Miller Electric AUTO ARC MW 4150 Owner's Manual
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Miller Electric AUTO ARC MW 4150 Owner's Manual

Miller Electric AUTO ARC MW 4150 Owner's Manual

Miller owner's manual arc welding equipment mw 4150, mw 4200, spw-1
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AUTO
ARCJ~
May
1991
FORM:OM-113
336D
Effective With Serial No. KA898403
MODEL: AUTO ARCfi MW
4150
AUTO ARCfi
MW 4200
SPW-1
OWNERS
MANUAL
IMPORTANT: Read
and understand the entire contents
of this
manual,
with
special emphasis
on
the
safety
material
throughout
the
manual,
before
MILLER ELECTRIC
Mfg.
Co.
AMIerGroupLld..Company
installing, operating,
or
maintaining
this
equipment.
This unit and these
instructions
are
for
use
only by
persons trained
and
experienced
in the
safe
Box 1079
Appleton,
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
not
fully
understand these instructions.
SB-087
313D
PRINTED
IN
U.S.A.

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Summary of Contents for Miller Electric AUTO ARC MW 4150

  • Page 1 This unit and these this equipment. in the experienced not allow untrained persons FORM:OM-113 336D MODEL: AUTO ARCfi MW AUTO ARCfi MW 4200 SPW-1 with MILLER ELECTRIC Mfg. before AMIerGroupLld..Company Box 1079 safe Appleton, WI 54912 Install, Tel. 414-734-9821 fully PRINTED 4150 U.S.A.
  • Page 2 ONE YEAR LIMITED WARRANTY This AUTO ARC warranties and is exclusive with warranty supersedes previous COVERAGE MILLER Electric Mfg. buyer purchases this AUTO ARC Welder personal, family household purposes (Consumer) Welderwillbefreefromdefectsinmaterialandworkmanshipfor period year from the date of purchase. only original purchaser of this Welder.
  • Page 3 ERRATA SHEET After this manual refinements printed, data later in this manual. appearing AMENDMENT TO SECTION MAINTENANCE & TROUBLESHOOTING Amend Section 7-lA. ROUTINE MAINTENANCE: Fan Motor exhaust fan and relies This unit is equipped with every six months 20 oil. using occurred.

  • Page 5: Table Of Contents

    Before unpacking equipment, check carton age that may have occurred during shipment. claims for loss with the damage delivering Assistance for filing settling claims may be obtained from the distributor and/or equipment Transportation Department. When information about this requesting provide the Model Description and Serial...
  • Page 6 Frames And Light Control Panel Controls And Gas Metal Arc (GMAW-P) With Optional Motor Brushes Replacement For MW 4150 Models MW 4200 Models For SPW-1 Panel For SPW-1 Panel For SPW-1 Panel Dual Timer/Pulser TROUBLESHOOTING & Continuous Seam Process Welding...
  • Page 7 Section SECTION PARTS LIST Figure 11-1. Main Assembly Figure 11-2. w/Components Baffle, Figure 11-3. Drive Assembly, Wire Figure 11-4. Panel, Rear w/Components Figure 11-5. Panel, Front w/Components Figure 11-6. Spot Panel Figure Circuit 11-7. Card, Dual Figure 11-8. Running Gear LIST OF CHARTS AND TABLES Table 3-1.

  • Page 9: Introduction

    SECTION SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1. INTRODUCTION We learn experience. Learning safety through sonal experience, like child touching harmful, wasteful, and unwise. Let the teach you. Safe practices developed from experience welding cutting described search, development, field evolved reliable...
  • Page 10 atmospheres containing minute even trichloroethylene perchioroethylene. Fire and Explosion Prevention Causes of fire and explosion combustibles reached are: flame, flying sparks, slag arc, misuse of rial; compressed gases short circuits. BE AWARE THAT flying sparks falling slag through cracks, along pipes, through floor through wall...
  • Page 11 Prohibited Never cylinder use. use a other than its intended NEVER use, roller. Locate cylinders they or secure cannot over. Passageways and work Keep cylinders areas. where they may be struck. areas Transporting cylinders. With crane, such platform cradle. Do NOT lift port as a ground by...
  • Page 12 ARC WELDING 1-3. Comply with precautions 1-1, 1-2, Welding, properly done, invites trouble. The careless operator high currents at significant voltages. and hot. Sparks fly, fumes rise, bright frared radiates, weidments energy pressed gases may be used. The wise risks and himself and others from protects unnecessary...

