Miller Electric AUTO ARC TIG 50A Specifications

AUTOARCJ~May1991FORM:OM-113336DEffectiveWithSerialNo.KA898403MODEL:AUTOARCfiMW4150AUTOARCfiMW4200SPW-1OWNERSMANUALIMPORTANT:Readandunderstandtheentirec

atmospherescontainingevenminuteamountsoftrichloroethyleneorperchioroethylene.C.FireandExplosionPreventionCausesoffireandexplosionare:combustiblesreach

Prohibiteduse.Neveruseacylinderoritscontentsforotherthanitsintendeduse,NEVERas asupportorroller.Locateorsecurecylinderssotheycannotbeknockedover.Passa

1-3.ARCWELDINGComplywithprecautionsin1-1, 1-2,andthissection.ArcWelding,properlydone,isasafeprocess,butacarelessoperatorinvitestrouble.Theequipmentcar

6.ANSIStandardZ49.2,FIREPREVENTIONINTHEUSEOFCUTTINGANDWELDINGPROCESSESobtainablefromtheAmericanNationalStandardsInstitute,1430Broadway,NewYork,NY10018

electricallyHOTbystraycurrentmayshock,possiblyfatally.DoNOTGROUNDtoelectricalconduit,ortoapipecarryingANYgasorflammableliquidsuchasoilorfuel.Three-pha

SECTION3SPECIFICATIONSTable3-1.SpecificatIonsRated~DutyCycleMCi~cuitInputAtRatedLoadOutput60HzSingle-PhasekwControlCircuitVoltageAtGunElectrodeWireFe

3-1.VOLT-AMPERECURVES(Chart3-1)3-3.DESCRIPTION(~3*RATEDOUTPUTThevolt-amperecurvesshowthevoltageandamperageoutputcapabilitiesoftheunit.Voltageandampera

3-5.ADDITIONALREQUIREDEQUIPMENT(Figure3-3)TheadditionalequipmentrequiredtocompletetheGasMetalArcWelding(GMAW)setupcanbeobtainedfromyourlocalweldingsup

3-6.OPTIONALEQUIPMENT3-7.CONSUMABLEPARTSThefollowingequipmentcanbeobtainedtoextendthecapabilitiesofthebasicunitortosuitspecialapplications:A.SPW-1,Spo

4-3.RUNNINGGEARINSTALLATION(Figure4-2)aWARNING:UNCONTROLLEDTILTINGORTIPPINGofunitcanresultinpersonalinjuryorequipmentdamage.Useequipmentofadequatecap

-~~ONEYEARLIMITEDWARRANTYEFFECTIVE:FEBRUARY17,1989ThiswarrantysupersedesallpreviousAUTOARCwarrantiesandisexclusivewithnootherguaranteesorwarrantiesexp

IMPORTANT:SPW-1SpotPanelwillnotprovidespotcapabilitiesfortheSpoolgun.Retainallhardwareremovedduringthisprocedureforreinstallation.Alldirections,suchas

RegulatorCO2InstallationSB-109492-A6.Slidetheremaininginsulatingsleeveovertheotherworkclamphandle.Step3Figure4-5.WorkClampInstallationB.JackPlugInstal

11.Insertthe1/4-20setscrewsintocenterandbot-1.Openaccessdoor.tornholesinjackplug,andtighten(E).2.Loosenthegun/feederconnectorsecuringknob12.Removecabl

HubFigure4-8.WeldingGunConnectionsDriveRollCoverWireOutletGuideHexNutMonocoilLinerFrontPanelOfUnitSpoolGun/FeederConnectorCompressionSpringRetainerRin

B.WeldCableConnectionsInsertSpoolGunweldingcableplugintoPOSITIVE(+)weldoutputreceptaclewithflatsidefacingthereceptaclekey.Rotateplugclockwise1/4turn.C

B.JumperLinkInstallation(Figures4-10And4-11)aWARNING:ReadandfollowsafetyinformationatbeginningofentireSection4-12beforeproceeding.Jumperlinksareusedto

aWARNING:ELECTRICSHOCKcankill.Donotconnectaninput(whiteorblack)conductortothegroundtermmal.Donotconnecttheground(green)conductortoaninputlinetermina

