Miller AUTO ARC 140 Owner's manual

Miller
Brand
Miller
Model
AUTO ARC 140
Category
Welding System
Type
Owner's manual

This manual is also suitable for

AUTO
ARCJ
April
Effec
1995
tive
With
Form:
Serial
No.
OM-151
016A
KD438829
OWNERS~~
MAN
UAL
Auto
Arcfi
140
Read
and
follow
these
instructions
and
all
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Give
this
manual
to
the
operator.
U
For
help,
call
your
distributor
tw
~-.J~
Call
your
distributor
if
you
do
not
understand
the
directions.
j~J
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
CV/DC
Welding
Power
Source/Wire
Feeder
For
OMAW
And
FCAW
Welding
120
Amperes,
21
Volts
At
30%
Duty
Cycle
Uses
230
Volts
AC,
Single-Phase
Input
Power
Feeds
.023
Thru
.035
Wire
Overheating,
Short-Circuit,
And
Motor
Overload
Protection
Includes
Gas
Valve
auto_arc
7193
ST-I
49
628-B
PRINTED
IN
USA
I]
Lu
LIMITED
WARRANTY
Effective
January
1,
1995
(Equipment
with
a
serial
number
preface
of
lCD
or
newer)
1.
Items
furnished
by
manufacturer,
but
manufactured
by
others,
such
as
engines
ortrade
accessories.
These
Items
are
covered
by
the
manufacturers
warranty,
if
any.
Consumable
components;
such
as
contact
tips.
cutting
nozzles,
Contactors
and
relays
or
parts
that
fail
due
to
normal
wear.
Equipment
that
has been
modified
by
any
party
other
than
manufacturer,
or
equipment
that
has
been
improperly
instated,
improperly
operated
or
misused
based
upon
Industry
standards,
or
equlpmenl
which
has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MANUFACTURERS
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPE
RIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT.
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be.
at
manutacturere
option:
(1)
repair~
or(2)
replacement;
or,
where
authorized
in
writing
by
manufacturer
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replacement
stan
authorized
service
station;
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
retum
of
the
goods
at
customers
risk
and
expense,
manufacturers
option
of
repair
or
replace
ment
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
F.O.B.
Stan
authorized
ser
vice
facility
as
determined
by
manufacturer.
Therefore
no
compensation
or
reim
bursement
for
transportation
costs
of
any
kind
will
be
allowed.
TO
ThE
EXTENT
PERMITTED
BY
LAW.
ThE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MANUFAC
TURER
BE
UABLE
FOR
DIRECT,
INDIRECT.
SPECIAL,
INCIDENTAL
OR
CON
SEQUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CONTRACT,
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE.
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION.
MIGHTARISE
BY
IMPLICATION.
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING.
IN
CLUDING
ANY
IMPUED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MANUFACTURER
IS
EXCLUDED
AND
DISCLAIMED
BY
MAN
UFACTURER.
Some
stales
In
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consequential
damages.
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
prpvides
spa-
cit
Ic
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
state
to
stale.
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
other
than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
and
exclusions
set
out
above
may
not
apply.
This
Umtted
,/s~
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
J~.Xvarv
from
orovince
to
orovlnce.
This
limited
warranty
supersedes
all
previous
manufacturers
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
betow,
warrants
to
its
*
Remote
Controls
original
retail
purchaser
that
new
equipment
sold
after
the
effective
date
of
this
lim-
Accessory
Kits
lied
warranty
is
tree
of
defects
in
material
and
workmanship
at
the
time
his
shipped
from
lactory.
THIS
WARRANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WAR-
ep
acement
arts
RANTIES.
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MER
CHANTABILITY
AND
FITNESS.
Limited
Warranty
shall
not
apply
to.
Within
the
warranty
periods
iisted
below,
manufacturerwill
repair
or
replace
any
war
ranted
parts
or
components
that
tail
due
to
such
detects
in
material
or
workmanship.
Manufacturer
must
be
notified
in
writing
within
thirty
(30)
days
of
such
defect
or
fail
ure,
at
which
time
manufacturer
will
provide
Instructions
on
the
warranty
claim
pro
cedures
to
be
followed.
2.
Manufacturer
shall
honor
warranty
Claims
Ofl
warranted
equipment
listed
below
in
the
event
of
sucfl
a
failure
within
the
warranty
lime
periods.
All
warranty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retaii
purchaser,
or
one
year
after
the
equipment
is
sent
to
a
North
American
distributor
or
eighteen
months
after
the
equipment
Is
sent
to
an
International
distributor.
1.
5
Years
Parts
-
3
Years
Labor
*
Original
main
power
rectifiers
2.
3
Years
Partsan~Labr
*
Translormer/Rectifier
Power
Sources
-
Plasma
Arc
Cutting
Power
Sources
Semi-Automatic
and
Automatic
Wire
Feeders
-
Robots
3.
2
Years
Parts
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
Air
Compressors
4.
1
Year
Parts
and
Labor
Motor
Driven
Guns
Process
Controllers
*
IHPS
Power
Sources
Water
Coolant
Systems
HF
Units
Grids
Spot
Welders
Load
Banks
SDX
Transformers
Running
Gear/Trailers
Plasma
Cutting
Torches
(except
APT,
ZIPCUT
&
PLAZCUT
Models)
Tecumseh
Engines
Deutz
Engines
(outside
North
America)
Field
Options
(NOTE:
Field
options
are
covered
under
the
limited
warranty
for
the
re
Inaining
warranty
period
of
the
product
they
are
installed
in,
or
for
a
mini
mum
of
one
year
whichever
is
greater.)
5.
6
Months
Batteries
8.
