Miller Electric S-42GL Owner`s manual

OM-716
199 981A
January 2001
Processes
Resistance Spot
Welding
Description
MSW-41, MSW-41T, MSW-42, MSW-42T,
And LMSW-52, LMSW-52T
Portable Resistance Spotwelders
Visit our website at
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller.
Now you can get the job done and get it done right. We
know you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller
products had to be more than the best they could be.
They had to be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
Miller is the first welding help you figure out what the problem is. The
equipment manufacturer in parts list will then help you to decide which
the U.S.A. to be registered to
the ISO 9001 Quality System exact part you may need to fix the problem.
Standard.
Warranty and service information for your
particular model are also provided.
Working as hard as you do
– every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor
to receive the latest full line catalog or
individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Resistance Spot Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . .
1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . .
1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Dangers liés au soudage par points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Installing Or Dressing Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Installing Or Cleaning Tongs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Adjusting Tong And Hand Lever Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Installing Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Mounting Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Connecting Input Power (T Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Connecting Input Power (Non-T Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls (T Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Controls (Non-T Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Overload Protection For 220 Volts Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart 7-1. Spot Welder Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING
spotom _nd_11/99
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
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.
1-2. Resistance Spot Welding Hazards
Y 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 NO TAG. Read and follow all Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
Y During operation, keep everybody, especially children, away.
D
D
D
D
D
SPOT WELDING can cause fire.
Sparks can fly off from the weld. The flying sparks,
hot workpiece, and hot equipment can cause fires,
burns, and explosions.
D
D
D
D
D
D
D
D
D
D
D
Protect yourself and others from flying sparks and hot metal.
Do not spot weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the weld. If this is not
possible, tightly cover them with approved covers.
Be alert that welding sparks can easily go through small cracks and
openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Do not spot weld on closed containers such as tanks or drums.
Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Do not exceed the equipment rated capacity.
Use only correct fuses or circuit breakers. Do not oversize or
bypass them.
D
D
D
D
D
FLYING SPARKS can cause injury.
Very often sparks fly off from the joint area.
D Wear approved face shield or safety goggles
with side shields.
D
D
ELECTRIC SHOCK can kill.
D
D
D
Touching live electrical parts can cause fatal shocks
or severe burns. The input power circuit and
machine internal circuits are also live when power is
on. Incorrectly installed or improperly grounded
equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR
1910.147 (see Safety Standards).
Properly install and ground this equipment according to this manual
and national, state, and local codes.
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 – always
double-check the supply ground before applying power.
When making input connections, attach the grounding conductor
first – double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged – bare wiring
can kill. Check ground conductor for continuity.
Turn off all equipment when not in use.
For water-cooled equipment, check and repair or replace any leaking hoses or fittings. Do not use any electrical equipment if you are
wet or in a wet area.
Use only well-maintained equipment. Repair or replace damaged
parts at once.
Wear a safety harness if working above floor level.
Keep all panels, covers, and guards securely in place.
Wear protective garments such as oil-free, flame-resistant leather
gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
Synthetic material usually does not provide such protection.
Protect others in nearby areas by using approved flame-resistant or
noncombustible fire curtains or shields. Have all nearby persons
wear safety glasses with side shields.
HOT METAL can cause burns.
Wear gloves or allow cooling period before servicing
tongs or tips.
D Always wear welding-type, insulated gloves
when using this equipment.
D
D
Do not touch workpiece, tips, or tongs with bare hands.
Allow tongs and tips to cool before touching.
OM-716 Page 1
D
D
D
D
D
MOVING PARTS can cause injury.
FUMES can be hazardous.
The tong tips, tongs, and linkages move during
operation.
Coatings, cleaners, paints, and platings can produce fumes when welded. Breathing these fumes
can be hazardous to your health.
Keep away from moving parts.
Keep away from pinch points.
Do not put hands between tips.
Keep all guards and panels securely in place.
OSHA and/or local codes may require additional guarding to suit
the application.
D
D
D
D
D
Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the weld to remove
fumes.
In confined spaces, use an approved air-supplied respirator.
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, or if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, coatings, and cleaners.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install or operate unit near flammables.
D Do not overload building wiring – be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can cause injury.
D Use equipment of adequate capacity to lift the
unit.
D Have two people of adequate physical strength
lift portable units.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before going near resistance spot welding operations.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce duty cycle before starting to weld
again.
D Secure unit during transport so it cannot tip or fall.
FLYING METAL or DIRT can injure eyes.
D Wear approved safety glasses with side
shields or wear face shield.
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.
