AUTO ARCJ September 1990 FORM: OM-112 875D Effective With Serial No. KA870779 MODEL: MW 4110 MW 4230 OWNERS MANUAL IMPORTANT: Read and understand the entire contents of this manual, with special emphasis on the safety material throughout the manual, before Installing, operating, or maintaining this equipment. This unit and these Instructions are for use only by persons trained and experienced in the Safe operation of welding equipment.
ONEYEAR LIMITED WARRANTY EFFECTIVE: FEBRUARY 11, 1989 This warranty supersedes alt previous AUTO ARC warranties and is exclusive with no otherguarantees orwarranties expressed or implied. COVERAGE MILLER Electric Mfg. Co. warrants to the buyer who purchases this AUTO ARC Welder (~WeIder) for personal, family or household purposes (Consumer) that this Welderwill be free from defects in material and workmanship for a peflod of one year from the date of purchase.
OM.1128750-e,gO - RECEIVING-HANDLING Before unpacking equipment, check carton for any damage that may have occurred dunng shipment. File any claims for loss or damage with the delivering carrier. Assistance for filing or settling claims may be obtained frorrt the distributor and/or the equipment manufactur- Use the following spaces to record the Model Designa or Style Number of your unit. The infor is located on the data card or the nameplate.
Page Section No. SECTION 6- SEQUENCE OF OPERATION 6-1. Gas Metal Arc 6-2. Shutting 17 Welding (GMAW) 18 Down SECTION 7- MAINTENANCE & TROUBLESHOOTING 7-1 7-2. 7-3. 7-4. 7-5. 7-6. 7-7. 7-8. 7-9. 7-10. 7-11.
SECTION 1 - SAFETY RULES FOR OPERATION INTRODUCTION 1.1. Safe practices developed from experience in the use of welding and cutting are described in this manual. Re search, development, and field experience have evolved reliable equipment and safe installation, opera tion, and servicing practices. Accidents occur when equipment is improperly used or maintained. The rea son for the safe practices may not always be given. Some are based on common sense, others may require technical volumes to explain.
atmospheres ~,containing even minute trichioroethylene or perchloroØthylene. C. Fire and amounts of Explosion Prevention Causes of fire and explosion are: combustibles reached by the arc, flame, flying sparks, hot slag or heated mate nal; misuse of compressed gases and cylinders; and menfas~ recommended in A6.O. Waterfilling just below working level may substitufe for inerting. A container with unknown contents should be cleaned (see preceding paragraph).
Prohibited use.~Never use a cylinder or its contents ior other than its intended use, NEVER as a support or outlet away from peo.ple and ~with a clean lintless c~om. of sources ignition. Wipe roller. regulator to cylinder. Before connecting, check regulator label and cylinder marking area, and thatthe regulator inlet ~nd cylinderoutlet match. NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas.
ARC WELDING 1-3. .Viewirig the 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 traredenergy radiates, weldments are hot, and com pressed gases may be used. The wise operator avoids unnecessary risks and protects himself and others from accidents.
electrically HOTtiy stray current may shock, possibly fa tally. Do NOT GROUND to electrical conduit, orto 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-phase line.
6. ANSI St~ndard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROC ESSES obtainable from the American National ~rorn the Compressed Gas Association, 1235 Jef ferson Davis Highway, Suite 501, Arlington, VA 22202. Standards Institute, 1430 Broadway, New York, NV 10018. 7. AWS Standard A6.0, WELDING AND CUTTING ~CONTAlNERS WHICH HAVE HELD COMBUS TIBLES obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126. 8.
SECTION 3- SPECIFICATIONS Table 3-1. SpecificatIons Welding Power Source Max. Model Rated Weld Output Open. Circuit Voitage MW 4110 90 Amperes @ 18 Volts DC 20%DutyCycle 30 input At Rated Load Single-Phase Voltage Amperes At At Gun 11SV 230V )(VA 20 10 3 @ 21 Volts DC 30% Duty Cycle Electrode Wire Feed Wire Diameter Speed Capability Weight Net KW 2.2 Ship 70-400 ipm (1.8-10.2mpm) .023 in. 88 lbs. 95 lbs. (0.6mm) (40kg) (43kg) 47-690 ipm (1.2-17.5mpm) .023 thru .035 in.