  • Page 13: General Information

    ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROC ESSES obtainable from the American National Standards Institute, 1430 Broadway, 10018. AWS Standard WELDING AND CUTTING A6.0, CONTAINERS WHICH HAVE HELD TIBLES obtainable from the American Society, 550 N.W.

  • Page 14: Safety

    electrically stray current Do NOT GROUND tally. electrical flammable carrying liquid Three-phase connection. Check phase requirements equipment before installing. only 3-phase available, connect single-phase equipment wires of the line. Do NOT 3-phase ment ground lead to the third (live) ment will become HOT-a electrically...

  • Page 15: Volt-Ampere

    Rated At Rated Input 60 Hz Ci~cuit Amperes Voltag Duty Cycle 200V 230V Amperes 26.5 23 Volts Chart 3-1. Volt-Ampere Curves > SECTION SPECIFICATIONS Table 3-1. SpecificatIons Load Output Control Single-Phase Circuit Voltage 460V 575V Volts Dimensions A: Width *Add 2-3/4 ~Add 5 lbs.

  • Page 16: Duty Cycle

    3-1. VOLT-AMPERE CURVES (Chart 3-1) (~3* RATED OUTPUT volt-ampere show the curves output capabilities of the unit. adjustment the FINE TUNING WIRE provided SPEED control. Curves of other setting shown. curves With the of the volt-ampere curves, it is determine the weld amperage age.
  • Page 17 3-5. ADDITIONAL REQUIRED EQUIPMENT 3-3) The additional equipment required Metal Arc Welding (GMAW) setup your local welding supplies distributor. A. Gas Cylinder of gas types generally used with Welding (GMAW) thin gauge sheet steel. Carbon dioxide (002) is the gas recommended for welding source/gun combination.