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
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
Welding current will cause electromagnetic fields. There has been and
still is some concern about such fields. However, after examining more
than 500 studies spanning 17 years of research, a special blue ribbon
OM-716 Page 2
committee of the National Research Council concluded that: “The body
of evidence, in the committee’s judgment, has not demonstrated that
exposure to power-frequency electric and magnetic fields is a humanhealth hazard.” However, studies are still going forth and evidence
continues to be examined.
SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT
UTILISATION
spotom _nd_Fre_4/97
1-1. Signification des symboles
Signifie Mise en garde ! Soyez vigilant ! Cette procédure
présente des risques de danger ! Ceux-ci sont identifiés
par des symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.
. Signifie NOTA ; n’est pas relatif à la sécurité.
Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y
a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportezvous aux symboles et aux directives ci-dessous afin de connaître les
mesures à prendre pour éviter tout danger.
1-2. Dangers liés au soudage par points
Y Les symboles représentés ci-dessous sont utilisés dans ce
manuel pour attirer l’attention et identifier les dangers possibles. Lorsque vous rencontrez un symbole, prenez garde et
suivez les instructions afférentes pour éviter tout risque. Les
instructions en matière de sécurité indiquées ci-dessous ne
constituent qu’un sommaire des instructions de sécurité plus
complètes fournies dans la normes de sécurité énumérées
dans la Section 1-4. Lisez et observez toutes les normes de sécurité.
D
D
D
Y Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil.
Y Pendant le fonctionnement, maintenez à distance toutes les
personnes, notamment les enfants de l’appareil.
D
D
LE SOUDAGE PAR POINTS peut
provoquer un incendie.
Des étincelles peuvent être projetées de la soudure.
La projection d’étincelles ainsi que les pièces et
équipements chauds peuvent provoquer des
incendies, des brûlures et des incendies.
D
D
D
D
D
D
D
D
D
D
D
Protégez-vous, ainsi que toute autre personne travaillant sur les
lieux, contre les étincelles et le métal chaud.
Ne soudez pas par points dans un endroit où des étincelles peuvent
tomber sur des substances inflammables.
Déplacez toute matière inflammable se trouvant dans un périmètre
de 10 m de la pièce à souder. Si cela est impossible, couvrez-les de
housses approuvées et bien ajustées.
Des étincelles du soudage peuvent facilement passer dans
d’autres zones en traversant de petites fissures et des ouvertures.
Afin d’éliminer tout risque de feu, soyez vigilant et gardez toujours
un extincteur à portée de main.
Ne soudez pas par points sur un récipient fermé tel un réservoir ou
un bidon.
Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou
vapeurs inflammables (vapeur d’essence, par exemple).
Avant de souder, retirez toute substance combustible de vos
poches telles qu’un briquet au butane ou des allumettes.
Une fois le travail achevé, assurez-vous qu’il ne reste aucune trace
d’étincelles incandescentes ni de flammes.
Ne dépassez pas la puissance permise de l’équipement.
Utiliser exclusivement des fusibles ou coupe-circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D
D
D
D
D
D
LES ÉTINCELLES VOLANTES
risquent de provoquer des
Des étincelles peuvent jaillir de la soudure.
blessures.
D Portez une visière ou des lunettes de sécurité
avec des écrans latéraux approuvées.
D
D
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Ne touchez pas aux pièces électriques sous tension.
Portez des gants isolants et des vêtements de protection secs et
sans trous.
Portez un équipement de protection: gants en cuir résistant au feu,
chemise épaisse, pantanlons sans revers, chaussures de sécurité
et casquette. Les matériaux synthétiques ne garantissent pas une
bonne protection.
Protégez les autres occupants du local à l’aide d’un rideau ou d’un
écran ignifuge approprié. Assurez-vous que ces personnes portent
des lunettes de sécurité avec protections latérales.
LE MÉTAL CHAUD peut provoquer
des brûlures.
Le fait de toucher à une pièce électrique sous
tension peut donner une décharge fatale ou entraîner des brûlures graves. L’alimentation d’entrée et
les circuits internes de l’appareil sont également
actifs lorsque le poste est sous tension. Un poste
incorrectement installé ou inadéquatement mis à la terre constitue un
danger.
D
D
Coupez l’alimentation d’entrée avant d’installer l’appareil ou
d’effectuer l’entretien. Verrouillez ou étiquetez la sortie d’alimentation selon la norme OSHA 29 CFR 1910.147(reportez-vous aux
Principales normes de sécurité).
Installez le poste correctement et mettez-le à la terre
conformément aux consignes de ce manuel et aux normes
nationales, provinciales et locales.