VOLT-Aii~lPERE 3-1. (3* ~Referio the Duty Cycle Charts (Chart 3-2) to determine the output of the welding power source at various duty cycles. CURV~S (Chart 3-1) RATED OUTPUT The volt-ampere curves show the minimum and maxi mum voltage and amperage output capabilities of the unit ft~om the minimum and maximum FINE TUNING/WIRE SPEED control. settings of the IMPORTANT: Decreasing welding amperes increases DUTY CYCLE welding power duty cycle. CAUTION: EXCEEDING RATINGS will damage a source.
a CAUTION: EXCEEDING THE RATED AM PERAGE WITH CO~ OR FAILING TO RE DUCE THE WELDING AMPERAGE OR DUTY CYCLE WHEN USING A MIXED SHIELDING GAS can result In damage to the gun. The weldi~ig power source is factory equipped with ft. (3 m) input power cord and built-in gas valve. 3-5. ADDITIONAL REQUIRED EQUIPMENT ure Do not exceed rated amperage when using a 10 (Fig 3-3) Co2. Reduce duty cycle ing gases such 3-3. as when using mixed shield carbon dioxide and argon.
D. Spool Of ~Jlre Selection of the correct welding wire is important in Gas Metal Arc Welding (GMAW). There are many types of wire from which to choose, but certain wires are best suited for welding thin gauge sheet steel. The American Welding Society (AWS) classification for GMAW wires is usually indicated on the label of the wire spool. Two AWS wire classes recommended are E7OS-6 and E7OS-3.
SITE SELECTION 4-1. (FIgure 3-1) B. Reguttor/Flowm.eter (Customer Supplied) (Fig. - Select an installation site which ure4-1) provides the following: 1. 1. Correct input power supply (see unit nameplate) 2. Shielding gas supply 3... Adequate ventilation and fresh air With the cylinder securely installed, remove the cylinder cap, stand to one side of cylinder valve, and open valve slightly. When gas flows from cyl inder, close valve.
1. Slide one piece of su~pIied insulating sleeve onto Place work cable inside the handle of the work with the flattest inner surface. Lockout/taggingprocedures consist of removing input power plug from receptacle, padlocking line disconnect switch in open position, remov ing fuses from fuse box, or shutting off and red tagging circuit breaker or other disconnecting Align the smaller hole in the work clamp handle with the hole in the work cable terminal lug.
WELDING GUN INSTALLATION (Figures 4.3 4-5. And a 4-4) WARNING: ELECTRIC SHOCK can kill. GUN receptacle, insert fully clckwise. WELDING 4-6. Do not touch live electrical parts. Shutdown welding powersource, and discon 1. input power employing lockout/tagging procedures before inspecting or installing. Open 2. Remove 3.
The MW 4110 models have a 20% duty cycle (2 minutes of every 10 minutes can be used for welding); therefore, ~a the supplied cord and attached plug comply with NEC standards for 20% duty cycle. Be sure that the building supply and receptacle comply with NEC standards and any additional state and local codes. supply. B. input Conductor ConnectIons For MW 4110 Models MW 4110 models are equipped can kill. Do not touch live, electrical parts.
WELDING WIRE cause can wounds; HOT SURFACES dnv~e rolipressurØ just tightly enough to prevent the wire from slipping on or against drive roll dur ing operation. puncture can cause severe burns. Do not press gun trigger until instructed to do SION Do not point gun toward any part of the body, any conductive surface, or other personnel when threading welding wire. Allow gun to cool before 2. Open install and secure welding Do not touching.
SECTION 5- OPERATOR CONTROLS Fine Tuning/ Wire Speed Control Power Switch Thicknessivoits Switch Gun Switch Gun T8-112 g43-A Receptaci. Figure 5-1. POWER SWITCH 5-1. Operator Controls (Figure 5-1) a POWER Do not can damage contact change position of THICKNESS! welding or under load. VOLTS switch while -e Arcing causes the contacts to become pitted and eventually inoperative. Placing the POWER switch in the ON position energizes the welding power source.