  • Page 18: Optional Equipment

    OPTIONAL EQUIPMENT 3-6. following equipment be obtained capabilities of the basic unit to suit tions: SPW-1, Continuous Spot, Pulse, cludes three spot nozzles) (for Section 4-4) Spool Gun cable holder 25 ft. (7.6 m) power cord extension. SECTION SITE SELECTION 4-1.
  • Page 19 RUNNING GEAR INSTALLATION 4-3. WARNING: UNCONTROLLED TILTING TIPPING of unit result in equipment damage. equipment adequate capacity unit. using lift forks handle this lift forks long enough to extend out of the opposite side of the base. place part unit while it is suspended.
  • Page 20 IMPORTANT: SPW- Spot Panel will not capabilities for the Spool gun. Retain moved during this procedure for reinstallation. tions, such left with right, respect facing the front panel. Remove module plate cover hand of front panel. corner Locate harness wiring clamped harness from first wiring...
  • Page 21 Regulator Gas Hose Washer Connection Male (5/8.18 Fitting Required) Installation Figure Slide the remaining insulating other work clamp handle. Step Step Step Steps 1 and 5 Clamp Figure 4-5. Work Installation Jack Plug Installation (Figure 4-6) supplied jack plugs used to cables the weld receptacles.
  • Page 22 Insert the 1/4-20 setscrews into center and bot- holes in torn jack plug, tighten (E). Remove cable from vise, and insert insulating sleeve. Slide insulating jack plug and cable until hole in lines up with rernaining hole in Insert the 8-32 self-tapping hole in insulating...
  • Page 23 Drive Roll Cover Wire Outlet Front Panel Guide Of Unit Monocoil Hex Nut Liner Gun/Feeder Connector Spool Compression Spring Retainer Gun/Feeder Ring SA.o72 573.A Connector Securing Knob Spool Installation Gun/Feeder Connector And Wire Figure 4.7. Gun Connections Figure 4-8. Welding OM-113 336 Page...
  • Page 24 Weld Cable Connections Insert Spool welding cable plug weld output receptacle with flat side tacle key. Rotate clockwise 1/4 plug SPOOL GUN Receptacle Connection 4-9) SPOOL A 3-socket SPOOL GUN receptacle making connections between the welding and the Spool Gun. To connect insert gun into...
  • Page 25 Jumper Link Installation (Figures WARNING: Read and follow tion at beginning of entire Section fore proceeding. links Jumper used allow the equipment from different line voltages. jumper attached input terminal board terminal board for the input highest voltage input voltage label.
  • Page 26 WARNING: ELECTRIC SHOCK not connect input (white ductor ground term not connect ground (green) input line terminal. Incorrect input connections electrically energized welding chassis. The ground terminal is connected to welding power source grounding only. purposes L2 Line Conductor Li Line Conductor Wall Receptacle...
  • Page 27 SECTION Cable Weld Spool Receptacle OPTIONAL POWER SWITCH AND PILOT LIGHT 5-1. 5-1) POWER 00FF the POWER switch in the ON Placing welding pilot light source. power whenever the POWER switch is indicates that the unit is receiving input POWER switch Placing in the down the...
  • Page 28 Arcing surfaces contact causes pitted. Eventually continuity plug longer works to select THICKNESS VOLTS selector jack plug tacles provide selection of heat input higher the numbered receptacle, the hotter the weld. IMPORTANT: After installing selector NESS VOLTS receptacle, rotate plug place.
  • Page 29 SECTION WARNING: ELECTRIC SHOCK MOVING PARTS can cause IMPROPER AIRFLOW ENVIRONMENT damage touch live electrical Keep away from moving Keep panels covers operating. Warranty is void if the welding operated with of the portion removed. RAYS, SPARKS, AND HOT SURFACES burn skin;...
  • Page 30 Table 6-1. Suggested Voltage Adjustment Receptacle Gauges Metal Inches Thickness Millimeters *Amperage .030 in. (0.8 mm) Wire *Amperage .035 in. (0.9 mm) Wire obtained *Amperage values by adjusting WARNING: ELECTRIC SHOCK touch live electrical Do nottouch wire orany metal welding contact with it while welding.

  • Page 31: Optional Spw-1

    Place Selector Switch optional CONTINUOUS position, and wire feed speed parameters Steps 8 thru 15 in Section and wire feed for metal thickness of speed ple metal.) IMPORTANT: Use CONTINUOUS adjustment for SPOTmode unit coarse length and weld puddle not be observed with welding nozzle installed...

  • Page 32: Section 7 Maintenance & Troubleshooting

    SECTION 7-1. ROUTINE MAINTENANCE IMPORTANT: six months Every inspect this unit for legibility. precautionary maintained in clearly readable when necessary. See Parts List precautionary labels. WARNING: ELECTRIC SHOCK touch live electrical Shutdown welding powersource, and discon nect input employing lockout/tagging power before procedures...

  • Page 33: Replacing

    7-2. REPLACING DRIVE ROLL AND WIRE GUIDE (Figure 7-1) result of change in wire wear or a replace the drive rolls and wire inlet necessary Proceed follows: WARNING: ELECTRIC SHOCK not touch live electrical Shut down welding powersource, nect input employing lockouVtagging power before...

  • Page 34: Drive Housing Realignment

    Reinstall drive roll cover roll assembly. Reinstall cotter onto pivot pin. installing changing lower drive Section 7-2B; otherwise, spring spring drive roll over close and door. secure access Replacing Lower Drive Roll WARNING: Read and follow tion beginning of entire Section proceeding.

  • Page 35: Inspecting And Replacing

    Retaining Hex Nut Ring Spring Fiber Washer Used With 8 In. (203 mm) Spools. INSPECTING 7-5. REPLACING BRUSHES (Figure 7-1) WARNING: ELECTRIC SHOCK touch live electrical Shutdown welding powersource, and discon nect input employing lockout/tagging power before procedures inspecting, maintaining, servicing.

