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Summary of Contents for Miller Auto Arc 160
- Page 1 OM-187 924B August 1998 Processes MIG (GMAW) Flux Cored (FCAW) Description Wire Feeder Auto Arc 160 For Technical Support, Contact: Milweld Inc., National Distributor P.O. Box 338, Hortonville, WI 54944-0338 Tel 920-779-0924 Fax 920-779-0924...
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Page 3: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _nd_5/97 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Y Marks a special safety message. - Page 4 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.
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Page 5: Principal Safety Standards
1-3. Additional Symbols for Installation, Operation, and Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables. -
Page 6: Emf Information
1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them. Electric And Magnetic Fields 2. Arrange cables to one side and away from the operator. Welding current, as it flows through welding cables, will cause electro- magnetic fields. - Page 7 SECTION 1. CONSIGNES DE SECURITE − LIRE AVANT UTILISATION som _nd_Fre_4/97 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. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...
- Page 8 LES RAYONS DE L’ARC peuvent pro- LES ACCUMULATIONS DE GAZ ris- voquer des brûlures dans les yeux et quent de provoquer des blessures ou sur la peau. même la mort. Le rayonnement de l’arc du procédé de soudage D Fermer l’alimentation du gaz protecteur en cas de génère des rayons visibles et invisibles intenses non utilisation.
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Page 9: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU DES ORGANES MOBILES peuvent D’EXPLOSION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou à proxi- D Rester à l’écart des organes mobiles comme le mité... -
Page 10: Principales Normes De Sécurité
Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel- Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, ding Society, 550 N.W. Lejeune Rd, Miami FL 33126 de la Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202. -
Page 11: Section 2 − Specifications
SECTION 2 − SPECIFICATIONS 2-1. Specifications Amperes Input at Maximum Open- Rated Welding Amperage Rated Load Output Weight Overall Circuit Voltage Output Range W/ Gun Dimensions 230 V, 60 Hz, Single-Phase Length: 17 in (432 mm) 130 A @ 20 Volts 4.49 3.83 80 lb... -
Page 12: Duty Cycle And Overheating
2-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. -
Page 13: Section 3 − Installation
SECTION 3 − INSTALLATION 3-1. Installing Work Clamp Insulator Bolt Smaller Hole Work Clamp Tabs Bend tabs around work cable. Work Cable From Unit Tools Needed: 3/8, 7/16 in Ref. ST-025 190-D 3-2. Installing Welding Gun And Changing Polarity Drive Assembly Gun Securing Bolt Gun End Loosen securing bolt. -
Page 14: Installing Gas Supply
3-3. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other station- Tools Needed: ary support so cylinder cannot fall and break off valve. 5/8, 1-1/8 in Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. -
Page 15: Selecting A Location And Connecting Input Power
3-4. Electrical Service Guide Input Voltage Input Amperes At Rated Output 19.4 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) 66 (20) Min Grounding Conductor Size In AWG/Kcmil Reference: 1996 National Electrical Code (NEC) S-0092-J 3-5. -
Page 16: Installing Wire Spool And Adjusting Hub Tension
3-6. Installing Wire Spool And Adjusting Hub Tension 1 Lb Wire Spool Standard Wire Spool Standard Wire Reel Part No. 135 615 Part No. 183 312 When a slight force is needed to turn spool, tension is set. Tools Needed: 15/16 in S-0499 OM-187 924 Page 14... -
Page 17: Installing Drive Roll, Wire Guide And Threading Welding Wire
3-7. Installing Drive Roll, Wire Guide And Threading Welding Wire Tools Needed: Drive roll Choose correct drive roll for wire type, and align drive roll with flat spot on shaft. Slide drive roll onto shaft and secure with screw. Inlet Wire Guide Remove guide by pressing on barbed area or cutting off one end near housing and pulling it out of... -
Page 18: Weld Parameter