Assurez-vous que le fil de terre du cordon d’alimentation est
correctement relié à la borne de terre du sectionneur ou que la fiche
du cordon est branchée à une prise correctement mise à la terre –
vous devez toujours vérifier la mise à la terre avant toute mise sous
tension.
Avant d’effectuer les connexions d’alimentation, vous devez
connecter en premier lieu le fil de terre - contrôlez les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez-les contre les étincelles et les pièces métalliques
chaudes.
Assurez-vous régulièrement que les câbles d’alimentation et de
masse ne sont pas endommagés ou dénudé par endroit. Remplacez-les immédiatement si c’est le cas : un câble dénudé peut
provoquer la mort. Contrôlez la continuité de la mise à la terre.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Dans le cas d’équipements refroidis par eau, contrôlez les
conduites et raccords; remplacez-les s’ils présentent des fuites.
N’utilisez pas d’équipement électrique si vous êtes mouillé ou dans
une zone humide.
Utilisez uniquement un équipement en bonne condition. Réparez
ou remplacez immédiatement toute pièce endommagée.
Portez un harnais de sécurité si vous devez travailler au-dessus du
sol.
Maintenez en place les panneaux, couvercles et protections de
sécurité.
Portez des gants ou laissez refroidir les électrodres
avant de procéder à l’entretien.
D Portez toujours de gants de soudeur lorsque
vous utilisez cet équipement.
D
D
Ne touchez pas les pièces ni les eléctrodes avec les mains.
Laissez les électrodes refroidir avant de les toucher.
OM-716 Page 3
DES ORGANES MOBILES peuvent
provoquer des blessures.
LES FUMÉES peuvent être
dangereuses.
Pendant le soudage, les bras et électrodes se
déplacent.
D
D
D
D
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement.
Ne placez pas les mains entre les électrodes.
Maintenez en place les panneaux et protections de sécurité.
Lors du soudage, les revêtements, produits de nettoyage, peintures et placages peuvent dégager des
fumées. Leur inhalation peut être dangereuse.
D
D
D
D
D
Ne respirez pas les fumées.
Si vous soudez à l’intérieur, ventilez le local et/ou ayez recours à
une ventilation aspirante installée près de la soudure pour évacuer
les fumées.
Dans des lieux exigus, utilisez un appareil respiratoire approprié.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement
n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé,
et si nécessaire, en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
Veuillez lire les consignes de sécurité et les instructions du
fabricant pour les métaux, revêtements et produits de nettoyage.
1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la
maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces infllammables.
D Ne pas installer ni faire fonctionner l’appareil à
proximité de substances inflammables.
D Porteurs de stimulateur cardiaque, restez à
distance.
D Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de
s’approcher des opérations de soudage par
points.
D Ne pas surcharger l’installation électrique – s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
LA CHUTE DE L’ÉQUIPEMENT peut
blesser.
D Prévoir une période de refroidissement;
respecter le cycle opératoire nominal.
D Réduire le facteur de marche avant de poursuivre le soudage.
D Utiliser un engin d’une capacité appropriée
pour soulever l’appareil.
D Faites déplacer les équipements portables par
deux personnes dotées d’une force suffisante.
D Durant le transport, immobilisez l’appareil pour éviter qu’il ne
bascule.
DES PIÈCES DE MÉTAL ou DES
SALETÉS peuvent provoquer des
blessures aux yeux.
D Porter des lunettes de sécurité à coques latérales ou un écran facial.
1-4. Principales normes de sécurité
Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126
Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402.
National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
Règles de sécurité en soudage, coupage et procédés connexes, norme
CSA W117.2, de l’Association canadienne de normalisation, vente de
normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.
Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute,
1430 Broadway, New York, NY 10018.
Cutting and Welding Processes, norme NFPA 51B, de la National Fire
Protection Association, Batterymarch Park, Quincy, MA 02269.
1-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et sur les effets, pour l’organisme,
des champs magnétiques basse fréquence
L’extrait suivant est tiré des conclusions générales du document intitulé
Biological Effects of Power Frequency Electric & Magnetic Fields –
Background Paper, OTA-BP-E-53 (Washington DC : U.S. Government
Printing Office, mai 1989), publié par le Office of Technology Assessment du Congrès américain : «... il existe maintenant d’abondantes
données scientifiques compilées à la suite d’expériences sur la cellule
ou d’études sur des animaux et des humains, qui montrent clairement
OM-716 Page 4
que les champs électromagnétiques basse fréquence peuvent avoir
des effets sur l’organisme et même y produire des transformations.
