Miller AUTO ARC 175 Owner's manual

Brand: Miller

Model: AUTO ARC 175

Category: Welding System

Type: Owner's manual

This manual is also suitable for

KF955478

OWNER’S

MANUAL

July 1996 Form: OM-170 823

Effective With Serial No. KF955478



auto_arc 6/95 – ST-801 348 PRINTED IN USA

Auto Arc 175

230 Volt Wire Welder For GMAW And FCAW Welding

Rated Welding Out-

put

Maximum Open-

Circuit Voltage

Amperes Input at

Rated Load Output

230 V, 60 Hz,

Single-Phase

KVA KW Weight

Overall

Dimensions

150 A @ 22 Volts DC,

40% Duty Cycle

32 26 (1.4)*

5.9

(0.33)*

4.9

(0.16)*

Net: 160 lb

(72.6 kg)

Ship: 180 lb

(81.6 kg)

Length: 34-1/2 in

(876 mm)

Width: 18-1/2 in

(470 mm)

Height: 22-1/4 in

(565 mm)

Wire Diameter Range Wire Feed Speed Range

.023 – .035 in (0.58 – 0.89 mm) 0 – 500 ipm (0 – 19.1 m/min)

* While idling

OM-170 823 Page 1

SECTION 1 – SAFETY PRECAUTIONS FOR ARC WELDING

safety_som1 4/95OM-170 823 - 7/96

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 ELECTRIC SHOCK, MOVING PARTS,

and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to

avoid the hazards.

Y Marks a special safety message.

. Means NOTE; not safety related.

1-2. Arc Welding Hazards

WARNING

The symbols shown below are used throughout this manual to call attention to and identify possible

hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The

safety information given below is only a summary of the more complete safety information found in the

Safety Standards listed in Section 1-4. Read and follow all Safety Standards.

Only qualified persons should install, operate, maintain, and repair this unit.

During operation, keep everybody, especially children, away.

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 big enough to prevent any physical contact with the

work or ground.

4. Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according

to OSHA 29 CFR 1910.147 (see Safety Standards).

5. Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

6. Always verify the supply ground – check and be sure that input

power cord ground wire is properly connected to ground terminal

in disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

7. When making input connections, attach proper grounding

conductor first – double-check connections.

8. Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

9. Turn off all equipment when not in use.

10. Do not use worn, damaged, undersized, or poorly spliced cables.

11. Do not drape cables over your body.

12. If earth grounding of the workpiece is required, ground it directly

with a separate cable – do not use work clamp or work cable.

13. Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

14. Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

15. Wear a safety harness if working above floor level.

16. Keep all panels and covers securely in place.

17. Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

ARC RAYS can burn eyes and skin;

NOISE can damage hearing; FLYING

SLAG OR SPARKS can injure eyes.

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Noise from some

processes can damage hearing. Chipping, grinding,

and welds cooling throw off pieces of metal or slag.

NOISE

1. Use approved ear plugs or ear muffs if noise level is high.

ARC RAYS

2. Wear a welding helmet fitted with a proper shade of filter to protect

your face and eyes when welding or watching (see ANSI Z49.1

and Z87.1 listed in Safety Standards).

3. Wear approved safety glasses with side shields.

4. Use protective screens or barriers to protect others from flash

and glare; warn others not to watch the arc.

5. Wear protective clothing made from durable, flame-resistant

material (wool and leather) and foot protection.

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. Keep your head out of the fumes. Do not breathe the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to

remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

4. Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instruction for metals, consumables, coatings,

cleaners, and degreasers.

5. Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained

watchperson nearby. Welding fumes and gases can displace air

and lower the oxygen level 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.

OM-170 823 Page 2

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, slag, open flames, sparks, and arcs.

2. Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never drape a welding torch over a gas cylinder.

5. Never allow a welding electrode to touch any cylinder.

6. Never weld on a pressurized cylinder – explosion will result.

7. Use only correct shielding gas cylinders, regulators, hoses, and

fittings designed for the specific application; maintain them and

associated parts in good condition.

8. Turn face away from valve outlet when opening cylinder valve.

9. Keep protective cap in place over valve except when cylinder is in

use or connected for use.

10. Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

WELDING can cause fire or

explosion.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks,

hot workpiece, and hot equipment can cause fires

and burns. Accidental contact of electrode to metal

objects can cause sparks, explosion, overheating,

or fire. Check and be sure the area is safe before

doing any welding.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

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, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see

Safety Standards).

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.

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.

12. Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

1-3. Additional Installation, Operation, And Maintenance Hazards

FIRE OR EXPLOSION can result from

placing unit on, over, or near

combustible surfaces.

1. Do not locate unit on, over, or near combustible

surfaces.

2. Do not install unit near flammables.

FALLING EQUIPMENT can cause

serious personal injury and equipment

damage.

1. Use lifting eye to lift unit only, NOT running gear,

gas cylinders, or any other accessories.

2. Use equipment of adequate capacity to lift unit.

3. If using lift forks to move unit, be sure forks are long

enough to extend beyond opposite side of unit.

HOT PARTS can cause severe burns.

1. Do not touch hot parts bare handed.

2. Allow cooling period before working on gun or

torch.

MOVING PARTS can cause injury.

1. Keep away from moving parts such as fans.

2. Keep all doors, panels, covers, and guards closed

and securely in place.

MAGNETIC FIELDS FROM HIGH

CURRENTS can affect pacemaker

operation.

1. Pacemaker wearers keep away.

2. Wearers should consult their doctor before going

near arc welding, gouging, or spot welding

operations.

MOVING PARTS can cause injury.

1. Keep away from moving parts.

2. Keep away from pinch points such as drive rolls.

FLYING PIECES OF METAL or DIRT can

injure eyes.

1. Wear safety glasses with side shields or face

shield.

WELDING WIRE can cause puncture

wounds.

1. Do not press gun trigger until instructed to do so.

2. Do not point gun toward any part of the body, other

people, or any metal when threading welding wire.

HIGH-FREQUENCY RADIATION can

interfere with radio navigation, safety

services, computers, and

communications equipment.

1. Have only qualified persons familiar with electronic

equipment perform this installation.

2. The user is responsible for having a qualified

electrician promptly correct any interference

problem resulting from the installation.

3. If notified by the FCC about interference, stop using

the equipment at once.

4. Have the installation regularly checked and

maintained.

5. Keep high-frequency source doors and panels

tightly shut, keep spark gaps at correct setting, and

use grounding and shielding to minimize the

possibility of interference.

OM-170 823 Page 3

OVERUSE can cause OVERHEATED

EQUIPMENT.

1. Allow cooling period.

2. Reduce current or reduce duty cycle before

starting to weld again.

3. Follow rated duty cycle.

STATIC ELECTRICITY can damage

parts on circuit boards.

1. Put on grounded wrist strap BEFORE handling

boards or parts.

2. Use proper static-proof bags and boxes to store,

move, or ship PC boards.

SIGNIFICANT DC VOLTAGE exists after

removal of input power on inverters.

1. Turn Off inverter, disconnect input power, and

discharge input capacitors according to

instructions in Maintenance Section before

touching any parts.

BUILDUP OF SHIELDING GAS can harm

health or kill.

1. Shut off shielding gas supply when not in use.

1-4. 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

Superintendent 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,

American Welding Society Standard AWS F4.1, from American

Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

National Electrical Code, NFPA Standard 70, from National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet

P-1, from Compressed Gas Association, 1235 Jefferson Davis

Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face

Protection, ANSI Standard Z87.1, from American National Standards

Institute, 1430 Broadway, New York, NY 10018.

Cutting And Welding Processes, NFPA Standard 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

The following is a quotation from the General Conclusions Section of

the U.S. Congress, Office of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields – Background

Paper, OTA-BP-E-53 (Washington, DC: U.S. Government 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 also recommended for pacemaker

wearers. Consult your doctor for complete information.

OM-170 823 Page 4

SECTION 2 – INSTALLATION

2-1. Installing The Running Gear

ST-801 364

See Parts List for descriptions.

Tools Needed:

Remove paint from axle grooves

before installing retaining rings.

Crimp S-hook and

snap to chain.

3/8, 9/16 in

2-2. 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

Ref. ST-025 190-D

Tools Needed:

3/8, 7/16 in

OM-170 823 Page 5

2-3. Installing Gas Supply

Chain gas cylinder to running gear,

wall, or other stationary support so

cylinder cannot fall and break off

valve.

