Miller Electric MW 4200 manual

AUTO ARCJ~ May 1991 FORM:OM-113 336D Effective With Serial No. KA898403 MODEL: AUTO ARCfi MW 4150 AUTO ARCfi MW 4200 SPW-1 OWNERS 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, operat[...]

-~ ~ ONE YEAR LIMITED WARRANTY EFFECTIVE: FEBRUARY 17, 1989 This warranty supersedes all previous AUTO ARC warranties and is exclusive with no other guarantees orwarranties expressed or implied. COVERAGE  MILLER Electric Mfg. Co. warrants to the for the purchase price (less reasonable depreciation based buyer who purchases this AUTO ARC Welder ([...]

ERRATA SHEET After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions to data appearing later in this manual. AMENDMENT TO SECTION 7 MAINTENANCE & TROUBLESHOOTING Amend Section 7-lA. ROUTINE MAINTENANCE: Fan Motor This unit is equipped with an exhaust fan and relies on forced draft for adequate coo[...]

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OM-113 3360 5191 RECEIVING-HANDLING Before unpacking equipment, check carton for any dam- Use the following spaces to record the Model Designa age that may have occurred during shipment. File any tion and Serial or Style Number of your unit. The infor claims for loss or damage with the delivering carrier. mation is located on the data card or th[...]

Section No. Page No. SECTION 5OPERATOR CONTROLS 5-1. Power Switch And Pilot Light 19 5-2. Thickness Volts Selector 19 5-3. Fine Tuning Wire Speed Control 20 5-4. Fan-On-Demand~ 20 5-5. Optional Spot/Pulse Panel Controls 20 SECTION 6 SEQUENCE OF OPERATION 6-1. Gas Metal Arc Welding (GMAW)-Continuous And Gas Metal Arc Welding-Pulsed Arc (GMAW-P[...]

Section No. Page No. SECTION 11  PARTS LIST Figure 11-1. Main Assembly 42 Figure 11-2. Baffle, Air w/Components 44 Figure 11-3. Drive Assembly, Wire 46 Figure 11-4. Panel, Rear w/Components 47 Figure 11-5. Panel, Front w/Components 48 Figure 11-6. SPW 1 Spot Panel (Optional) 50 Figure 11-7. Circuit Card, Dual Timer/Pulser P050 51 Figure 11-8. Ru[...]

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SECTION 1  SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE 1-1. INTRODUCTION We learn by experience. Learning safety through per sonal experience, like a child touching a hot stove is harmful, wasteful, and unwise. Let the experience of oth ers teach you. Safe practices developed from experience in the use of welding and cutting are descr[...]

atmospheres containing even minute amounts of trichloroethylene or perchioroethylene. C. Fire and Explosion Prevention Causes of fire and explosion are: combustibles reached by the arc, flame, flying sparks, hot slag or heated mate rial; misuse of compressed gases and cylinders; and short circuits. BE AWARE THAT flying sparks or falling slag can pa[...]

Prohibited use. Never use a cylinder or its contents for other than its intended use, NEVER as a support or roller. Locate or secure cylinders so they cannot be knocked over. Passageways and work areas. Keep cylinders clear of areas where they may be struck. Transporting cylinders. With a crane, use a secure sup port such as a platform or cradle. D[...]

1-3. ARC WELDING Comply with precautions in 1-1, 1-2, and this section. Arc Welding, properly done, is a safe process, but a careless operator invites trouble. The equipment carries high currents at significant voltages. The arc is very bright and hot. Sparks fly, fumes rise, ultraviolet and in frared energy radiates, weidments are hot, and com pre[...]

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROC ESSES obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018. 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUS TIBLES obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126. 8. N[...]

electrically HOT by stray current may shock, possibly fa tally. Do NOT GROUND to electrical conduit, or to a pipe carrying ANY gas or flammable liquid such as oil or fuel. Three-phase connection. Check phase requirements of equipment before installing. If only 3-phase power is available, connect single-phase equipment to only two wires of the 3-pha[...]