Même s’il s’agit de travaux de très grande qualité, les résultats sont
complexes. Cette démarche scientifique ne nous permet pas d’établir
un tableau d’ensemble cohérent. Pire encore, elle ne nous permet pas
de tirer des conclusions finales concernant les risques éventuels, ni
d’offrir des conseils sur les mesures à prendre pour réduire sinon éliminer les risques éventuels». (Traduction libre)
SECTION 2 – INTRODUCTION
2-1. Specifications
AC Input
Voltage
50/60 Hz
1-Phase
Work Capacity
Combined
Thickness
Mild Steel
Rated
Output At
50% Duty
Cycle*
MSW-41T
110
1/8 in
(3.2 mm)
MSW-42T
220
LMSW-52T
220
Model
Welder Dimensions
Weight
Height
Width
Length
Net
Ship
1.5 kVA
6 in
(152 mm)
4-1/2 in
(114 mm)
13 in
(330 mm)
34 lb
(15.4 kg)
38 lb
(17.2 kg)
1/8 in
(3.2 mm)
1.5 kVA
6 in
(152 mm)
4-1/2 in
(114 mm)
13 in
(330 mm)
34 lb
(15.4 kg)
38 lb
(17.2 kg)
3/16 in
(4.7 mm)
2.5 kVA
6 in
(152 mm)
4-1/2 in
(114 mm)
16 in
(406 mm)
42 lb
(19.1 kg)
45 lb
(20.4 kg)
*Based on 10 second time period; means unit can weld for 5 seconds out of each 10 second time period.
Model
Tong Length
MSW-41, 41T
6 in
(152 mm)
Input Volts
12 in
(305 mm)
MSW-42, 42T
18 in
(457 mm)
6 in
(152 mm)
12 in
(305 mm)
110
Output Amps
±10%
5500
4500
LMSW-52, 52T
18 in
(457 mm)
6 in
(152 mm)
12 in
(305 mm)
220
3600
5500
18 in
(457 mm)
220
4500
3600
6750
5800
4850
SECTION 3 – INSTALLATION
3-1. Installing Or Dressing Tips
A. Installing Tips
1
2
3
Threaded Tip
Tip With Hexhead Screw
Tong
Coat threads with supplied heat
sink compound and install tip onto
tong. Do not overtighten.
2
1
3
OR
Tools Needed:
3/16 in
3
9/16 in
Ref. ST-800 155-B / Ref. ST-800 154
OM-716 Page 5
B. Dressing The Tips
1
2
3
New Tip
Used Tip Requiring Dressing
Dressing Method – Keep top
diameter same as a new tip.
d = <1/8 in (3.2 mm)
diameter
for 1.5 kVA models;
5/32 in (4 mm)
for 2.5 kVA models
Tools Needed:
1
d
d
3
2
OR
OM-716 Page 6
3-2. Installing Or Cleaning Tongs
Y Turn off and unplug welder.
Y OSHA and/or local codes may require additional guarding to suit the application.
. Be sure tong ends are clean
and not corroded before
installing. Clean tongs with fine
steel wool.
Bottom Tong:
1
2
3
Bottom Tong
Hole In Spatter Guard
Bottom Tong Securing Screws
(4)
Loosen the four screws. If needed,
use a rubber mallet to loosen tong.
Slide tong into bottom tong holder
as far as possible, and position so
that tip is pointing straight up.
6
5
Loosely tighten screws.
Top Tong:
4
5
6
4
Top Tong
Top Tong Holder/Pivot Casting
Top Tong Securing Screws (4)
Loosen the four screws. If needed
for removal, use a rubber mallet to
loosen tong.
2
Slide tong into pivot casting as far
as necessary, so that tip mates with
bottom tip when tongs are closed.
3
7
1
Loosely tighten screws.
7
Tips
Adjust tong positions to line up centers of tips as shown. Tighten
screws.
Tong Alignment
4
4
7
7
1
1
Front View
Side View
Tools Needed:
3/16 in
9/16 in
Fine
Steel
Wool
ST-800 155-A / Ref. ST-800 154-A
OM-716 Page 7
3-3. Adjusting Tong And Hand Lever Pressure
2
1
4
6
3
5
7
Tools Needed:
9/16, 11/16 in
Ref. ST-800 156
Y Turn off and unplug welder.
Y Excessive tong pressure can damage tips. Do not use tongs as a clamp
or vice to hold workpiece together. If
the two pieces of material to be
welded do not make good contact at
the point of the intended weld, clamp
material to provide good contact between surfaces.
. Tong pressure is adjustable, and must
be checked and/or set before operation.