1 Cap

2 Cylinder Valve

3 Cylinder

4 Regulator/Flowmeter

5 Gas Hose Connection

Fitting has 5/8-18 right-hand

threads.

6 Flow Adjust

Typical flow rate is 20 cfh (cubic feet

per hour). Check wire manufactur-

er’s recommended flow rate.

Make sure flow adjust is closed

when opening cylinder to avoid

damage to the flowmeter.

7CO

Adapter

8 O-Ring

Install adapter with O-ring between

regulator/flowmeter and CO

cylinder.

Tools Needed:

7 8

ssb3.1* 5/94 – ST-158 697-A / Ref. ST-149 827-B

Argon Gas Or

Mixed Gases

Gas

5/8, 1-1/8 in

2-4. Gas Hoses And Interconnecting Cord Connections

Ref. ST-800 365 / Ref. ST-801 366

1 Gas In Fitting And Gas Hose

From Regulator/Flowmeter

Connect gas hose from regulator/

flowmeter (see Section 2-3).

2 Gas Out Fitting And Wire

Feeder Gas Hose

Connect gas hose from wire feeder.

3 Interconnecting Cord And

Plug

4 Interconnecting Receptacle

Connect to receptacle as follows:

align keyway, insert plug, and

tighten threaded collar.

OM-170 823 Page 6

2-5. Connecting To Weld Output Receptacles

ST-801 366

1 Positive (+) Weld Output

Receptacle

2 Negative (–) Weld Output

Receptacle

3 Weld Cable

4 Work Cable

Y Be sure cables are secure in

receptacles before welding,

and do not change recep-

tacles while welding.

For GMAW direct current electrode

positive (DCEP), connect weld

cable plug to positive (+) weld out-

put receptacle and work cable plug

to negative (–) weld output recep-

tacle.

For GMAW direct current electrode

negative (DCEN), reverse cable

connections.

For FCAW direct current electrode

negative (DCEN), connect weld

cable plug to negative (–) weld out-

put receptacle and work cable plug

to positive (+) weld output recep-

tacle.

For FCAW direct current electrode

positive (DCEP), reverse cable

connections.

2-6. Installing Welding Gun

1 Gun End

2 Gun Securing Nut

3 Drive Assembly

Loosen securing nut. Insert gun

end through opening until it bottoms

against drive assembly. Tighten

nut.

4 Gun Trigger Receptacle

5 Gun Trigger Plug

Insert plug into receptacle, and

tighten threaded collar.

Close door.

Tools Needed:

ST-800 849-A

1/2 in

2345

OM-170 823 Page 7

2-7. Electrical Service Guide

Input Voltage

230

Input Amperes At Rated Output

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)

80 (24)

Min Grounding Conductor Size In AWG/Kcmil

Reference: 1993 National Electrical Code (NEC) S-0092-J

2-8. Selecting A Location

ST-801 367

Have only qualified persons make

this installation.

1 Rating Label

Supply correct input power.

2 Plug

3 Receptacle

Obtain and install correct

receptacle.

Y Special installation may be

required where gasoline or

volatile liquids are present –

see NEC Article 511 or CEC

Section 20.

18 in (457 mm) of

space for airflow

L1L2

GND/PE

230 VAC, 1

Size and ratings must comply with

applicable codes. Install conductors

in conduit or equivalent into a deener-

gized line disconnect device.

GND/PE

Connect First

OM-170 823 Page 8

2-9. Installing Wire Spool And Adjusting Hub Tension

ST-800316 / S-0499

Standard Spool Installation

Tools Needed:

Remove and retain

Install 1 lb spool

1 lb Spool Installation

When a slight force is needed to turn spool, tension is set. If tension

is to tight, circuit breaker CB1 can open (see Section 4-3)

9/16 in

OM-170 823 Page 9

2-10. Threading Welding Wire

Ref. ST-800 851-A / Ref. ST-170 725 / S-0627-A

1 Wire Spool

2 Inlet Wire Guide

3 Pressure Adjustment Knob

4 Drive Roll

5 Outlet Wire Guide

6 Gun Conduit Cable

Lay gun cable out straight.