SECTION 6- SEQUENCE OF OPERATION a WARNING: ELECTRIC SHOCK can kill; MOVING PARTS can cause serious Injury; IMPROPER AIRFLOW AND EXPOSURE TO ENVIRONMENT can damage Internal parts. Do not touch live electrical parts. Keep away Keep all operating. from covers 3. Wear 4. Be sure polarity changeover position (see Section 4-4). Select 5. 4-8. Install in panels welding wire and and clothing. links are while place to Section shielding gas according to Section 4-2. Connect work 6.
6-2. SHUTTING DOWN 3. Stop welding. 2. Place POWER switch in OFF Shut off gas position. Table 6-1. Suggested SettIngs MW 4110 Models co2 20cfh+ *AdjuSt +cth = Page Welding GMAW ~_______ 12 ga. 14 ga. 16 ga. 18 ga. 20 ga. 22 ga. 24 ga. Range 4 3 2 2~ 1 1 1 70% 55% 48% 43% 25% 10% 6% 3 3 2 1 1 80% 60% 70% 60% 50% Speed* Range Feed 18 when not in use. Settings Speed* FINE TUNING/WIRE SPEED control as cubic feet per hour OM.
MW 4230 Models Wire Type, Shielding Gas, And Flow Rate Wire )Derator Diameter Control (Inch) - GMAW And FCAW Material Thickness 1/4 In. 3/16 In. 1/8 In. Settings (6.4 mm) (4.8 mm) (3.2 mm) Range 14 ga. 16 ga. 18 ga. 22 ga. 24 ga. 3 2 2 1 1 100% 80% 70% 60% 55% 45% 4 3 2 2 1 1 60% 60% 50% 40% 30% 4 1 .023 Feed ,~. Speed* E7OS-6 Range Co2 4 35% .
SECTION 7- MAINTENANCE & TROUBLESHOOTING ROUTINE MAINTENANCE 7-1 (Table 7-1) IMPORTANT: Ever, 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 outer enclosure, and use a clean, dry airstream or vac uum suction for the cleaning operation. If dusty or dirty conditions C. are present, clean the unit monthly.
OVERI~.OAD PROTECTION 7-2. - Lbckoutitaggingproceduresconsistof removing plug from receptacle, padlocking line disconnect switch in open position, remov ing fuses from fuse box, or shutting off and red tagging circuit breaker or other disconnecting input powr Short Circuit Shutdown A. The unit is protected from damage due to contact tube short by optical coupler OC1 on motor control circuit board PCi. If the contact tube is shorted to the work- piece while welding, device.
REPLACING PRESSURE BEARING 7.4. (Figure Loosen wire 4. inlet.~uide securing screw. 7-1) stall WARNING: ELECTRIC SHOCK can kill. A~ Do not touch live electrical parts. Shutdown we/ding powersource, anddiscon nect input power employing locko uttagging pro cedures before inspecting, maintaining, or serv icing.
- .~Hub Support Standoff Wire Drive Mounting Motor Control Board PCI Wire Drive Motor Ref. SO-log 354-E Figure a 7-2. Motor Control Board PCi WARNING: ELECTRIC SHOCK can kill. Do not touch live electrical parts. 1. Remove wrapper. 2. Remove terminal RC1 on PCi. 3.
3 4 Remove any accumu~ation around the switch. Repair replace or as required all hose and cab 1. Remove nozzle... 2. Cutoff any portion of the electrode wire which tends beyond end of tube. I~ng. give particular attention to frayed and insulation and cracked area where it enters Remove contact tube and 3. equipment. 5 Remove grease and grime from components and new con Replace nozzle, and 4. resume operation. parts and cables.
13. install corftact tube. 14. Reinstall nozzle. 15. Reinstall gun to wire drive 16. Thread welding wire according to Section 4-8, and resume operation. assembly. 7-11~ 1ROUBLESHOOTING (Table 7.2) a WARNING: ELECTRIC SHOCK can kill. Do not touch live electrical parts. Shut down wire feeder and welding power source, and disconnect input power employing before inspecting, lockout/tagging procedures maintaining, or servicing.