  • Page 36: Thermal Overload Protection

    Circuit Breaker CB2 WARNING: Read and follow tion beginning of entire Section 7-6 before proceeding. Circuit breaker CB2 the 24 volts protects transformer Ti from overload. CB2 is located under the door. Should CB2 open, the access would open thereby stopping output If CB2 opens, manually...
  • Page 37 TROUBLE No weld wire does not Line Disconnect output; feed. position. Improper nections. Input voltage jumper proper Line Main rectifier SRi (thermal shutdown). leads. POWER Switch No weld wire feeds. THICKNESS VOLTS output; secure Work etc. Contact Low weld output. Input voltage jumper wrong Electrode wire...

  • Page 38: Section 8 Electrical Diagrams

    M. Replace panel circuit board See Section Authorized Service Station. See Section panel circuit board Authorized Service Station. ELECTRICAL DIAGRAMS 8.1. Circuit For MW 4150 Models Diagram REMEDY plug receptacle. Authorized Service Sta nearest Factory Manual. Authorized Service Sta nearest...

  • Page 39: Circuit Diagram

    < PLOP 230V. Diagram 8-2. CONT. SPOT NC55 Diagram Circuit For MW 4200 Models Diagram 68f~1~69 PLO 51 <P S5OA ____________________ Circuit For SPW-i Panel 8-3. Diagram PLG2 POSITIVE NEGATIVE Circuit Diagram No. SB-i 37 Circuit Diagram No. A-ago 568-A OM.113 336 Page...

  • Page 40: Diagram

    RC SE C-090 711-B Wiring Diagram For SPW-1 Panel 8-4. Wiring Diagram Diagram OM113 Page...

  • Page 41: Diagram

    Diagram 8-5. Circuit SPW-1 Panel Dual Timer/Pulser Diagram ~~~~~~~1 Circuit Diagram No. B-092 817-A PC5O Board OM.113 336 Page...

  • Page 42: Section 9 Welding Techniques

    SECTION WELDING TECHNIQUES WELDING CURRENT CAUTION: vehicle components tronic components. Disconnect both battery cables vehicle. on a Place work clamp close electrical possible avoid long sure source as power connections work clamp tight. To be 100 free of risk, percent computer(s) from the vehicle.

  • Page 43: Gas Metal Arc

    Direction of Arc Travel Backhand Technique Figure The vertical up and/or vertical down techniques the direction of travel when the welding in the vertical position. In both of these positioning extremely important because the of the kept leading edge puddle Vertical Figure 9-5.

  • Page 44: Gas Metal Arc

    9-3. GAS METAL ARC WELDING Figure 9-7. Spot Weld Instead of having continuous pulsed pieces of sheet steel together, welding 1-1/2 inches (25-38 mm) apart welding process fuses two spot pieces gether by penetrating entirely through into the other. The spot process is designed...

  • Page 45: Plug Welds

    9-4. PLUG WELDS Plug welds provide joining a means metal where the thickness of the sheet is normal range of the welding power sheet metal sections too thin to welded without pulsed producing distortion throughs. plug weld is made by drilling hole top sheet, the metal sections...
  • Page 46 Excessive Spatter Possible Causes Excessive when C02 shield- spatter using gas. Fusion Incomplete (Lack fusion) Possible Causes Workpiece dirty. Insufficient heat input. Improper welding technique. Lack of Fusion Possible Causes Improper joint preparation. weld Improper technique. Insufficient heat input. OM-113 336 Page Corrective Select...
  • Page 47 Excessive Penetration (Burn-Through) Possible Causes Excessive heat input. Cracks Weld Metal Possible Causes Improper joint preparation. Heat input high causing excessive shrinkage and distortion. Waviness of Bead Possible Causes Welding wire extends Unsteady hand. Humping Possible Causes Excessive heat input. Figure 9-12.