OPTIONALWeldCableSECTION5OPERATORCONTROLSFineTuningWireSpeedControlGunTriggerPowerSwitchFigure5-1.OperatorControls5-1.POWERSWITCHANDPILOTLIGHT(Figur

Arcingcausesthecontactsurfacestobecomepitted.Eventuallycontinuityislostandtheselectorplugnolongerworkstoselectoutputrange.TheTHICKNESSVOLTSselectorjac

SECTION6SEQUENCEOFOPERATIONf%~WARNING:ELECTRICSHOCKcankill;a~MOVINGPARTScancauseseriousinjury;IMPROPERAIRFLOWANDEXPOSURETOENVIRONMENTcandamageinterna

ERRATASHEETAfterthismanualwasprinted,refinementsinequipmentdesignoccurred. Thissheetlistsexceptionstodataappearinglaterinthismanual.AMENDMENTTOSECTION

Table6-1.SuggestedParametersForContinuousGasMetalArcWelding(GMAW)VoltageAdjustmentReceptacle123456MetalThicknessGauges22-1818-1616-1414-1212-1010orHea

b.PlaceSelectorSwitchonoptionalSPW-1panelinCONTINUOUSposition,andsetweldingvoltageandwirefeedspeedparametersaccordingtoSteps8thru15inSection6-1.(Setvo

SECTION7MAINTENANCE&TROUBLESHOOTING7-1.ROUTINEMAINTENANCEIMPORTANT:Everysixmonthsinspectthelabelsonthisunitforlegibility.Allprecautionarylabelsmu

7-2.REPLACINGDRIVEROLLANDWIREINLETGUIDE(Figure7-1)Asaresultofwearorachangeinwiresize,itmaybenecessarytoreplacethedriverollsandwireinletguide.Proceedas

d.Reinstalldriverollcoverandpivotpinintodriverollassembly.e.Reinstallcotterpinontopivotpin.f.Ifinstallingorchanginglowerdriveroll,proceedtoSection7-2B

7-5.INSPECTINGANDREPLACINGMOTORBRUSHES(Figure7-1)WARNING:ELECTRICSHOCKcankill.Donottouchliveelectricalparts.Shutdownweldingpowersource,anddisconnect

B.CircuitBreakerCB2aWARNING:ReadandfollowsafetyinformationatbeginningofentireSection7-6beforeproceeding.CircuitbreakerCB2protectsthe24voltsacwindingof

Table7-2.TroubleshootingTROUBLEPROBABLECAUSEREMEDYNoweldoutput;wiredoesnotfeed.LineDisconnectSwitchinOFFposition.PlaceLineDisconnectSwitchinONposition

Table7.2.Troubleshooting(Continued)TROUBLEPROBABLECAUSEREMEDYNoopen-circuitvoltage.THICKNESSVOLTSplugnotsecureinreceptacle.Securepluginreceptacle.Cont

ACB5C3Diagram8-2.CircuitDiagramForMW4200ModelsOFFTiMEPLO5168f~1~69~SVCONT.<PS5OASPOTPULSE____________________PCircuitDiagramNo.A-ago568-ADiagram8-3

OM113336Page32WiringDiagramNo.C-090711-BDiagram8-4.WiringDiagramForSPW-1PanelRCSE

-~~~~~~~1IIIIIIIICircuitDiagramNo.B-092817-ADiagram8-5.CircuitDiagramForSPW-1PanelDualTimer/PulserBoardPC5OOM.113336Page33

SECTION9WELDINGTECHNIQUES&TROUBLESHOOTINGaCAUTION:WELDINGCURRENTcandamagevehiclecomponentsandotherelectroniccomponents.Disconnectbothbatterycabl

BackhandTechniqueForehandTechniqueFigure9-4.LongitudinalGunPositionsTheverticalupand/orverticaldowntechniquesdescribethedirectionofarctravelwhenthewel

9-3.GASMETALARCWELDING(GMAW)-SPOTInsteadofhavingacontinuousorpulsedweldtojointwopiecesofsheetsteeltogether,weldinginspotof1to1-1/2inches(25-38mm)apart

9-4.PLUGWELDSPlugweldsprovideameansofjoiningtwopiecesofmetalwherethethicknessofthetopsheetisbeyondthenormalrangeoftheweldingpowersourceorwheresheetmet

B.ExcessiveSpatterPossibleCausesCorrectiveActions1.ExcessivespatterwhenusingC02shield-gas.SelectlowervoltagerangeoradjustFINETUNINGWIRESPEEDcontrol.C.