Table 7-2. TROUBLE TroubleshootIng REMEDY PROBABLE CAUSE No weld output; wire does not feed. Power cord plug not wall secure in Secure plug in receptacle. receptacle. . Line fuse circuit or breaker Replace line fuse or reset circuit breaker. open. Thermal overload. Allow Gun switch connection not Se- a cooling period (see Section 7-2). Secure gun switch connector in receptacle RC3. cure. open. Replace gun switch switch leads. Power switch S2. Replace S2.
SECTION 8 ELECTRICAL DIAGRAMS Circuit Diagram No. SB-119 059 Diagram 8-1. Circuit Diagram For MW 4110 Models 230 Circuit Diagram No. SB-119 063-C Diagram 8-2.
Circuit Diagram 8-3. Circuit Diagram Diagram For MW 4110 Motor Control Board PCI Circuit Diagram OM-112 875 Page 28 8-4. Circuit Diagram No. SC-i 37 798 Diagram No.
132-B P2 SC-1 9 No. Diagram CORD Wiring Models 41 0 MW For Diagram Wiring 8-5.
74 -C 23 SC-i No. Diagram Wiring Models MW-4230 For Diagram Wiring 8-6.
~SECTION 9 a .- WELDING TECHNIQUES & CAUTION: WELDING CURRENT can dam age vehicle components and other elec tronic ~ seam TROUBLESHOOTING before lowering the helmet and pressing the gun trigger. components. Disconnect both ing on a vehicle. battery cables before weld Place work clamp as close to the weld to avoid long electrical paths. as possible Be sure gun to power source as well as cable connections to work clamp are clean and tight.
Direction of Arc Travel Direction of Arc Tray Backhand Technique Forehand Figure 9-4. LongitudInal Gun 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 extremely important because the arc must be kept on the leading edge of the puddle to ensure cornis Figure 9-2. A. Positions plete weld penetration.
Correct~ve Actions ~..Posslble Causes 1. Remove spatter from the gun Inadequate shieldin g gas coverage. nozzle: Check gas hoses for leaks. Eliminate drafts (from fans, open doors, etc.) blowing into the welding ,.. arc. Place nozzle 114 tO 5/16 in. (6-8 mm) from Increase gas flow to displace all worlcpiece. air from the weld zone. Decrease excessive gas flow to avoid turbulence and the trapment of air in the weld en zone. Hold gun at end of weld until molten metal solidifies.
Corrective Causes Actions Clean weld surfaces of impurities (grease, oil, moisture, rust, paint, dirt, etc.) prior Select to welding. higher voltage range or adjust FINE TUNING/ WIRE SPEED control. When technique. using a weaving technique dwell momentarily on the side walls of the groove. Provide improved Keep access at root of electrode directed at the joints. leading edge of the puddle. Provide proper gun angle (see Section 7.1). FIgure 9-8.
F. Cracks in Weld Metal Possible Causes 1. Corrective Actions Material too thick. Joint improper joint preparation. maintaining preparation and design must be ade the b~):\om of the groove while proper welding wire extension and arc characteris quate to provide access to tics. ~. 2. Heat input shrinkage and too Select lower voltage range and reduce wire speed. high causing excessive distortion. Increase travel speed. G. Wavinessof Bead ~. ~ Figure 9-10.
SECTION 10- AUTO BODY REPAIR APPLICATION a CAUTION: WELDING CURRENT can dam age vehicle computers and other electronic Clamp the new metal in place, 20. and prepare to spot weld. components. Disconnect both battery cables before weld ing on a vehicle. Place work possible to clamp as close to the weld avoid long electrical paths. -Be sure gun to power source connections to work clamp as Place the VOLTAGE ADJUSTMENT switch in the 21. 3 Install the spot nozzle 23.
If door t~s the we(~ 3. an outer panel reinforcement, Grind off the hem flange and 4. remove break the old panel. 5. Repair any damage 6. Position the to the inner panel. .welded ir~ place. Car-and body manufacturers have the panels welded in different places. so it will be necessary inspect the body to detet~nine where the welds are lo cated in each case. After the old panel is removed, the inner panels must be carefully checked, straightened or to replaced. Continuous Seam the end 7.