90
Days
Parts
and
Labor
MIG
Guns/TIG
Torches
-
APT.
ZIPCLJT
&
PLAXCUT
Model
Plasma
Cuttino
Torches
0
U
4
~
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
or
damage
with
the
delivering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
tating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date
of
Purchase
brand_acct
4/95
ARC
WELDING
SAFETY
PRECAUTIONS
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Arc
rays
from
the
welding
process
produce
intense
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
Read
the
Material
Safety
Data
Sheets
(MSDS5)
and
the
manufacturers
instruction
for
metals,
consumables,
coatings,
and
cleaners.
WELDING
can
cause
fire
or
explosion.
Sparks
and
spatter
fly
off
from
the
welding
arc.
The
flying
sparks
and
hot
metal,
weld
spatter,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
orwelding
wire
to
metal
objects
can
cause
sparks,
overheating,
or
fire.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
U
this
is
not
possible,
tightly
cover
them
with
approved
covers.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
through
small
cracks
and
openings
to
adjacent
areas.
ARC
RAYS
2.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
(see
ANSI
Z49.
1
listed
in
Safety
Standards)
to
protect
your
face
and
eyes
when
welding
or
watching.
3.
Wear
approved
safety
glasses.
Side
shields
recommended.
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
4
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Shielding
gases
used
for
welding
can
displace
air
causing
injury
or
death.
Be
sure
the
breathing
air
is
safe.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
containing
these
elements
can
give
off
toxic
fumes
if
welded.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
6.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
7.
Do
not
weld
on
closed
containers
such
as
tanks
or
drums.
8.
Connect
work
cable
to
the
work
as
close
to
the
welding
area
as
practical
to
prevent
welding
current
from
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
hazards.
a
WARNING
ARC
WELDING
can
be
hazardous.
PROTECT
YOURSELF
AND
OTHERS
FROM
POSSIBLE
SERIOUS
INJURY
OR
DEATH.
KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY
UNTIL
CONSULTING
YOUR
DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that
will
be
found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
AND
REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
burns.
The
electrode
and
work
circuit
is
electrically
live
whenever
the
output
is
on.
The
input
power
circuit
and
machine
internal
circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live,
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
When
making
input
connections,
attach
proper
grounding
conductor
first.
7.
Turn
off
all
equipment
when
not
in
use.
8.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
9.
Do
not
wrap
cables
around
your
body.
10.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
11.
Do
not
touch
electrode
if
in
contact
with
the
work
or
ground.
12.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
13.
Wear
a
safety
harness
if
working
above
floor
level.
14.
Keep
all
panels
and
covers
securely
in
place.
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
1.
2.
3.
4.
1.
2.
3.
4.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
-
10.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
FLYING
SPARKS
AND
HOT
METAL
can
1.
Wear
approved
face
shield
or
safety
goggles.
Side
shields
cause
injury,
recommended.
Chipping
and
grinding
cause
flying
metal.
As
welds
2.
Wear
proper
body
protection
to
protect
skin.
cool,
they
can
throw
off
slag.
Sri
9/92
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to
treat
them
carefully.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
and
arcs.
2.
Install
and
secure
cylinders
in
an
upright
position
by
chaining
them
to
a
stationary
support
or
equipment
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
5.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
6.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
7.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
8.
Read
and
follow
instructions
on
compressed
gas
cylinders.
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
ENGINES
can
be
hazardous.
1.
Use
equipment
outside
in
open,
well-ventilated
areas.
2.
If
used
in
a
closed
area,
vent
engine
exhaust
outside
and
away
from
any
building
air
intakes.
1.
Stop
engine
before
checking
or
adding
fuel.
2.
Do
not
add
fuel
while
smoking
or
if
unit
is
near
any
sparks
or
open
flames.
3.
Allow
engine
to
cool
before
fueling.
If
possible,
check
and
add
fuel
to
cold
engine
before
beginning
job.
4.
Do
not
overfill
tank
allow
room
for
fuel
to
expand.
5.
Do
not
spill
fuel.
If
fuel
is
spilled,
clean
up
before
starting
pn(,inp
PRINCIPAL
SAFETY
STANDARDS
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superinten
dent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
Ameri
can
Welding
Society
Standard
AWS
F4.
1,
from
American
Welding
So
ciety,
550
N.W.
LeJeune
Rd. Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Pro
tection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
High
way,
Suite
501,
Arlington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Bou
levard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
ForOccupationAndEducationalEyeAndFace
Protec
tion,
ANSI
Standard
Z87.1,
from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
a
WARNING
ENGINE
EXHAUST
GASES
can
kill.
Engines
produce
harmful
exhaust
gases.
ENGINE
FUEL
can
cause
fire
or
explosion.
Engine
fuel
is
highly
flammable.
1.
MOVING
PARTS
can
cause
injury.
Moving
parts,
such
as
fans,
rotors,
and
belts
can
cut
fingers
and
hands
and
catch
loose
clothing,
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
3.
4.
5.
6.
Have
only
qualified
people
remove
guards
or
covers
for
maintenance
and
troubleshooting
as
necessary.
To
prevent
accidental
starting
during
servicing,
disconnect
negative
()
battery
cable
from
battery.
Keep
hands,
hair,
loose
clothing,
and
tools
away
from
moving
parts.
Reinstall
panels
or
guards
and
close
doors
when
servicing
is
2.
Stop
eng
ne
before
installing
or
connecting
unit,
finished
and
before
starting
engine.
SPARKS
can
cause
BATTERY
GASES
1.
Always
wear
a
face
shield
when
working
on
a
battery.
TO
EXPLODE;
BATTERY
ACID
can
burn
eyes
and
skin,
2.