Correct tong pressure is necessary to
create a quality weld and to prevent
damage to tips.
Too much tong pressure causes the
weld nugget to dimple and material to
OM-716 Page 8
splash out around the nugget area.
If tong pressure is too weak, parts are
loose when the tongs close, severe arcing occurs between workpieces, and no
weld can be made.
1 Front Nut
2 Rear Nut
3 Pivot Casting
4 Hand Lever
5 Tongs
To increase tong pressure, loosen front nut.
The farther the front nut is turned out, the
greater the pressure on the tips when the
hand lever is closed. Turn the rear nut up to
the pivot casting to lock the position.
To decrease tong pressure, loosen the rear
nut and turn the front nut up to the pivot casting.
6
Machine Screw
The farther down the screw is turned, the farther the hand lever will close. Adjustment of
this screw will determine if the tongs lock on
the material, or just pull up tight. Adjust screw
to allow lever to be raised easily after the
weld has been completed.
7
Hex Nut
To adjust pressure needed to push down
hand lever, turn the hex nuts located on each
side of the pivot casting.
3-4. Installing Handle
MSW 41 And 41T Models
1
2
3
MSW 42, 52, 42T, And 52T Models
2
1
1
2
Tools Needed:
Ref. ST-802 056
7/16, 3/8 in
Y
1
2
3
Turn off and unplug welder.
Wodden Handle
Handle Bolt
Brackets (41 And 41T Models Only)
Install handle onto the spot welder as shown
above. For 42, 52, 42T, and 52T Models,
install handle onto either side as desired for
either right-hand or left-hand use.
OM-716 Page 9
3-5. Mounting Control Box
Push-in slots are provided on rear
of box for wall mounting if desired.
The slots will fit over 1/4 inch hexhead screws. To mount box, proceed as follows:
1
1
Control Box
2
Push-In Slots (Not Shown)
Use slots as template and install
screws at desired locations leaving
1/8 inch stickout.
2
Push rear slots firmly against screw
heads, and slide box down onto
screws.
OR
Ref. ST-800 156
3-6. Connecting Input Power (T Models)
Operate spot welder from a separately fused or circuit breaker protected circuit, and use correct size
input conductors.
5
4
1
Rating Label (Not Visible As
Shown On Spot Welder)
2
Cord
3
Parallel Plug On 110 Volts AC
Models
4
Tandem Plug On 220 Volts
AC Models
1
3
OR
1
Do not cut ground terminal off plug.
2
5
Grounded Receptacle
Connect plug
to
grounded receptacle.
Model
Input Conductor
Size (AWG)
Fuse/Circuit Breaker
Size In Amperes
1.5 kVA 110 Volt
No. 10
30
1.5 kVA 220 Volt
No. 12
15
2.5 kVA 220 Volt
No. 10
30
matching
Ref. ST-800 156
OM-716 Page 10
3-7. Connecting Input Power (Non-T Models)
Y Input power supply wiring
and receptacle must meet
National Electrical Code and
all other code requirements.
5
3
4
Or
1
2
Operate spot welder from a separately fused or circuit breaker protected circuit, and use correct size
input conductors.
1
Rating Label
2
Cord
3
Parallel Plug On 110 Volts AC
Models
4
Tandem Plug On 220 Volts
AC Models
Do not cut ground terminal off plug.
5
Grounded Receptacle
Connect plug
to
grounded receptacle.
Model
Input Conductor
Size (AWG)
Fuse/Circuit Breaker
Size In Amperes
1.5 kVA 110 Volt
No. 10
30
2.5 kVA 220 Volt
No. 10
30
matching
Ref. ST-800 156
OM-716 Page 11
SECTION 4 – OPERATION
4-1. Controls (T Models)
1
Spot Weld Timer And Pilot
Light
Weld time adjusts from 0 to 5
seconds. The pilot light turns on
when the weld cycle begins and off
when the cycle ends.
2
1
Hand Lever
Use lever to open and close tongs.
Close the hand lever during the
welding process to compress the
material between the tips. To adjust
tong pressure, see Section 3-3.
4
3
2
Start Switch
Move start switch sideways in either direction to start weld cycle.
When weld cycle time ends, or the
start switch is released, weld output
stops, and the timer resets for
another weld cycle.
4
Power Switch
3
ST-146 013-A
4-2. Controls (Non-T Models)
1
Hand Lever
Use lever to open and close tongs.
Close the hand lever during the
welding process to compress the
material between the tips. To adjust
tong pressure, see Section 3-3.
2
Start Switch
Use switch to turn weld current On
and Off. Move switch sideways in
either direction to start weld current.
