 21...
  • Page 24 072 065-C Figure 8-4. Circuit Diagram For MSW-42T And LMSW-52T Effective With Style No. JA-41 And Following TM-716 Page 22 MSW And LMSW Series...
  • Page 25 TM-716D 2011−03 Eff. w/Style Number HD-6 Processes Resistance Spot Welding Description MSW-41, MSW-41T, MSW-42, MSW-42T, LMSW-52, And LMSW-52T Portable Resistance Spotwelders Visit our website at www.MillerWelds.com...

  • Page 26: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 145 048-E Figure 9-1. Main Assembly Quantity Model Item Dia. Part Mkgs. Description 41,41T 42,42T 52,52T Figure 9-1. Main Assembly ....019 643 HANDLE, carrying .
  • Page 27 Quantity Model Item Dia. Part Mkgs. Description 41,41T 42,42T 52,52T Figure 9-1. Main Assembly (Continued) ....010 716 CLAMP, connecting top tong braid ....
  • Page 28 Replace Coils At Factory Or Factory Authorized Service Station. Quantity Model Item Part Description 41,41T 42,42T 52,52T 036 825 036 950 036 826 Figure 9-2. Transformer, Power Main (Figure 9-1 Item 38) 095 345 095 350 095 354 ..
  • Page 29 Quantity Model Item Dia. Part Mkgs. Description 115V 230V Figure 9-3. Timer, Spot (230V Illustrated) 041 081 041 082 ......NAMEPLATE, (order by model and style numbers) .
  • Page 30 Chart 9-1. Spot Welder Tips 6” (152 mm) 040 197 3-1/2” (89 mm) Standard Flat 12” (305 mm) 040 198 18” (457 mm) 040 199 STANDARD 040 211 040 212 6” (152 mm) 040 200 3-1/2” (89 mm) Offset 12” (305 mm) 040 201 18”...
  • Page 31 Notes...
  • Page 32 An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA International Headquarters−USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com  ORIGINAL INSTRUCTIONS − PRINTED IN USA 2011 Miller Electric Mfg. Co.

This manual is also suitable for:

Msw-41tMsw-42Msw-42tLmsw-52Lmsw-52t

Table of Contents