(I) m C, -l 0 z 28 29 30 -I -I Cl) r Cl) -I 11-3 1 -4 897~B SD-1 2 Fig& 27 26 25 24 23 22 21 ilustraed) 20 19 4230 18 MW Arc (Auto Asembly Main 1 -1.
Quantity Model Item No. Dia. Mkgs. Part No. Description Figure ~2 3 3 110 720 089899 112814 127 738 4 134 464 5 +111 833 6 1 11-1.
Quantity Item No. Model Dia. Mkgs. Part No. Description Figure ~~44 44 PLG1 PLG1 45 46 47 47 48 48 GS1 GS1 Z Z 49 50 Ti 50 Ti 113494 127933 111 443 112 811 116 996 128 751 112 635 123 609 111827 113 515 112 049 123 962 123749 51 52 53 54 54 55 56 57 58 59 59 60 11-1. Main MW 4110 I MW 4230 Assembly (Continued) CORDSET,pwr300Vl4ga3/c7ft CORDSET,pwr300Vl2ga3/c6ft 1 BUSHING, strain relief .240/.510 ID x .
Part Item No. Description No. Figure 1 2 3~ 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 21 22 23 24 25 26 Assembly, Wire 11-1 Item (Fig 15) 126 838 090416 124 817 114 415 111 523 112 031 604 741 010224 058 549 085 242 085 244 090 415 092 237 WIRE DRIVE, 126652 604538 126 653 602 238 KNOB,plstcT2.000lgx.312-18 1 WASHER,flatstlSAE.312 WASHER, flat nyl .312 ID x .625 OD WASHER, fiat-SAE 3/16 WASHER, lock-split No.
SA-137 796 Figure OM-112 875 Page 42 11-3.
Dia. Mkgs; Part No. Quantity Description PCi 137 797 Figure Cl ,2 C3 035 833 097 488 059 122 CAPACITOR, polye film .033uf 100VDC CAPACITOR, cer mono .l5uf 50V CAPACITOR,cerdisc.Oluf500V 2 031 677 000 348 CAPACITOR, tantlm 5.6uf 35VDC CAPACITOR, tantim .47uf 35V CAPACITOR, elctlt 68uf 35VDC CAPACITOR, cerdisc.Oluf 100 VDC CAPACITOR, elctlt luf 5OVDC CAPACITOR, cer disc .O5uf 500VDC RELAY, end 24VDC SPDT 1 DIODE, rect 1A 400V DIODE, zener 18V 1W DIODE,zener4.7V1W DIODE, sig .
SA-137 799 Figure OM-112 875 Page 44 11-4.
Dia. Part Mkgs. No. Pci 137 800 Figure Cl ,2 C3 035 097 059 031 000 CAPACITOR, poiye film .033uf IOOVDC CAPACITOR, cer mono .15u1 50V CAPACITOR, cer disc .01 uf 500V CAPACITOR, elcttt 5.6uf 35V0C CAPACITOR, tantlm .47uf 35V CAPACITOR, elctlt 68uf 35V0C CAPACITOR, cer disc .Oiuf 1000VDC CAPACITOR, elcttt luf 5OVDC CAPACITOR, cer disc .O5uf 500VDC RELAY, end 24VDC SPOT DIODE, rect 1A 400V DIODE, zener 4.7V 1W DIODE, sig .020A 75V FUSE, mintr gI $10 blo 1 2A CLIP, fuse 15A .
9 2 ~-1o 1 1 11 16 17 12 18 19 SC-uo B32-C Figure OM-112 875 Page 46 11-5.
4 2 3 I 1 tern No. Part No. 110 720 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 110793 110 795 110780 110 779 110781 128 878 110782 112 743 112 747 Figure 11-5. Exploded View Of GA-16C Gun 1) 1 2 1 JACKET, head tube ~STOP,nozzle ADAPTER, head tube/nozzle SPRING,nozzle TUBE, contact Auto Arc .024 (.06 mm) NOZZLE, Auto Arc 1/2 ort 110797 112 745 110 784 SLEEVE, rbr LINER, Auto Arc lOft (consisting of) COLLET, liner .023-.030 wire 0-RING, .500 ID x .