3-8. Weld Parameter Material Thickness Wire Type Wire Type, Wire Wire Operator Shielding Gas, Diameter 1/4 in 3/16 in 1/8 in Controls And Flow Rate (inch) (6.4 (4.8 (3.2 14 ga 16 ga 18 ga 20 ga 22 ga Voltage Tap* −−... -
Page 19: Section 4 − Operation
SECTION 4 − OPERATION 4-1. Controls Wire Speed Control Use control to select a wire feed speed. As Voltage switch setting in- creases, wire speed range also in- creases (see weld setting label in welding power source). Voltage Switch The higher the selected number, the thicker the material that can be welded (see weld setting label in welding power source). -
Page 20: Section 5 − Maintenance &Troubleshooting
SECTION 5 − MAINTENANCE &TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Repair or Clean unreadable replace tighten weld labels. cracked terminals. weld cable. 6 Months Blow out or vacuum inside. during heavy service, clean monthly. 5-2. -
Page 21: Cleaning Or Repairing Drive Assembly
5-4. Cleaning Or Repairing Drive Assembly Y Turn power before Tools Needed: cleaning or repairing drive assembly. Wire Spool Nozzle Cut welding wire off at nozzle. Re- tract wire onto spool and secure. Pressure Roll Arm Cotter Pin Screw Bearing Remove bearing. -
Page 22: Cleaning Or Replacing Gun Liner
5-6. Cleaning Or Replacing Gun Liner Tools Needed: Y Disconnect gun from unit. 3/8 in Head Tube 3/8 in Remove nozzle, contact tip, and liner collet. 3/8 in Remove liner. To Reassemble Gun: Install contact tip. Lay gun cable out straight before installing new liner. -
Page 23: Troubleshooting Table
5-7. Troubleshooting Table Trouble Remedy Secure power cord plug in receptacle (see Section 3-5). No weld output; wire does not feed; fan does not run does not run. Replace building line fuse or reset circuit breaker if open (see Section 3-5). Secure gun trigger plug in receptacle (see Section 3-2). -
Page 24: Section 6 − Electrical Diagram
SECTION 6 − ELECTRICAL DIAGRAM SB-210 034 Figure 6-1. Circuit Diagram OM-187 924 Page 22... -
Page 25: Section 7 − Mig Welding (Gmaw) Guidelines
SECTION 7 − MIG WELDING (GMAW) GUIDELINES 7-1. Typical MIG Process Connections 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. Regulator/ Flowmeter Wire Feeder/... -
Page 26: 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. 1/8 or Convert Material .125 in Thickness to... -
Page 27: 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. Hold Gun and Control Gun Trigger Workpiece... -
Page 28: 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. ° Push ° Perpendicular Drag GUN ANGLES AND WELD BEAD PROFILES Short Normal Long... -
Page 29: 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. Stringer Bead − Steady Movement Along Seam Weave Bead −... -
Page 30: Troubleshooting − Excessive Spatter
7-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long. -
Page 31: Troubleshooting − Lack Of Penetration
7-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics. -
Page 32: Troubleshooting − Waviness Of Bead
7-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand. -
Page 33: 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 34: Section 8 − Parts List
SECTION 8 − PARTS LIST Hardware is common and not available unless listed. ST-801 996 Figure 8-1.Complete Assembly OM-187 924 Page 32... - Page 35 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Complete Assembly ....126 838 DRIVE ASSEMBLY, wire (consisting of) .......
- Page 36 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Complete Assembly ....026 843 INSULATOR, vinyl ..........
- Page 37 Item Part Description Quantity Figure 8-2. Complete Assembly ♦121 934 ... TIP, contact .035 (10 pack) ......... . . ♦112 746 .
- Page 38 Notes...
- Page 39 Warranty Effective January 1, 1998 (Equipment with a serial number preface of “KJ” or newer) This limited warranty supersedes all previous manufacturers Limited Warranty shall not apply to: warranties and is exclusive with no other guarantees or Items furnished by manufacturer, but manufactured by warranties expressed or implied.
- Page 40 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number 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: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment...
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