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AUTO ARC 120 User Manual

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AUTO
ARC}fi
April
1994
Form:
OM-151
015A
Effective
With
Serial
No.
KD461
760
OWNERS
MANUAL
U
Read
and
follow
these
instructions
and
all
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the
directions.
Give
this
manual
to
the
operator.
11111
For
help,
call
your
distributor,
MILLER
Electric
Mfg.
Co.,
P.O.
Box
Appleton,
WI
54912
414-734-9821
or:
1079,
Auto
Arcfi
120
CV/DC
Welding
Power
Source/Wire
Feeder
For
GMAW
And
FCAW
Welding
90
Amperes,
18
Volts
At
20%
Duty
Cycle
Usable
Range
Of
30
To 130
Amperes
Uses
115
Volts
AC,
Single-Phase
Input
Power
Overheating,
Short
Circuit,
And
Motor
Overload
Protection
Includes
Gun,
Welding
Wire,
Gas
Valve,
And
Instructional
Video
auto_arc
7/93
ST-I
49
330
PRLNTED
IN
USA
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AUTO ARC 120 Specifications

General IconGeneral
BrandAUTO ARC
Model120
CategoryWelding System
LanguageEnglish

Summary

LIMITED WARRANTY

RECEIVING AND HANDLING

Procedures for inspecting, handling, and recording equipment details upon receipt.

ERRATA SHEET

CHANGES TO PARTS LIST

Lists modifications and deletions to the parts list after the manual's initial printing.

ARC WELDING SAFETY PRECAUTIONS

ELECTRIC SHOCK HAZARDS

Warnings and precautions regarding the dangers of electric shock from welding equipment.

ARC RAYS, NOISE, AND FUMES HAZARDS

Safety measures to protect against arc rays, hearing damage from noise, and hazardous fumes.

FIRE, EXPLOSION, AND FLYING DEBRIS HAZARDS

Precautions to prevent fires, explosions, and injuries from sparks, spatter, and hot metal.

CYLINDER AND ENGINE SAFETY

Safety guidelines for handling gas cylinders and operating engines.

PRINCIPAL SAFETY STANDARDS

Lists key safety standards and recommended practices for welding.

EMF INFORMATION

EMF AND WELDING CONSIDERATIONS

Discusses the effects of electromagnetic fields on biological systems during welding.

PACEMAKER SAFETY ADVISORY

Specific advice for individuals with pacemakers working near welding operations.

SECTION 1 – SAFETY INFORMATION

SAFETY SYMBOLS AND TERMINOLOGY

Explains warning symbols, signal words, and basic safety terminology used in the manual.

SECTION 2 – SPECIFICATIONS

WELDING POWER SOURCE SPECIFICATIONS

Details the technical specifications of the welding power source, including output and input.

VOLT-AMPERE CURVES

Illustrates the voltage and amperage output capabilities of the welding power source.

DUTY CYCLE EXPLANATION

Defines duty cycle and its impact on equipment operation and longevity.

SECTION 3 – INSTALLATION

INSTALLING WORK CLAMP

Step-by-step instructions for correctly attaching the work clamp to the workpiece.

GUN POLARITY SELECTION

Guidance on setting the correct polarity for different welding wire types.

LOCATION AND INPUT POWER CONNECTION

Instructions for selecting an installation location and connecting the input power safely.

THREADING WELDING WIRE

Procedure for loading and threading welding wire through the wire feeder.

INSTALLING GAS SUPPLY

Steps for connecting the shielding gas cylinder and regulator/flowmeter.

SECTION 4 – OPERATION

OPERATIONAL SAFETY PRECAUTIONS

General safety guidelines to follow during the operation of the welding equipment.

SECTION 5 – MAINTENANCE & TROUBLESHOOTING

ROUTINE MAINTENANCE PROCEDURES

Schedule and steps for regular maintenance to ensure optimal performance.

OVERLOAD PROTECTION AND FUSE LOCATION

Information on the motor fuse (F1) and its role in overload protection.

OVERHEATING AND SHORT CIRCUIT SHUTDOWN

Explains the unit's protective features for overheating and short circuits.

DRIVE ASSEMBLY CLEANING AND REPAIR

Instructions for cleaning and repairing the wire drive assembly components.

WIRE SPOOL INSTALLATION AND HUB TENSION

Steps for installing a wire spool and adjusting the hub tension for proper feeding.

GENERAL TROUBLESHOOTING

Guides users through common welding and wire drive issues and their solutions.

SECTION 6 – ELECTRICAL DIAGRAMS

CIRCUIT DIAGRAM FOR POWER SOURCE

Provides the schematic diagram for the internal circuitry of the welding power source.

SECTION 7 – WELDING METHODS & TROUBLESHOOTING

WELDING SAFETY GUIDELINES

Reinforces safety practices specific to welding methods discussed in this section.

FCAW AND GMAW WELDING TECHNIQUES

Explains how to hold and position the welding gun for different weld types.

WELD BEAD CHARACTERISTICS AND TROUBLESHOOTING

Discusses factors affecting weld bead shape and common porosity issues.

WELDING DEFECTS: SPATTER, FUSION, AND PENETRATION

Identifies and provides corrective actions for excessive spatter, incomplete fusion, and lack of penetration.

WELDING DEFECTS: PENETRATION, BURN-THROUGH, WAVINESS, AND DISTORTION

Addresses issues like excessive penetration, burn-through, bead waviness, and distortion.

SECTION 8 – PARTS LIST

MAIN ASSEMBLY COMPONENTS

Lists and illustrates components of the main assembly of the welding unit.

MAIN ASSEMBLY DETAILS

Continues the detailed listing and illustration of main assembly components.

DRIVE ASSEMBLY WIRE COMPONENTS

Lists and illustrates the components of the wire drive assembly.

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