SECTION 3 SPECIFICATIONS Table 3-1. SpecificatIons Rated ~ Duty Cycle M Ci~cuit Input At Rated Load Output 60 Hz Single-Phase kw Control Circuit Voltage At Gun Electrode Wire Feed Speed Electrode Wire Diameter Capability Amperes At 230V 460V kva e Voltag 200V 575V 150 Amperes At 23 Volts DC 32 26.5 24 12 9.6 5.5 4.8 24 Volts DC 60to486 ipm (1.5 [...]

3-1. VOLT-AMPERE CURVES (Chart 3-1) 3-3. DESCRIPTION (~3* RATED OUTPUT The volt-ampere curves show the voltage and amper age output capabilities of the unit. Voltage and amper age adjustment is provided by the FINE TUNING WIRE SPEED control. Curves of other setting fall between the curves shown. With the use of the volt-ampere curves, it is possibl[...]

3-5. ADDITIONAL REQUIRED EQUIPMENT (Fig ure 3-3) The additional equipment required to complete the Gas Metal Arc Welding (GMAW) setup can be obtained from your local welding supplies distributor. A. Gas Cylinder Two types of gas are generally used with Gas Metal Arc Welding (GMAW) of thin gauge sheet steel. Carbon dioxide (002) is the gas recommend[...]

3-6. OPTIONAL EQUIPMENT 3-7. CONSUMABLE PARTS The following equipment can be obtained to extend the capabilities of the basic unit or to suit special applica tions: A. SPW-1, Spot, Pulse, Continuous Panel (in cludes three spot nozzles) (for installation see Section 4-4) Spool gun Gun cable holder D. 25 ft. (7.6 m) power cord extension. The followin[...]

4-3. RUNNING GEAR INSTALLATION (Figure 4-2) a WARNING: UNCONTROLLED TILTING OR TIPPING of unit can result in personal injury or equipment damage.  Use equipment of adequate capacity to lift the unit.  If using lift forks to handle this unit, be sure the lift forks are long enough to extend out of the opposite side of the base.  Do not plac[...]

IMPORTANT: SPW- 1 Spot Panel will not provide spot capabilities for the Spool gun. Retain all hardware re moved during this procedure for reinstallation. All direc tions, such as left or right, are with respect to the opera- for facing the front panel. 1. Remove module cover plate from upper right- hand corner of front panel. 2. Locate wiring harne[...]

Regulator CO2 Installation SB-109 492-A 6. Slide the remaining insulating sleeve over the other work clamp handle. Step 3 Figure 4-5. Work Clamp Installation B. Jack Plug Installation (Figure 4-6) 0250 The supplied jack plugs are used to connect the weld cables to the weld output receptacles. Install jack plugs onto weld cables as follows: 1. Remov[...]

11. Insert the 1/4-20 setscrews into center and bot- 1. Open access door. torn holes in jack plug, and tighten (E). 2. Loosen the gun/feeder connector securing knob 12. Remove cable from vise, and insert jack plug into (see Figure 4-7). insulating sleeve. Slide insulating sleeve over jack plug and cable until hole in insulating sleeve IMPORTANT: Wi[...]

Hub Figure 4-8. Welding Gun Connections Drive Roll Cover Wire Outlet Guide Hex Nut Monocoil Liner Front Panel Of Unit Spool Gun/Feeder Connector Compression Spring Retainer Ring Gun/Feeder Connector SA.o72 573.A Securing Knob Figure 4.7. Gun/Feeder Connector And Wire Spool Installation A B C OM-113 336 Page 15[...]

B. Weld Cable Connections Insert Spool Gun welding cable plug into POSITIVE (+) weld output receptacle with flat side facing the recep tacle key. Rotate plug clockwise 1/4 turn. C. SPOOL GUN Receptacle Connection (Figure 4-9) SPOOL GUN A 3-socket SPOOL GUN receptacle RC3 is provided for making connections between the welding power source and the Sp[...]

B. Jumper Link Installation (Figures 4-10 And 4-11) a WARNING: Read and follow safety informa tion at beginning of entire Section 4-12 be fore proceeding. Jumper links are used to allow the equipment to operate from different line voltages. The jumper links may be in a bag attached to the input terminal board or installed on the input terminal boar[...]

a WARNING: ELECTRIC SHOCK can kill.  Do not connect an input (white or black) con ductor to the ground term mal.  Do not connect the ground (green) conductor to an input line terminal. Incorrect input connections can result in an electrically energized welding power source chassis. The ground terminal is connected to the welding power source [...]