  • Page 48: Section 10 Auto Body Repair Application

    SECTION CAUTION: WELDING CURRENT age vehicle and other electronic computers components. Disconnect both cables before weld battery vehicle. on a Place close work clamp sible avoid electrical long sure power source as connections work clamp tight. To minimize risk, disconnect the from the vehicle.
  • Page 49 OM-113 336 Page SECTION PARTS LIST cOa~~...
  • Page 50 If door has outer panel reinforcement, the weld. Grind off the flange panel. Repair damage to the inner Position the outer panel the end flange the inner over Spot weld outer panel reinforcement panel. Spot weld flange Metal finish exterior surface, paint interior trim and...
  • Page 51 Item Dia. Part Mkgs. Figure WRAPPER 115521 008 072 HOUSING PLUG & 058 791 TERMINAL, PLG2 008 073 HOUSING RECEPTACLES & TERMINAL, 058 972 11-2 BAFFLE, 11-4 PANEL, 039 778 RECEPTACLE, PLG1 023 210 CABLE SKID, 083 175 CLIP, mtg 079 781 RESISTOR, STABILIZER...
  • Page 52 11-3 SC-132 Figure Baffle, w/Components 11-2. OM-113 Page...
  • Page 53 Item Dia. Part Mkgs. Figure RING, 058 427 085 980 NUT, WASHER, 605 941 SPRING, 057 543 057 971 WASHER, 010 191 WASHER, 058628 WASHER, 057 745 SPRING, 058428 HUB, 026 837 INSULATOR, BAFFLE, 044 995 CR2,3 006 393 RELAY, GROMMET, ANGLE, mtg 082 907...
  • Page 54 Item Dia. Part Mkgs. 122 192 Figure SPRING, 057 551 058 549 GUIDE, GUIDE, 087 331 120 370 HOUSING, PIN, 605 525 NUT, GEAR, 057 590 010 929 WASHER, 044 994 INSULATOR, 605 287 KEY, MOTOR, 119 040 130 820 BRUSH &...
  • Page 55 Item Dia. Part Mkgs. Figure 137 914 RECTIFIERiWINDTUNNEL, 137 913 RECTIFIERiWINDTUNNEL, 604515 THERMOSTAT,NC 006 334 THERMOSTAT, D3,4 037 306 D7,9 037 957 605 886 WASHER, 605 884 C1-4 031 689 C14-17 031 689 037 305 D6,8 037 956 086 323 137 912 032 662 BLADE,...
  • Page 56 SC-131 148-A Figure 11-5. Panel, Front w/Components OM-113 336 Page...
  • Page 57 Item Dia. Part Mkgs. Figure RECEPTACLE, 039 801 RECEPTACLE, 039 800 RECEPTACLE, jack 057 608 072 334 091 542 091 541 010 291 604 668 605 787 601 881 NAMEPLATE, +119 543 113 604 LABEL, PANEL, 119 191 073 383 RECEPTACLE, 052 236 PLUG,...
  • Page 58 Item Dia. Part Mkgs. Figure POTENTIOMETER, 028 769 028 770 POTENTIOMETER, 028 768 POTENTIOMETER, SWITCH, rotary 073 914 WASHER, 605 890 RESISTOR, 080 509 GROMMET, PLG51 HOUSING PLUG & 135 560 079 747 TERMINAL, PLG 50 079 798 HOUSING, TERMINAL, PC5O 097 897 CIRCUIT...
  • Page 59 Dia. Part Mkgs. PC5O 097 897 Figure A50,51 009 159 CAPACITOR, 039482 CAPACITOR C51,53,55 032 820 C52,56 073 714 CAPACITOR C54,57,58 073 739 CAPACITOR 090 573 CAPACITOR, CR50 027 810 RELAY, CR51 099 019 RELAY, CR52 099018 RELAY, SPRING, 079 844 091 861 SOCKET, DIODE,...
  • Page 60 Dia. Part Mkgs. Figure 108940 SCREW, 025193 HANDLE, GRIP, 604 423 057478 BRACKET, support CHAIN, 022617 602389 HOOK, 602387 CHAIN, 602384 SNAP, 070 799 WHEEL, 602250 WASHER, 052693 RACK, 052692 AXLE, RING, 601 944 SCREW, 602211 WASHER, 601 869 NUT, stl hex 008999 CASTER, plastic...

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Auto arc mw 4200Spw-1

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