Tools Needed:

1245

6 in

(150 mm)

Hold wire tightly to keep

it from unraveling.

Tighten

WOOD

Welding wire is electrically

live when feeding welding

wire with gun trigger.

Turn On.

Cut off wire. Close and latch door.

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Remove gun nozzle

and contact tip.

Push wire thru guides into gun;

continue to hold wire.

Pull and hold wire, cut off end.

Open pressure assembly.

Close and tighten pressure assembly,

and let go of wire.

Press gun trigger until wire

comes out of gun. Reinstall

contact tip and nozzle.

OM-170 823 Page 10

SECTION 3 – OPERATION

Ref. ST-801 368 / Ref. ST-177 114 / ST-177 115

1 Wire Speed Control

Use control to select a wire feed

speed. As Voltage switch setting in-

creases, wire speed range also in-

creases. The numbers around the

control are not a wire feed speed

and are for reference only.

2 Voltage Switch

Use switch to select an arc voltage.

The higher the selected number,

the thicker the material that can be

welded.

3 Power Switch

OFF

3-1. Controls

OM-170 823 Page 11

4 Minutes Welding 6 Minutes Resting

3-2. 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.

Y Exceeding duty cycle can

damage unit or gun and void

warranty.

Overheating

A or V

Reduce Duty Cycle

Minutes

duty1 4/95 – SB-173 353

40% Duty Cycle At 150 Amperes

6 Minutes Welding 4 Minutes Resting

UNIT

GUN

3 Minutes Welding 7 Minutes Resting

60% Duty Cycle At 160 Amperes Using CO

30% Duty Cycle At 160 Amperes Using Mixed Gases

Chart

OM-170 823 Page 12

SECTION 4 – MAINTENANCE & TROUBLESHOOTING

4-1. Routine Maintenance

Y Disconnect power before maintaining.

3 Months

Repair Or

Replace

Cracked

Weld

Cable

Replace

Unreadable

Labels

Clean And

Tighten

Weld

Terminals

6 Months

Blow Out Or Vacuum

Inside,

During Heavy Service,

Clean Monthly

4-2. Fuses F1 And F2

ST-801 369

Y Turn Off power. Remove

wrapper.

1 Fuse F1

2 Fuse F2

Pull fuse(s) from fuse holder, and

check and replace if needed. To re-

install, push fuse into fuse holder.

Reinstall wrapper.

Tools Needed:

3/8 in

4-3. Circuit Breaker CB1

ST-800 850-A

1 Circuit Breaker CB1

CB1 protects the wire feeder motor

from overload. If CB1 trips, wire

feeding stops. Check for jammed

wire or misaligned drive roll. Cor-

rect problem, reset breaker.

OM-170 823 Page 13

4-4. Cleaning Or Repairing Drive Assembly

Ref. ST-800 851-A / ST-155 578

Y Turn Off and unplug unit.

1 Wire Spool

2 Gun Contact Tip

Cut welding wire off at contact tip.

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 onto pin and secure

with cotter pin.

8 Setscrew

9 Smooth Groove For Hard

Wire

10 Drive Roll

Remove drive roll as shown.

Use a wire brush to clean drive roll.

Push drive roll onto shaft with de-

sired groove in. Turn drive roll so

one setscrew faces flat side of

shaft, and tighten both setscrews.

11 Knurled Groove For

Flux-Cored Wire

12 Wire Inlet Guide

Remove guide by pressing on

barbed area or cutting off 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

2-10).

Tools Needed:

5/64 in

4-5. Replacing Gun Contact Tip

ST-149 632-C

Y Turn Off power before re-

placing contact tip.

1 Nozzle

2 Contact Tip

Cut off welding wire at contact tip.

Remove nozzle.

Remove contact tip and install new

contact tip. Reinstall nozzle.

Tools Needed:

OM-170 823 Page 14

4-6. Cleaning Or Replacing Gun Liner

Ref. ST-155 509

Tools Needed:

3/8 in

To Reassemble Gun:

Install contact tip.

Insert new liner.

Install collet onto liner and tighten

into gun/feeder connector using

wrench.

Cut liner off near collet so that liner

end is as close to drive rolls as pos-

sible without touching.

Install nozzle.

Y Turn off welding power

source and disconnect gun.