 OPTIONAL Weld Cable SECTION 5 OPERATOR CONTROLS Fine Tuning Wire Speed Control Gun Trigger Power Switch Figure 5-1. Operator Controls 5-1. POWER SWITCH AND PILOT LIGHT (Figure 5-1) POWER e 00FF Placing the POWER switch in the ON position energizes the welding power source. The pilot light comes on whenever the POWER switch is in the ON po[...]

Arcing causes the contact surfaces to become pitted. Eventually continuity is lost and the selec tor plug no longer works to select output range. The THICKNESS VOLTS selector jack plug and recep tacles provide a selection of heat input to the weld. The higher the numbered receptacle, the hotter the weld. IMPORTANT: After installing selector plug in[...]

SECTION 6 SEQUENCE OF OPERATION f%~ WARNING: ELECTRIC SHOCK can kill; a~ MOVING PARTS can cause serious injury; IMPROPER AIRFLOW AND EXPOSURE TO ENVIRONMENT can damage internal parts.  Do not touch live electrical parts.  Keep away from moving parts.  Keep all covers and panels in place while operating. Warranty is void if the welding p[...]

Table 6-1. Suggested Parameters For Continuous Gas Metal Arc Welding (GMAW) Voltage Adjustment Receptacle 1 2 3 4 5 6 Metal Thickness Gauges 22-18 18-16 16-14 14-12 12-10 10 or Heavier Inches .035+ .047+ .059+ .067+ .104+ .134+ Millimeters .8+ 1.2+ 1.5+ 1.9+ 2.6+ 3.4+ *Amperage For .030 in. (0.8 mm) Wire 30-55 55-85 85-105 105-130 130-150 150-180 *[...]

b. Place Selector Switch on optional SPW-1 panel in CONTINUOUS position, and set welding volt age and wire feed speed parameters according to Steps 8 thru 15 in Section 6-1. (Set voltage and wire feed speed for metal thickness of sam ple metal.) IMPORTANT: Use in CONTINUOUS position serves as coarse adjustment of unit for SPOTmode operation. Arc le[...]

SECTION 7 MAINTENANCE & TROUBLESHOOTING 7-1. ROUTINE MAINTENANCE IMPORTANT: Every six months inspect the labels on this unit for legibility. All precautionary labels must be maintained in a clearly readable state and replaced when necessary. See Parts List for part number of precautionary labels. a WARNING: ELECTRIC SHOCK can kill.  Do no[...]

7-2. REPLACING DRIVE ROLL AND WIRE INLET GUIDE (Figure 7-1) As a result of wear or a change in wire size, it may be necessary to replace the drive rolls and wire inlet guide. Proceed as follows: a WARNING: ELECTRIC SHOCK can kill.  Do not touch live electrical parts.  Shut down welding powersource, and discon nect input power employing lockou[...]

d. Reinstall drive roll cover and pivot pin into drive roll assembly. e. Reinstall cotter pin onto pivot pin. f. If installing or changing lower drive roll, proceed to Section 7-2B; otherwise, reengage pressure spring over spring pin on drive roll cover, and close and secure access door. B. Replacing Lower Drive Roll a WARNING: Read and follow safe[...]

7-5. INSPECTING AND REPLACING MOTOR BRUSHES (Figure 7-1) WARNING: ELECTRIC SHOCK can kill.  Do not touch live electrical parts.  Shutdown welding powersource, and discon nect input power employing lockout/tagging procedures before inspecting, maintaining, or servicing. Lockout/tagging procedures Consist of removing input power plug from recep[...]

B. Circuit Breaker CB2 a WARNING: Read and follow safety informa tion at beginning of entire Section 7-6 before proceeding. Circuit breaker CB2 protects the 24 volts ac winding of transformer Ti from overload. CB2 is located under the access door. Should CB2 open, the contactor W coil would open thereby stopping all output from the welding power so[...]