Release switch to stop weld current.
1
2
ST-145 104
OM-716 Page 12
SECTION 5 – MAINTENANCE AND TROUBLESHOOTING
5-1. Routine Maintenance
Y Disconnect power before maintaining.
Every Use
3 Months
6 Months
Replace
Unreadable
Labels
Inspect
Tips
Blow Off
Or
Vacuum
Unit
OR
During Heavy Service,
Clean Monthly
5-2. Overload Protection For 220 Volts Model
Y Turn Off unit and disconnect
input power.
If fuse opens, unit shuts down. To
replace fuse, proceed as follows:
1
Fuse Holder Cover
2
Fuse F1 (See Parts List)
1
2
Ref. ST-800 233 / Ref. ST-800 185-A
5-3. Troubleshooting
Trouble
No weld output.
Remedy
Check line fuses, and replace if necessary.
For 220 V models, check fuse F1, and replace if necessary (see Section 5-2).
Low weld output.
Dress or replace tips (see Section 3-1).
Check tip threads. Replace tips if necessary (see Section 3-1).
Remove and clean tongs (see Section 3-2).
OM-716 Page 13
Trouble
Remedy
Clean ends of tongs and tong holders (see Section 3-2).
Check power switch (T models only) and/or start switch. Replace if necessary.
Longer than normal weld time required.
Dress or replace tips (see Section 3-1).
Clean workpieces.
Adjust tong pressure (see Section 3-3).
Clean ends of tongs and tong holders (see Section 3-2).
Check input line voltage.
Burn through at point of weld.
Shorten weld time (see Section 4-1).
Adjust tong pressure (see Section 3-3).
Dress or replace tips (see Section 3-1).
Realign tips (see Section 3-2).
OM-716 Page 14
SECTION 6 – ELECTRICAL DIAGRAMS
SA-162 466-B
Figure 6-1. Circuit Diagram For 110 Volts T-Models
SA-072 065-B
Figure 6-2. Circuit Diagram For 220 Volts T-Model
OM-716 Page 15
SA-162 467-B
Figure 6-3. Circuit Diagram For 110 And 220 Volts Non-T Models
OM-716 Page 16
Notes
OM-716 Page 17
SECTION 7 – PARTS LIST
. Hardware is common and
not available unless listed.
17
11
9
7
6
10
3
18
10
19
12
8
13
14
15
20
16
5
21
22
23
4
3
31
2
17
30
1
32
19
29
28
46
3
27
45
33
37
36
35
25
24
26
34
38–Fig 6–2
42
43
41
40
39
44
ST-145 048-C
Figure 7-1. Main Assembly
OM-716 Page 18
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Model
41,41T 42,42T 52,52T
Figure 7-1. Main Assembly
. . . 1 . . . . . . . . . . . . . 019 643 . . HANDLE, carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 1 . . . . . . . . . . . . . 019 646 . . HANDLE, carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . . . . . . . . . . . . 601 865 . . NUT, stl hex full fnsh .250-20 . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 3 . . . . . . . . . . . . . 602 009 . . SCREW, cap stl sch .250-20 x 1.250 . . . . . . . . . . . . . . . . . 7 . . . . 7 . . . .
. . . 4 . . . . . . . . . . . . . 023 660 . . WIRING HARNESS, switch . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 5 . . . . . . . . . . . . . 023 199 . . LEVER, operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
. . . 5 . . . . . . . . . . . . . 082 090 . . LEVER, operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . . . . 010 714 . . PIN, spring CS .312 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 7 . . . . . . . . . . . . . 010 712 . . LINK, tgl connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 8 . . . . . . . . . . . . . 010 713 . . PIN, spring CS .312 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 9 . . . . . . . . . . . . . 010 715 . . BOLT, pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 10 . . . . . . . . . . . . . 601 876 . . NUT, stl hex jam .437-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 11 . . . . . . . . . . . . . 010 668 . . SCREW, cap stl sch .250-20 x 1.500 . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 12 . . . . . . . . . . . . . 017 668 . . HOLDER, tong top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 13 . . . . . . . . . . . . . 010 709 . . CLAMP, tong top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 14 . . . . . . . . . . . . . 010 623 . . BRAID, tong set of four . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 15 . . . . . . . . . . . . . 010 716 . . CLAMP, connecting top tong braid . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 16 . . . . . . . . . . . . . 602 008 . . SCREW, .250-20 x 1.000soc hexhd . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . .
. . . 17 . . . . . . . . . . . . . 602 262 . . HANDLE, wood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 18 . . . . . . . . . . . . . 024 130 . . BRACKET, mtg handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 19 . . . . . . . . . . . . . 601 778 . . BOLT, crg stl .250-20 x 4.500 . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 20 . . . . . . . . . . . . . 601 854 . . NUT, al hex .375-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 21 . . . . . . . . . . . . . 095 297 . . STUD, stl .375-24 x 3.750 . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 22 . . . . . . . . . . . . . 026 607 . . GUARD, spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 23 . . . . . . . . . . . . . 128 237 . . SCREW, 10-32 x .500hexwhd slt stl . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 24 . . . . . . . . . . . . . 070 017 . . INSULATION, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 25 . . . . S1 . . . . . *011 746 . . SWITCH, control (consisting of) . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . 011 291 . . . . CONTACT, assembly switch . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . 023 987 . . . . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . . 011 292 . . . . TOGGLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . . . . . . . . . . . . . . . . . 070 035 . . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 26 . . . . . . . . . . . . . 122 210 . . SCREW, 10-32 x .625hexwhd slt stl . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 27 . . . . . . . . . . . . . 026 759 . . INSULATOR, plug sec scr . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 28 . . . . . . . . . . . . . . 010 711 . . PIN, spring .375-3.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 29 . . . . . . . . . . . . . 169 122 . . HOUSING, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 30 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE (order by model and style number) . . . . . . 1 . . . . 1 . . . .
. . . 31 . . . . . . . . . . . . . 602 024 . . SCREW, drive U 2 x 3/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . .
. . . 32 . . . . . . . . . . . . . 010 708 . . RETAINER, clamp tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 33 . . . . . . . . . . . . . 026 605 . . INSULATION, bottom clamp . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 34 . . . . . . . . . . . . . 181 179 . . INSULATION, tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 35 . . . . . . . . . . . . . 602 004 . . SCREW, cap stl sch .250-20 x .750 . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
. . . 36 . . . . . . . . . . . . . 010 707 . . CLAMP, bottom tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 37 . . . . . . . . . . . . . 039 052 . . CLAMP, threaded connecting tong braid
(included w/Item 5, Fig 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 38 . . . . T1 . . . . +095 345 . . TRANSFORMER, pwr main (Fig 6-2) . . . . . . . . . . . . . . . . 1
. . . 38 . . . . T1 . . . . +095 350 . . TRANSFORMER, pwr main (Fig 6-2) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . T1 . . . . +095 354 . . TRANSFORMER, pwr main (Fig 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 143 140 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 39 . . . . . . . . . . . . . 600 675 . . SPLICE, butt 16-14 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 40 . . . . . . . . . . . . . . 111 630 . . SCREW, 10-32 x .250hexwhd slt stl . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 41 . . . . . . . . . . . . . 019 642 . . COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . .
. . . 42 . . . . . . . . . . . . . 601 847 . . NUT, stl slflkg hex mscr 10-32 . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . .
. . . 43 . . . . . . . . . . . . . 134 900 . . STRAIN RELIEF, cable flexible .270-.480 cable . . . . . . . . 1 . . . . 1 . . . .
. . . 44 . . . . . . . . . . . . . 094 503 . . CABLE, pwr 10ft 16ga 3/C (Not Req On T Models) . . . . 1
. . . 44 . . . . . . . . . . . . . 094 504 . . CABLE, pwr 10ft 16ga 3/C (Not Req On T Models) . . . . . . . . . . . 1 . . . .
. . . 45 . . . . . . . . . . . . . 026 763 . . TUBING, gl acrylic No. 7 x 2.500 . . . . . . . . . . . . . . . . . . . . 3 . . . . 3 . . . .
. . . 46 . . . . . . . . . . . . . 128 237 . . SCREW, 10-32 x .500hexwhd slt stl . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . .
1
1
7
1
1
1
2
1
1
2
3
1
1
1
1
4
1
1
2
1
1
2
1
1
1
1
1
1
2
2
1
1
1
4
1
1
1
2
1
1
1
1
1
1
1
4
1
1
3
2
*Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and style number required when ordering parts from your local distributor.
OM-716 Page 19
Replace Coils At Factory Or Factory Authorized Service Station.
Item
No.
Part
No.
Quantity
Model
41,41T 42,42T 52,52T
Description
Figure 7-2. Transformer, Power Main (Fig 7-1 Item 38)
...
...
...
...
...
...
...
...
...
...
1
1
2
2
2
3
3
4
5
5
. . . . . . . 026 601
. . . . . . . 026 602
. . . . . . . 095 312
. . . . . . . 095 309
. . . . . . . 095 308
. . . . . . . 010 157
. . . . . . . 010 156
. . . . . . . 137 943
. . . . . . +033 123
. . . . . . +033 122
..