Stop
engine
before
disconnecting
or
connecting
battery
cables.
Batteries
contain
acid
and
generate
explosive
3.
4.
Do
not
allow
tools
to
cause
sparks
when
working
on
a
battery.
Do
not
use
welder
to
charge
batteries
or
jump
start
vehicles.
ases.
5.
Observe
correct
polarity
(+
and
)
on
batteries.
~.
~
2
~-.
STEAM
AND
COOLANT
can
skin.
The
coolant
in
the
r
under
pressure.
PRESSURIZED
burn
face,
eyes,
adiator
can
be
very
h
HOT
and
ot
and
1.
2.
3.
Do
not
remove
radiator
cap
when
engine
is
hot.
Allow
engine
to
cool.
Wear
gloves
and
put
a
rag
over
cap
area
when
removing
cap.
Allow
pressure
to
escape
before
completely
removing
cap.
sri
9/92
Page is loading ...
Page is loading ...
EMF
INFORMATION
TABLE
OF
CONTENTS
SECTION
1
SAFETY
INFORMATION
1
SECTION
2
SPECIFICATIONS
2-1.
Volt-Ampere
Curves
2
2-2.
Duty
Cycle
2
SECTION
3-
INSTALLATION
3-1.
Installing
Work
Clamp
3-2.
Installing
Gas
Supply
3-3.
Gun
Polarity
For
Wire
Type
3-4.
Selecting
A
Location
And
Connecting
Input
Power
3-5.
Installing
Wire
Spool
3-6.
Threading
Welding
Wire
SECTION
4OPERATION
8
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
5-1.
Routine
Maintenance
5-2.
Overload
Protection
5-3.
Cleaning
Or
Repairing
Drive
Assembly
5-4.
Troubleshooting
SECTION
6
ELECTRICAL
DIAGRAMS
14
SECTION
7
WELDING
METHODS
&
TROUBLESHOOTING
7-1.
Flux
Cored
Arc
Welding
(FCAW)
And
Gas
Metal
Arc
Welding
(GMAW)
7-2.
Welding
Troubleshooting
SECTION
8-
PARTS
LIST
Figure
8-1.
Main
Assembly
22
Figure
8-2.
Baffle,
Center
w/Components
24
Figure
8-3.
Drive
Assembly,
Wire
26
OM-151
016A4/95
NOTE
D~
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
The
following
isa
quotation
from
the
General
Conclusions
Section
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
Backg
round
Paper,
OTA-BP-E-53
(Washington,
DC:
U.S.
Govemment
Printing
Office,
May
1989):.
.
.
there
is
now
a
very
large
volume
of
scientific
findings
based
on
experiments
at
the
cellular
level
and
from
studies
with
animals
and
people
which
clearly
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
questions
of
possible
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
or
avoid
potential
risks.
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
procedures:
1.
Keep
cables
close
together
by
twisting
or
taping
them.
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
3.
Do
not
coil
or
drape
cables
around
the
body.
4.
Keep
welding
power
source
and
cables
as
far
away
as
practical.
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
About
Pacemakers:
The
above
procedures
are
among
those
also
normally
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
modlo.1
4/93
3
3
4
5
6
6
11
11
12
13
16
18
Page is loading ...
SECTION
1
SAFETY
IN
FORMATION
Read
all
safety
messages
throughout
this
manual.
Obey
all
safety
messages
to
avoid
injury.
Learn
the
meaning
of
WARNING
and
CAUTION.
Figure
1-1.
Safety
Information
SECTION
2
SPECIFICATIONS
Table
2-1.
Welding
Power
Source
modl.1
2/93
1
2
WY
~~AI~
2
\~
3
ELECTRIC
SHOCK
can
kiII.i
Do
not
touch
live
electrical
parts.
~fl
Disconnect
input
power
before
~
installing
or
servicing.
JJ
/
a
CAUTION
5
MOVING
PARTS
can
injure.
~
I~$lh~~,
S
Keep
away
Iron,
moving
parts.
I
Keep
all
panels
and
covers
closed
I
when
operating.
I
1
Safety
Alert
Symbol
2
Signal
Word
WARNING
means
possible
death
or
serious
injury
can
happen.
CAUTION
means
possible
minor
injury
or
equipment
damage
can
happen.
3
Statement
Of
Hazard
And
Result
~
READ
SAFETY
BLOCKS
at
start
of
______
Section
3-1
before
proceeding.
7H
NOTE
~
4
Safety
Instructions-To
Avoid
Hazard
Turn
Off switch
when
using
high
frequency
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
Read
safety
blocks
for
each
sym
bol
shown.
7
NOTE
Special
instructions
for
best
oper
ation
not
related
to
safety.
Specifications
Type
Of
Output
Rated
Weld
Output
Type
Of
Input
Constant
Voltage/Direct
Current
(CV/DC)
Description
Input
Amperes
At
Rated
Output
KVA/KW
Used
At
Rated
Output
Max.
Open-Circuit
Voltage
Control
Circuit
Voltage
At
Gun
Welding
Processes
120
Amperes,
21
Volts
DC
At
30%
Duty
Cycle
(See
Section
2-2)
Single-Phase;
230
Volts
AC;
60
Hertz
20
Amperes
4.7
kVAJ3.9
kW
32
Volts
DC
24
Volts
DC
Wire
Feed
Speed
Range
Wire
Diameter
Range
Gas
Metal
Arc
Welding
(GMAW)
(Uses
Solid
Hard
Or
Aluminum
Wire
And
External
Shielding
Gas)
Flux
Cored
Arc
Welding
(FCAW)
(Uses
Wire
With
Flux
Inside
And
Requires
No
External
Shielding
Gas)
Input
Power
Cord
With
Plug
Overall
Dimensions
Weight
47
To
690
ipm
(1.2
To
17.5
mpm)
.023
To
.035
in
(0.58
To
0.89
mm)
5ft(1.5m)
Length:
27
in
(686
mm);
Width:
12
in
(305
mm),
Height:
22-1/2
in
(571
mm)
Net:
117
lb
(53
kg);
Ship:
120
lb
(54
kg)
OM-151
016
Page
1
2-1.