Table 7-2. Troubleshooting TROUBLE PROBABLE CAUSE REMEDY No weld output; wire does not feed. Line Disconnect Switch in OFF position. Place Line Disconnect Switch in ON position. . Improper electrical input con- nections. See Section 4-12 for proper input connections. Input voltage jumper links not in proper position. See Section 4-12 for proper jum[...]

Table 7.2. Troubleshooting (Continued) TROUBLE PROBABLE CAUSE REMEDY No open-circuit voltage. THICKNESS VOLTS plug not secure in receptacle. Secure plug in receptacle. Contactor W points. Contact nearest Factory Authorized Service Sta tion. Gun switch. See gun Owners Manual. Transformer Ti. Contact nearest Factory Authorized Service Sta tion. Pl[...]

AC B 5C3 Diagram 8-2. Circuit Diagram For MW 4200 Models OFF Ti ME PLO 51 68f~1~69 ~ S V CONT. <P S5OA SPOT P UL SE ____________________ P Circuit Diagram No. A-ago 568-A Diagram 8-3. Circuit Diagram For SPW-i Panel < SI PLOP 230V. :3 TE I 4 PLG2 POSITIVE NEGATIVE Circuit Diagram No. SB-i 37 373 NC55 56 OM.113 336 Page 31[...]