E.ExcessivePenetration(Burn-Through)PossibleCausesCorrectiveActions1.Excessiveheatinput.Selectlowervoltagerangeandreducewirespeed.Increasetravelspeed.

SECTION10AUTOBODYREPAIRAPPLICATIONCAUTION:WELDINGCURRENTcandamagevehiclecomputersandotherelectroniccomponents.Disconnectbothbatterycablesbeforeweldi

04,9C,,1~SECTION11PARTSLIST\\4cOa~~C)(I)(I)(51~U..OM-113336Page42

OM-11333605191RECEIVING-HANDLINGBeforeunpackingequipment,checkcartonforanydam-UsethefollowingspacestorecordtheModelDesignaagethatmayhaveoccurreddurin

3.Ifdoorhasanouterpanelreinforcement,breaktheweld.4.Grindoffthehemflangeandremovetheoldpanel.5.Repairanydamagetotheinnerpanel.6.Positionthenewouterpan

QuantityModelItemDia.PartMWMWNo.Mkgs.No.Description41504200Figure11-1.MainAssembly1115521WRAPPER112008 072HOUSINGPLUG&PINS,(consistingof)11058791.

1011Figure11-2.Baffle,Airw/Components2425SC-1322436311718192021Fig11-31514282711OM-113336Page44

Figure11-2.Baffle,Airw/Components(Fig11-1Item4)058427085980605941057 543057971010191058628057745058428026837044995006393083147082907C60317280829020828

122192Figure11-3.DriveAssembly,Wire(Fig11-2Item30)Figure11-3.DriveAssembly,WireBESURETOPROVIDEMODELANDSERIALNUMBERWHENORDERINGREPLACEMENTPARTS.ItemDia

ItemDia.No.Mkgs.PartNo.QuantityMqdelMWMW41504200BESURETOPROVIDEMODELANDSERIALNUMBERWHENORDERINGREPLACEMENTPARTS.DescriptionFigure11-4.Panel,Rearw/Comp

1213)1415SC-131148-A2Figure11-5.Panel,Frontw/ComponentsOM-113336Page46

ItemDia.PartNo.Mkgs.No.DescriptionQuantityFigure11-5.Panel,Frontw/Components(Fig11-1Item15)1039801RECEPTACLE,jackplugblk(consistingof)11039800RECEPTAC

Figure11-6.SPW1SpotPanel(Optional)Figure11-6.SPWISpotPanel(Optional)BESURETOPROVIDEMODELANDSERIALNUMBERWHENORDERINGREPLACEMENTPARTS.ItemDia.No.Mkgs.Pa

Figure11-7.CircuitCard,DualTlmer/PulserPC5OBESURETOPROVIDEMODELANDSERIALNUMBERWHENORDERINGREPLACEMENTPARTS.Dia.PartMkgs.No.DescriptionQuantityPC5O097

SectionNo.PageNo.SECTION5OPERATORCONTROLS5-1.PowerSwitchAndPilotLight195-2.ThicknessVoltsSelector195-3.FineTuningWireSpeedControl205-4.Fan-On-Demand~

Figure11-8.RunningGearFigure11-8.RunningGearBESURETOPROVIDEMODELANDSERIALNUMBERWHENORDERINGREPLACEMENTPARTS.Dia.Mkgs.PartNo.DescriptionQuantity1108940

I

SectionNo.PageNo.SECTION11PARTSLISTFigure11-1.MainAssembly42Figure11-2.Baffle,Airw/Components44Figure11-3.DriveAssembly,Wire46Figure11-4.Panel,Rearw/

SECTION1SAFETYRULESFOROPERATIONOFARCWELDINGPOWERSOURCE1-1.INTRODUCTIONWelearnbyexperience.Learningsafetythroughpersonalexperience,likeachildtouchinga