Volt-Ampere
Curves
a
CAUTION
EXCEEDING
DUTY
CYCLE
RATINGS
will
damage
unit.
Do
not
exceed
indicated
duty
cycles.
warn7.1
2/92
200
I~0
U,
Ui
~
80
70
60
DUTY
CYCLE
~
sbl.22192SB-124624
Figure
2-2.
Duty
Cycle
Chart
SECTION
3INSTALLATION
Table
3-1.
Items
Included
With
Welding
Power
Source
Item
Quantity
Welding
Gun
Shipped
Set
To
Feed
.030
in
(0
.8
mm)
Wire
1
(See
Gun
Owners
Manual
Form
112
934)
10
ft
(3
m)
Work
Cable
And
Clamp
1
6ft(1.8m)AirHose
j
Contact
Tubes
(3
.023
in,
2
.030
in,
And
3
.035
in)
8
Monocoil
Liner
For
.023
Thru
.030
in
Wire
1
Ui
0
-)
C
>
C
40
30
20
IC
0
The
volt-ampere
curves
show
the
minimum
and
maximum
voltage
and
amperage
output
capabilities
of
the
welding
power
source.
Curves
of
other
settings
fall
between
the
curves
shown.
sSbl.1
10/91
/SB-124
625
SO
00
50
200
250
D.C.
AMPERES
Figure
2-1.
Volt-Ampere
Curves
2-2.
Duty
Cycle
Duty
cycle
is
how
long
the
unit
can
operate
within
a
ten
minute
period
without
causing
overheating
or
damage.
This
unit
is
rated
at
30%
duty
cycle
allowing
welding
3
minutes
out
of
every
10
minutes
at
rated
load.
If
the
welding
amperes
decrease,
the
duty
cycle
increases.
1.5
20
25
30 40
50
60
70
80
90
00
OM-151
016
Page
2
NOTE
~
]
Customer
must
obtain
proper
welding
wire
and
application.
shielding
gas
for
desired
3-1.
Installing
Work
Clamp
1
Insulator
2
Bolt
3
Smaller
Hole
4
Work
Clamp
Tabs
Bend
tabs
around
work
cable.
5
Work
Cable
From
Unit
6
Nut
Tools
Needed:
3/8,7116in
Ref.
ST-025
190.C
Figure
3-1.
Work
Clamp
Installation
3-2.
Installing
Gas
Supply
a
WARNING
.-.
:~
C
YLINDERS
can
explode
if
damaged.
~
~
BUILDUP
OF
SHIELDING
GAS
can
harm
Keep
cylinders
away
from
welding
and
other
~
health
or
kill.
electrical
circuits.
Shut
off
shielding
gas
Supply
when
not
in
use.
Never
touch
cylinder
with
welding
electrode.
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary_support.
wam4.1
9/91
A.
Installing
Safety
Chain
1
Cylinder
Bracket
As
Shipped
2
S-Hook
2
.
Crimp
between
small
hole
in
bracket
and
chain.
3
Chain
4
Snap
Crimp
onto
open
end
of
chain.
5
Cylinder
Bracket
For
Large
Gas
Cylinder
6
Gas
Fitting
Tools
Needed:
ST-160
791
3
Figure
3-2.
Installing
Safety
Chain
OM-151
016
Page
3
B.
Installing
Regulator/Flowmeter
Figure
3-3.
Typical
Regulator/Flowmeter
Installation
3-3.
Gun
Polarity
For
Wire
Type
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
Swami
.1
2/93
1
Polarity
Changeover
Label
2
Polarity
Jumper
Links
Always
read
and
follow
wire
man
ufacturers
recommended
polarity.
There
are
two
jumper
links
(1
set)
across
each
set
of
terminals.
Be
sure
to
move
each
set
of
links
when
changing
polarity.
Close
door.
Ret.
sT-14g631.c
1
2
6
Obtain
gas
cylinder
and
chain
to
running
gear,
wall,
or
other
station
ary
support
so
cylinder
cannot
tall
and
break
off
valve.
1
Cap
2
Cylinder
Valve
Remove
cap,
stand
to
side
of
valve,
and
open
valve
slightly.
Gas
flow
blows
dust
and
dirt
from
valve.
Close
valve.
3
Cylinder
4
Regulator/Flowmeter
Install
so
face
is
vertical.
5
Gas
Hose
Connection
Fitting
has
5/8-18
right-hand
threads.
Install
supplied
air
hose.
6
Flow
Adjust
Typical
flow
rate
is
20
cth
(cubic
feet
per
hour).
Check
wire
man
ufacturers
recommended
flow
rate.
5
OR
4
Argon
Gas
Tools
Needed:
~
1-1/8,5/Sin
7
8
7
CO2
Adapter
8
0-Ring
Install
adapter
with
0-ring
between
regulator/flowmeter
and
CO2
cylinder.
CO2
Gas
ssb3.i
12/92
ST-158
697-A
/
STRAIGHT
I
REVERSE
-
(
:1::)
c<~~~~b
For
Solid
For
Flux
Steel
Or
Cored
Wires
Aluminum
I
POLARITY
POLARITY
Process)
Process)
)GMAW)
OCEN
DCEP
I
(FCAW
~
Wires
GUN
POLARITY
cHANGEovER
Tools
Needed:
~
3/Bin
Figure
3-4.