OM113 336 Page 32 Wiring Diagram No. C-090 711-B Diagram 8-4. Wiring Diagram For SPW-1 Panel RC SE[...]

- ~~~~~~~1 I I I  I I I I I Circuit Diagram No. B-092 817-A Diagram 8-5. Circuit Diagram For SPW-1 Panel Dual Timer/Pulser Board PC5O OM.113 336 Page 33[...]

SECTION 9 WELDING TECHNIQUES & TROUBLESHOOTING a CAUTION: WELDING CURRENT can dam age vehicle components and other elec tronic components.  Disconnect both battery cables before weld ing on a vehicle.  Place work clamp as close to the weld as possible to avoid long electrical paths.  Be sure gun to power source as well as cable conn[...]

Backhand Technique Forehand Technique Figure 9-4. Longitudinal Gun Positions The vertical up and/or vertical down techniques describe the direction of arc travel when the welding must be done in the vertical position. In both of these techniques gun positioning is extremely important because the arc must be kept on the leading edge of the puddle to[...]

9-3. GAS METAL ARC WELDING (GMAW)-SPOT Instead of having a continuous or pulsed weld to join two pieces of sheet steel together, welding in spot of 1 to 1-1/2 inches (25-38 mm) apart can be done. The MIG spot welding process fuses two pieces of sheet steel to gether by penetrating entirely through one of the pieces into the other. The spot process [...]

9-4. PLUG WELDS Plug welds provide a means of joining two pieces of metal where the thickness of the top sheet is beyond the normal range of the welding power source or where sheet metal sections are too thin to be spot welded or pulsed welded without producing distortion or burn throughs. The plug weld is made by drilling or punching a hole in the[...]

B. Excessive Spatter Possible Causes Corrective Actions 1. Excessive spatter when using C02 shield- gas. Select lower voltage range or adjust FINE TUNING WIRE SPEED control. C. Incomplete Fusion (Lack of fusion) Figure 9-10. Incomplete Fusion Possible Causes Corrective Actions 1. Workpiece dirty. Clean weld surfaces of impurities (grease, oil, mois[...]

E. Excessive Penetration (Burn-Through) Possible Causes Corrective Actions 1. Excessive heat input. Select lower voltage range and reduce wire speed. Increase travel speed. F. Cracks in Weld Metal Possible Causes Corrective Actions 1. Improper joint preparation. Material too thick. Joint preparation and design must be ade quate to provide access to[...]

SECTION 10 AUTO BODY REPAIR APPLICATION CAUTION: WELDING CURRENT can dam age vehicle computers and other electronic components.  Disconnect both battery cables before weld ing on a vehicle.  Place work clamp as close to the weld as pos sible to avoid long electrical paths.  Be sure gun to power source as well as cable connections to wor[...]

0 4, 9 C,, 1~ SECTION 11  PARTS LIST 4 cOa~~ C) (I) (I) (5 1~ U.. OM-113 336 Page 42[...]

3. If door has an outer panel reinforcement, break the weld. 4. Grind off the hem flange and remove the old panel. 5. Repair any damage to the inner panel. 6. Position the new outer panel over door and bend the end flange over the inner flange. 7. Spot weld outer panel reinforcement to new door panel. Spot weld new hem flange to inner panel. Metal [...]

Quantity Model Item Dia. Part MW MW No. Mkgs. No. Description 4150 4200 Figure 11-1. Main Assembly 1 115521 WRAPPER 1 1 2 008 072 HOUSING PLUG & PINS, (consisting of) 1 1 058 791 . TERMINAL, male 1 pin 8 8 3 PLG2 008 073 HOUSING RECEPTACLES & SOCKETS, (consisting of) 1 1 058 972 TERMINAL, female iskt 8 8 4 Fig 11-2 BAFFLE, air w/components [...]

10 11 Figure 11-2. Baffle, Air w/Components 24 25    SC-132 243 6 31 17 18 19 20 21 Fig 11-3 15 14 28 27 11 OM-113 336 Page 44[...]

Figure 11-2. Baffle, Air w/Components (Fig 11-1 Item 4) 058 427 085 980 605 941 057 543 057 971 010 191 058628 057 745 058428 026 837 044 995 006 393 083 147 082 907 C6 031 728 082 902 082 875 CR1 072817 052 704 R5 006 537 605 741 R3 059 642 038 620 TEl 026189 034 260 W 035519 024 493 046 685 035 704 083 431 010 145 122 192 031 773 RING, retaining [...]

122 192 Figure 11-3. Drive Assembly, Wire (Fig 11-2 Item 30) Figure 11-3. Drive Assembly, Wire BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. Item Dia. No. Mkgs. Part No. Description Quantity 1 057 551 SPRING, pressure drive roll 1 2 058 549 GUIDE, wire inlet 1/16 1 2 087 331 GUIDE, wire outlet .025 1 3 120 370 HOUSING,[...]

Item Dia. No. Mkgs. Part No. Quantity Mqdel MWMW 4150 4200 BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. Description Figure 11-4. Panel, Rear w/Components (Fig 11-1 Item 5) 1 SRi 137 914 RECTIFIERiWINDTUNNEL, si diode (consisting of) 1 1 SRi 137 913 RECTIFIERiWINDTUNNEL, si diode (consisting of) 1 2 TP1 604515 THERMOST[...]

12 13 ) 14 15 SC-131 148-A 2 Figure 11-5. Panel, Front w/Components OM-113 336 Page 46[...]

Item Dia. Part No. Mkgs. No. Description Quantity Figure 11-5. Panel, Front w/Components (Fig 11-1 Item 15) 1 039 801 RECEPTACLE, jack plug blk (consisting of) 1 1 039 800 RECEPTACLE, jack plug red (consisting of) 1 1 057 608 RECEPTACLE, jack plug yellow (consisting of) 6 2 072 334 . RECEPTACLE & NUT, jack plug yellow 1 3 091 542 RECEPTACLE &am[...]

Figure 11-6. SPW 1 Spot Panel (Optional) Figure 11-6. SPW I Spot Panel (Optional) BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. Item Dia. No. Mkgs. Part No. Description Quantity 1 R50 028 769 POTENTIOMETER, C sltd sft lIT 2W 750K ohm 2 3 R51 R52 028 770 028 768 POTENTIOMETER, C sltd sft l/T 2W 1 meg ohm POTENTIOMETER, [...]

Figure 11-7. Circuit Card, Dual Tlmer/Pulser PC5O BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. Dia. Part Mkgs. No. Description Quantity PC5O 097 897 Figure 11-7. Circuit Card, Dual Timer/Pulser (Fig 11-6 Item 10) A50,51 C50 C51,53,55 C52,56 C54,57,58 C59 CR50 CR51 CR52 D50-53,55,57-66 D56 050,51 Q52 R50 R51 R52,71 R53[...]

Figure 11-8. Running Gear Figure 11-8. Running Gear BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS. Dia. Mkgs. Part No. Description Quantity 1 108940 2 025193 3 604 423 4 057478 5 022617 6 602389 7 602387 8 602384 9 070 799 10 602250 11 052693 12 052692 13 121 614 14 601 944 15 602211 16 601 869 17 008999 18 052691 19 60[...]

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