..
..
..
..
..
..
..
..
..
095 345 095 350 095 354
INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COIL, pri 115V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
COIL, pri 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
COIL, pri 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STUD, stl No. 10-32 x 8.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4
STUD, stl No. 10-32 x 11.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NUT, core stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . .
BAR, sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
BAR, sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
4
4
1
1
2
3
4
5
. Hardware is common and
not available unless listed.
ST-141 482-A
Figure 7-2. Transformer, Power Main
+Item 37 on Figure 7-1 is included when ordering these items as replacement parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and style number required when ordering parts from your local distributor.
OM-716 Page 20
Item
No.
Dia.
Mkgs.
Description
Quantity
Model
115V 230V
Figure 7-3. Timer, Spot (230V Illustrated)
041 081 041 082
Part
No.
... 1 ........................
. . . 2 . . . . S1 . . . . . . 124 511 . .
. . . 3 . . . . . W . . . . . 194 307 . .
. . . . . . . . . . . . . . . . . . . 188 210 . .
. . . 4 . . . . . . . . . . . . . 032 152 . .
. . . 5 . . . . T2 . . . . . 605 856 . .
. . . 6 . . . . . . . . . . . . . 168 308 . .
. . . 7 . . . . TD1 . . . . 605 952 . .
. . . 8 . . . . . . . . . . . . . 046 432 . .
. . . 9 . . . . F1 . . . . . *012 653 . .
. . . 10 . . . . . . . . . . . . . 087 179 . .
. . . 11 . . . PLG1 . . . 096 822 . .
. . . 11 . . . PLG1 . . . 096 481 . .
. . . 12 . . . . . . . . . . . . . 134 900 . .
NAMEPLATE, (order by model and style numbers) . . . . . . . . . . . . . 1 . . . .
SWITCH, tgl DPST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
CONTACTOR, 40A 3P (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
LINK, connecting contactor terminal . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
CABINET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
TRANSFORMER, control 230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
TIMER, delay reset 5sec 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
HOLDER, fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUSE, mintr gl .5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CABLE, interconnecting 10ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . .
CABLE, pwr 10ft 16ga 3/c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CABLE, pwr 10ft 16ga 3/c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STRAIN RELIEF, cable flexible .270-.480 cable . . . . . . . . . . . . . . . . 2 . . . .
3
2
1
1
1
2
1
1
1
1
1
1
1
1
2
4
1
12
11
5
6
10
9
8
7
ST-146 012-E
Figure 7-3. Timer, Spot (230V Illustrated)
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and style number required when ordering parts from your local distributor.
OM-716 Page 21
Chart 7-1. Spot Welder Tips
3-1/2”
(89 mm)
STANDARD
3-1/2”
(89 mm)
MO OFFSET
6-1/2” (165 mm)
6” (152 mm) 040 197
12” (305 mm) 040 198
Standard
Flat
18” (457 mm) 040 199
040 211
6” (152 mm) 040 200
12” (305 mm) 040 201
040 212
MO
Offset
18” (457 mm) 040 202
040 215
12” (305 mm) 040 203
Standard
Flat
18” (457 mm) 040 204
TT-6
9-1/2”
(241 mm)
040 211
12” (305 mm) 040 205
Standard
040 212
Flat
18” (457 mm) 040 206
040 211
TT-9
7-1/2”
(190 mm)
8” (203 mm) 040 207
8” (203 mm) 040 208
040 213
5” (127 mm) 040 209
OM-716 Page 22
040 212
FF
FF
FH
Flat
Standard
040 211
G-7
040 212
FH
040 214
S-0550
Effective January 1, 2000
(Equipment with a serial number preface of “LA” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
*
LIMITED WARRANTY – Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants
to its original retail purchaser that new Miller equipment sold
after the effective date of this limited warranty is free of defects
in material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail 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
*
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Supplies
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources
Water Coolant Systems
HF Units
Grids
Maxstar 140
Spot Welders
Load Banks
Miller Cyclomatic Equipment
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction Heating Coils and Blankets
*
*
*
*
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate 185 & Spoolmate 250
Canvas Covers
Miller’s True Blue Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED 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 Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement 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 MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMED BY MILLER.
Some states 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
provides specific legal rights, and other rights may be
available, but may vary from state to state.
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 Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.
miller_warr 7/00
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters–USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters –
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
Contact the Delivering Carrier for:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
PRINTED IN USA
 2001 Miller Electric Mfg. Co.
1/01