Gun
Polarity
Jumper
Link
Position
OM-151
016
Page
4
3-4.
S&ecting
A
Location
And
Connecting
Input
Power
a
WARNING
BLOCKED
AIRFLOW
causes
overheating
and
possible
damage
to
unit.
Do
not
block
or
filter
airflow
Warranty
is
void
if
any
type
of
filter
is
used.
swarn3.1
2/93
Table
3-2.
Electrical
Service
Requirements*
Input
Voltage
230
Input
Amperes
At
Rated
Output
20
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes1
30
Input
Conductor
Size
In
AWG/KcmiI2
14
Max
Input
Conductor
Length
In
Feet
(Meters)3
65
(20)
Grounding
Conductor
Size
In
AWG/KcmiI4
14
*
These
values
are
calculated
from
the
1990
edition
of
the
National
Electrical
Code
(NEC).
1
Recommended
fuse
or
circuit
breaker
size
is
that
closest
to
150%
of
rated
input
amperage
of
the
welding
power
source.
Article
630-12(a)
of
NEC
allows
fuse
or
circuit
breaker
sizing
up
to
200%
of
rated
input
amperage.
2
Input
conductor
size
is
for
insulated
copper
wire
with
75C
rating
with
not
more
than
three
single
current-carrying
conductors
in
a
cable
or
raceway
(Table
310-16
of
NEC).
3
Maximum
length
is
to
prevent
more
than
a
3%
voltage
drop
between
service
entrance
and
input
terminals
of
the
welding
power
source
(Articles
210-19(a)
and
215-2(b)
of
NEC).
4
The
grounding
conductor
shall
be
colored
or
identified
as
specified
in
the
NEC.
Grounding
conductor
size
for
copper
wire
is
not
required
to
be
larger
than
input
conductor
(Article
250-95
of
NEC).
S-0092-F
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Oft
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
Have
only
qualified
persons
install
unit.
Installation
must
meet
National
Electrical
Code
and
all
other
codes.
5
7
4
1
18
in
(457
mm)
Open
Space
At
Front
And
Rear
2
Rating
Label
Supply
correct
input
power.
3
230
Volts
AC
Wall
Receptacle
4
Input
Conductors
Select
size
and
length
using
Table
3-2.
Conductor
rating
must
comply
with
national,
state,
and
local
codes.
5
Line
Disconnect
Device
Of
Proper
Rating
Obtain
and
install
switch
and
wall
receptacle.
6
Grounding
Conductor
Select
size
and
length
using
Table
3-2.
Be
sure
grounding
con
ductor
goes
to
an
earth
ground.
Install
and
connect
input
conduc
tors
and
grounding
conductor
in
conduit
or
equivalent
between
wall
receptacle
and
deenergized
line
disconnect
device.
7
Overcurrent
Protection
Select
type
and
size
using
Table
3-2.
Install
into
deenergized
line
disconnect
device
(fused
dis
connect
switch
shown).
Connect
deenergized
supply
con
ductors
to
line
disconnect
device.
8
Input
Power
Plug
Turn
Off
unit
Power
switch,
and
connect
plug
to
wall
receptacle.
Place
line
disconnect
switch
in
On
position
before
using
welding
power
source.
ssb2.2
3/93
ST-149
630-C
.3
Figure
3-5.
Location
And
Input
Power
Connections
OM-151
016
Page
5
3-5.
Installing
Wire
Spool
a
WARNING
ELECTRIC
SHOCK
can
kill.
~
Do
not
touch
live
electrical
parts.
I
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
7
NOTE
if
hub
tension
is
too
tight,
motor
fuse
Fl
can
open
(see
Section
5-2).
If
hub
tension
is
too
loose,
wire
unravels
and
can
become
tangled
inside
unit.
Turn
Off
and
unplug
unit.
1
Wire
Spool
2
Gun
Contact
Tube
If
necessary,
cut
welding
wire
off
at
contact
tube,
and
retract
wire
onto
spool
and
secure.
3
Retaining
Ring
Remove
ring
and
pull
off
spool.
4
Compression
Spring
2
\
~
Compression
spring
is
used
with
8
in
(200
mm)
spools.
5
Hub
6
Slide
spool
onto
hub
so
wire
feeds
off
bottom.
Turn
spool
until
hub
pin
fits
hole
in
back
of
spool.
Reinstall
retaining
ring.
7
Hub
Tension
Nut
Grasp
spool
in
one
hand
and
turn
while
using
a
wrench
to
adjust
hub
tension
nut.
When
a
slight
force
is
needed
to
turn
spool,
tension
is
set.
Tools
Needed:
Thread
welding
wire
(see
Section
3-6).
Close
door.
~:
15/16
in
Ret.
ST-150
193-C
/
SA-072
573.B
Figure
3-6.
Welding
Wire
Spool
Installation
3-6.
Threading
Welding
Wire
a
WARNING
CYLINDERS
can
explode
if
damaged.
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
Never
touch
cylinder
with
welding
electrode.
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
The
welding
wire,
drive
rolls,
drive
assembly,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live
when
welding
or
feeding
wire
using
gun
trigger.
WELDING
WIRE
can
cause
puncture
wounds.
Do
not
press
gun
trigger
until
instruct~d
to
do
so.
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
HOT
SURFACES
can
burn
skin.
Allow
gun
to
cool
before
touching.
Swarfll.1
2/93
!