Remove nozzle,

contact tip, and

liner collet.

3/8 in

Head Tube

Gun/feeder

Connector

Blow out

gun casing.

Remove liner.

OM-170 823 Page 15

4-7. Welding Trouble

Trouble Remedy

No weld output; wire does not feed; fan does not run. Secure power cord plug in receptacle (see Section 2-8).

Replace line disconnect fuse or reset circuit breaker if open (see Section 2-8).

Secure gun trigger plug in receptacle or repair leads, or replace trigger switch (see Section

2-6).

No weld output; wire does not feed; fan motor contin-

ues to run.

Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the

unit has cooled (see Section 3-2).

Check circuit breaker CB1, and reset if necessary (see Section 4-3).

No weld output; wire feeds. Connect work clamp to get good metal to metal contact.

Check for proper weld cable connections.

Replace contact tip (see Section 4-5).

Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 2-8).

4-8. Wire Drive/Gun Trouble

Trouble Remedy

Electrode wire feeding stops during welding. Straighten gun cable and/or replace damaged parts.

Adjust drive roll pressure (see Section 2-10).

Change to proper groove (see Section 4-4).

Readjust hub tension (see Section 2-9).

Replace contact tip if blocked (see Section 4-5).

Clean or replace wire inlet guide or liner if dirty or plugged (see Section 4-6).

Replace drive roll or pressure bearing if worn or slipping (see Section 4-4).

Secure gun trigger plug in receptacle or repair leads, or replace trigger switch (see Section

2-6).

Check circuit breaker CB1, and reset if necessary (see Section 4-3).

Check and clear any restrictions at drive assembly and liner (see Sections 4-4 and 4-6).

Have nearest Factory Authorized Service Agent check drive motor.

OM-170 823 Page 16

SECTION 5 – ELECTRICAL DIAGRAMS

SB-170 520-A

Figure 5-1. Circuit Diagram For Welding Power Source

OM-170 823 Page 17

SECTION 6 – WELDING METHODS & TROUBLESHOOTING

mod4.1 9/92

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 (MSDSs) 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.

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.

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.

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.

WELDING CURRENT can damage elec-

tronic parts in vehicles.

• Disconnect both battery cables before welding on a

vehicle.

• Place work clamp as close to the weld as possible.

See Safety Precautions at beginning of manual for ba-

sic welding safety information.

swarn6.2 10/91

6-1. Flux Cored Arc Welding (FCAW) And Gas Metal Arc Welding (GMAW)

Welding wire is not energized until gun trigger is pressed; therefore, welding wire

should extend not more than 1/2 in (13 mm) beyond edge of nozzle and tip of wire

placed on seam before lowering helmet and pressing trigger.

NOTE

1 Hold Gun And Control Gun

Trigger

2 Workpiece

3 Work Clamp

4 Electrode Extension (Stickout)

1/4 To 1/2 in (6 To 13 mm)

5 Cradle Gun And Rest Hand

On Workpiece

S-0421-A

90° 90°

0°-15°

45°

GROOVE WELDS FILLET WELDS

End View Of Work Angle Side View Of Gun Angle End View Of Work Angle Side View Of Gun Angle

0°-15°

Figure 6-1. Holding And Positioning Welding Gun

OM-170 823 Page 18

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.

NOTE

S-0634

Short Normal Long

10°

GUN ANGLES AND WELD BEAD PROFILES

ELECTRODE EXTENSIONS (STICKOUT)

FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)

Push Perpendicular Drag

GUN TRAVEL SPEED

Slow

Normal Fast

Figure 6-2. Conditions That Affect Weld Bead Shape

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.

NOTE

1 Stringer Bead – Steady Move-

ment Along Seam

2 Weave Bead – Side To Side

Movement Along Seam

3 Weave Patterns

Use weave patterns to cover a wide

area in one pass of the electrode.

Do not let weave width exceed

2-1/2 times diameter of electrode.

S-0054-A

Figure 6-3. Gun Movement During Welding

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Miller AUTO ARC 175 Owner's manual

Brand: Miller

Model: AUTO ARC 175

Category: Welding System

Type: Owner's manual

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KF955478

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Miller AUTO ARC 175 Owner's manual

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Miller AUTO ARC 175 Owner's manual

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