Swarn2.l
9/91
/
swam5.1
10191
OM-151
016
Page
6
Hold
wire
tightly
to
keep
it
from
unraveling.
1
Wire
Spool
2
Welding
Wire
3
Inlet
Wire
Guide
4
Pressure
Adjustment
Knob
5
Drive
Roll
6
Outlet
Wire
Guide
7
Gun
Conduit
Cable
Lay
gun
cable
out
straight.
Tools
Needed:
Close
and
tighten
pressure
assembly,
and
let
go
of
wire.
Feed
wire
to
check
drive
roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
~I
~ee
S
0
_____
4
in~
(102
mm)
~
Cut
off
wire.
Close
and
latch
door.
Figure
3-7.
Threading
Welding
Wire
23
5
6
Open
pressure
assembly.
Push
wire
thru
guides
into
gun;
continue
to
hold
wire.
ION
POWER
I
OO~I
Pull
and
hold
wire;
cut
offend.
Remove
gun
nozzle
and
contact
tube.
1111
II
Set
switch.
Press
gun
trigger
until
wire
comes
out
of
gun.
Reinstall
contact
tube
and
nozzle.
Ref.
ST-149
632-C/
Ref.
ST-i50
193/
Ref.
ST-i
59272!
S-0627-A
OM-151
Ol6Page7
SECTION
4
OPERATION
a
WARNING
ELECTRIC
SHOCK
can
kill.
Always
wear
dry
insulating
gloves.
Insulate
yourself
from
work
and
ground.
Do
not
touch
live
electrical
parts.
Keep
all
panels
and
covers
securely
in
place
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Ventilate
area,
or
use
breathing
device.
Read
Material
Safety
Data
Sheets
(MSDS5)
and
manufacturers
instructions
for
material
used.
WELDING
can
cause
fire
or
explosion.
Do
not
weld
near
flammable
material.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
Do
not
weld
on
closed
containers.
Allow
work
and
equipment
to
cool
before
handling.
1
Work
Cable
2
Tools
Needed:
~
2
Work
Clamp
Connect
work
clamp
to
a
clean,
paint-free
location
on
workpiece,
as
close
to
weld
area as
possible.
Use
wire
brush
or
sandpaper
to
clean
metal
at
weld
joint
area.
Use
chipping
hammer
to
remove
slag
after
welding.
sb4.l
2)93
Ret.
5T-156
258
Figure
4-2.
W
ork
Clamp
1
Shielding
Gas
Cylinder
2
Valve
3
Gun
Trigger
Open
valve
on
cylinder
just
before
welding.
Gun
trigger
turns
weld
output
and
gas
flow
on
and
off.
Close
valve
on
cylinder
when
fin
ished
welding.
sb5.1
6/92S.0621.C
p
~
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
welding
helmet
with
correct
shade
of
filter.
Wear
correct
eye,
ear,
and
body
protection.
0
0
MOVING
PARTS
can
cause
injury.
Keep
away
from
pinch
points
such
as
drive
rolls.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
~
-
L.~
MAGNETIC
FIELDS
FROM
HIGH
CUR
RENTS
can
affect
pacemaker
operation.
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
opera
tions.
See
Safety
Precautions
at
beginning
of
manual
for
ba
sic
welding
safety
information.
swam6.~
10/91
1
~
2
~
Figure
4-1.
3
~
Safety
Equipment
1
Insulating
Gloves
2
Safety
Glasses
With
Side
Shields
3
Welding
Helmet
Wear
dry
insulating
gloves,
safety
glasses
with
side
shields,
and
a
welding
helmet
with
a
correct
shade
of
filter
(see
ANSI
Z49.1).
sb3.1
10/91
BUILDUP
OF
SHIE
LDING
GAS
can
harm
health
or
kill.
Shut
off
shielding
gas
supply
when
not
in
use.
1~.J
waml.19/91
Figure
4-3.
Shielding
Gas
OM-151
016
Page
8
I
Fine
TuninglWire
Speed
Control
Use
control
to
select
a
wire
feed
speed.
As
ThicknessNoltage
switch
setting
increases,
wire
speed
range
also
increases.
The
numbers
around
the
control
are
not
a
wire
feed
speed
and
are
for
reference
only
(see
Table
4-1).
2
ThicknessNoltage
Switch
Use
switch
to
select
an
arc
voltage.
The
higher
the
selected
number,
the
thicker
the
material
that
can
be
welded
(see
Table
4-1).
3
Power
Switch
Use
switch
to
turn
unit
and
fan
On
and
Off.
a
CAUTION
ARCING
can
damage
switch.
Do
not
change
ThicknessNoltage
switch
position
while
welding.
Arcing
inside
switch
can
damage
contacts,
causing
switch
to
fail.
warn5.I
2/93
Figure
4-4.
Contros
Ret
ST-I
50
092-Al
Ret.
ST-I
58 258
OM-151
OI6Page9
lnstall&
~
Put
On~\\
Turn
On
Do
)
Control
Connect
j
)
Personal
Safety
I
)Equipment
&
Gas
I
)
Set
Controls))
Sample
Weld
For
Production
J
And
Prepare
J
Equipment
J)
Equipment
JJ
(lfApplicable~,/
________________
________________
Ssb4.1
tO/91
Figure
4-5.
Sequence
Of
Operation
For
Hard
And
Flux
Cored
Wires
Install
&
Connec~\~\
Adjust
Hub
~~\
Adjust
Drive
Roi\\
p~~51\~Vu~
On
~
I
Equipment
Using
I
Tension
To
I
J
Pressure
To
I
Put
On
And
Adjust
Gas
Keep
Gun
C
J
Knurled
Groovejj
Minimum
JJ
Minimum
}JSafety
Equipmen~}j
To
30
cfh
Straight
)
Do
Sample
Weld
And
Prepare
For
D)ReadJustContro~
__________________
Welding
Figure
4-6.
Sequence
Of
Operation
For
Aluminum
Welding
Table
4-1.
Suggested
Welding
Settings
Wire
Type,
Shielding
Gas,
And
Flow
Rate
Wire
Diameter
(inch)
Operator
Control
Settings
Material_Thickness
1/4
in
(6.4
mm)
3/16
in
(4.8
mm)
1/8
in
(3.2
mm)
14
ga
16
ga
18
ga
22
ga
24
ga
E7OS-6
CO2
20
cfh+
.023
Voltage
4
3
2
2
1
1
1
Wire
Speed*
100%
80% 70%
60%
55%
45%
35%
.030
Voltage
4
4
3
2
2
1 1
Wire
Speed*
80%
75%
60% 60% 50%
40%
30%
.035
Voltage
4
4
3 2
1 1 1
Wire
Speed*
65%
60%
50%
40%
30%
20%
15%
E7OS-6
75%
Argon
25%
CO2
20
cfh+
.023
Voltage
4
3 2
2
1
1
1
Wire
Speed*
100%
90%
80%
70%
60%
50%
40%
.030
Voltage
4
3 3 2
2
1
1
Wire
Speed*
90%
80%
70%
60%
50%
45%
30%
.035
Voltage
4
3
3
3
2
2
1
Wire
Speed*
75%
70%
60% 50%
40%
33%
25%
E71T-GS
Flux
Core
.030
Voltage
3
3
2
1
1
1
Wire
Speed*
40%
65%
45%
40%
30% 20%
.035
Voltage
3
3
2
1
1
1
Wire
Speed*
60%
50%
40%
30%
20%
10%
ER
308
Stainless
Steel
Tn-Mix
20
cfh+
.023
Voltage
4
4
3
3
3
2
1
Wire
Speed*
100%
100%
90%
85%
75%
70%
60%
.030
Voltage
4
4
3
3
2
2
Wire
Speed*
75%
75%
65%
60% 55%
50%
.035
Voltage
4
4
3
Wire
Speed*
60%
60%
50%
Aluminum
Argon
30
cfh+
.030
Voltage
4
3
3
2
1
1
Wire
Speed*
90%
85%
80% 90% 90%
85%
.035
Voltage
4
4
3
2
2
1
Wire
Speed*
85% 85%
85%
90%
90%
80%
*
Do
not
change
ThicknessNoltage
switch
position
while
welding.
Fine
Tuning/Wire
Speed
value
in
Table
4-1
is
a
starting
value
only,
and
Fine
Tuning/Wire
Speed
control
setting
can
be
fine
tuned
during
welding.
cfh
=
cubic
ft
per
hour
OM-151
016
Page
10
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
__
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting,
maintaining,
or
servicing.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
maintaining
or
servicing.
5-1.
Routine
Maintenance
Turn
Off
all
power
before
maintaining.
3
Months
See
Section
Replace
Unreadable
Labels
~/H~
5-2.
Overload
Protection
Figure
5-1.
Maintenance
Schedule
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
1
Thermostat
TP1
protects
the
unit
from
damage
due
to
overheating.
If
rectifier
SR2
gets
too
hot,
TP1
oper~s
and
weld
output
stops.
The
fan
keeps
running
to
cool
SR2.
Wait
several
minutes
before
trying
to
weld.
Short
Circuit
Shutdown
If
contact
tube
is
shorted
and
sticks
to
workpiece,
the
unit
shuts
down,
but
fan
runs.
To
resume
operation,
release
gun
trigger,
turn
Off
unit,
and
remove
contact
tube
from
workpiece.
Check
contact
tube
and
replace
if
damaged.
Turn
On
unit
to
continue
operation.
MOVING
PARTS
can
cause
Injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
Maintenance
to
be
performed
only
by
qualified
persons.
9warn8.2
2/93
-~
3
Months
Replace
~
Cracked
Parts
Trigger
Cord
Gas
Hose
Gun
Cable
A.
Overheating
OM-151
016
Page
11
C.
Motor
Fuse
Fl
5-3.
Cleaning
Or
Repairing
Drive
Assembly
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
Figure
5-2.
Fuse
Fl
Location
Tools
Needed:
Turn
Off
and
unplug
unit.
I
Wire
Spoof
2
Gun
Contact
Tube
Cut
welding
wire
off
at
contact
tube.
Retract
wire
onto
spool
and
secure.
3
Pressure
Roll
Arm
4
Cotter
Pin
5
Pin
6
Screw
7
Bearing
Remove
bearing
as
shown.
Install
new
bearing
and
secure
with
screw.
Reinstall
arm.
8
Securing
Screw
9
Washers
10
Drive
Roll
Remove
drive
roll
as
shown.
Use
a
wire
brush
to
clean
drive
roll.
Push
drive
roll
onto
shaft
and
secure
with
washers
and
screw.
11
Wire
Inlet
Guide
Remove
guide
by
pressing
on
barbed
area
or
cutting
oft
one
end
near
housing
and
pulling
it
out
of
hole.
Push
new
guide
into
hole
from
rear
until
it
snaps
in
place.
Thread
welding
wire
(see
Section
3-6).
Close
door.
Ret.
ST-150
193-c
I
ST-i
55
578
Figure
5-3.
Removing
Drive
Roll,
Drive
Bearing,
And
Wire
Inlet
Guide
OM-151
Ol6Pagel2
5-4.
Troubleshooting
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting,
maintaining,
or
servicing.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
servicing
gun
or
unit.
Table
5-1.
Welding
Trouble
*See
Gun
Owners
Manual
MOVING
PARTS
can
cause
Injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
shooting
to
be
performed
only
by
qualified
swamg.2
10/91
Table
5-2.
Wire
DrivefGun
Trouble
Adjust
drive
roll
pressure.
Change
to
proper
groove.
Readjust
hub
tension.
Replace
contact
tube
if
blocked.
*See
Gun
Owners
Manual
Trouble
~o
weld
output;
wire
does
not
teed;
fan
_
does
not
run.
Remedy
Secure
power
cord
plug
in
receptacle.
Replace
line
disconnect
fuse
or
reset
circuit
breaker
if
open.
Secure
gun
trigger
plug
in
receptacle
or
repair
leads,
or
replace
trigger
switch.
No
weld
output;
wire
does
not
feed;
fan
H
-~
motor
continues
to
run.
j
Section
~
3-4
~
3-4
*
No
weld
output;
wire
feeds.
Thermostat
TP1
open
(overheating).
Allow
fan
to
run;
the
thermo
stat
will
close
when
the
unit
has
cooled.
Check
motor
fuse
Fl,
and
replace
if
necessary.
j---I.
-~
5-2A
-s
5-2C
Connect
work
clamp
to
get
good
metal
to
metal
contact.
Low
weld
output.
Replace
contact
tube.
Check
for
proper
connections
at
polarity
changeover
board.
Figure
4-2
-~
3.3
-~
~
]
--~_Connect
unit
to
proper
input
voltage
or
check
for
low
line
voltage._~
-~
3.4
--~
Trouble
Remedy
Section
Electrode
wire
feeding
stops
during
~
-~
Straighten
gun
cable
and/or
replace
damaged
parts.
*
welding.
]
_____________________________________________________
___________
3~6
5.3
3-5
*
~
53,*
.~
5.3
..
*
5-2C
~
*
---~
--
Clean
or
replace
wire
inlet
guide
or
liner
if
dirty
or
plugged.
--a
--a
Replace
drive
roll
or
pressure
bearing
if
worn
or
slipping.
Secure
gun
trigger
plug
in
receptacle
or
repair
leads,
or
replace
trigger
switch.
Check
motor
fuse
Fl,
and
replace
if
necessary.
Check
and
clear
any
restrictions
at
drive
assembly
and
liner.
Have
nearest
Factory
Authorized
Service
Station/Service
Distribu
tor
check
drive
motor.
OM-151
016
Page
13
230
VOLTS
SECTION
6
ELECTRICAL
DIAGRAMS
Figure
6-1.
Circuit
Diagram
For
Welding
Power
Source
SB-I
62
243
IDENTICAL
CONNECTED
VOLTAGE(S)
200
VOLTS
220
VOLTS
T~CH
OM-151
016
Page
14
01
0 0
-
0
2
4(6
8
CR
I
I~3~5~
~A
166(CRI-6)
J
J
I
L
8A(RC3
2)
)
I
I
~
88(PLG2-14
I
4B(PLG2-2)
146(ORIVE
~T~)
DRIVE MOTOR
COIL)
286(11)
58(PLG2-
2)
5A(PC3
I)
5C(FM
24V
L
26(52
WIPER)
WHITE(POWER
CONO)
278(05)
COIL)
J~
216(5)
CC8UION)
7A(PLG2-)O
P
CR2
3A(S2
WIPER)
BLACK(POWER
Cr110
2
3
4
5 6
7
8 9
10
2
)3
4
PC
I
PC
I
IOA(Rl
-COW)
14B)CPI-5)
l9A)TI-E~)
13A)T
I-BEG)
126(R)-CW)
17A(CPI-3)
158(CP)-2(
116(R)-WIPER
66
(
CR
I-B)
7A(CR2
RIGHT)
30B(TEI-POS)
58(C52
COIL)
3IA(TE)-I~EG
68(cP)-A)
PLG2
56(05)
2)
46
(CR)
-5)
IOA(Pt.G2))
~
_~f~_
~
H
S2
J~jI~
-j
0
Li
6
Li
U
In
~
I
2
3
4
00
RC3
32(TE)
Wt11)(
Li
((A
lT~l
1I~IHl
5C(C92
COIL)
IA
S2
ON)
TE
I
32)WOPI(
cLAP.~
~
WOR)(
A\
(
31A)PLG2-)3
(1~11~T
31C)SP2
pos~a~
a14
~
)-POs)
24V.
(A)TPI
I
ZI
278(012
1)])
RIGHT
)9A(PLG2-3)
~
)3A(PLG2-4)
23(5)) 24(51)
E
~
(952-AC)
Ti
(15
B-
\\~a~c1
T)-~C.
\sN..~,~j4
c~~rJi
f)-~C.
U,
~
~
(0
01
~
N
POS.j
296)C)-POS)
~
~
e
~
3)C)TE)-(G)
AC
~
o
SR2
AC
25(SI)
0
(Ii
a
(a
CR
J
-I
/
2881012
1(1)
LEFT
~IIJ
C)
(POS)
C)
(POS)
C~)
R3~1~i~1
CI(UEG)
C)
((G)
-S
SC-162
244
W)4ITE(012
BO1!GH)
RnTrrl4)
66(011-6)
ILIUM
DLVI
I11EEN
~J
GND
POWER
CORD
(PLC
I)
Figure
6-2.
Wiring
Diagram
For
Welding
Power
Source
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Miller AUTO ARC 140 Owner's manual

Miller
Brand
Miller
Model
AUTO ARC 140
Category
Welding System
Type
Owner's manual
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