AUTO ARC 255

Miller AUTO ARC 255, KF869436 Owner's manual

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AUTO

ARCJﬁ

April

1995

Form:

OM-157

066C

Effective

With

Serial

No.

KF869436

OWNERS

MANUAL

Auto

Arcﬁ

Model

255





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



Call

your

distributor

if

you

do

not

understand

I~J



or:

MILLER

Electric

Mfg.

Co.,

P.O.

Box

1079,

the

directions.



Appleton,

WI

54912

414-734-9821



DC/CV

Welding

Power

Source/Wire

Feeder



For

GMAW

And

FCAW

Welding



Uses

.023



.045

Hard

Wire

And

.030



.045

Flux

Cored

Wire



200

Amperes,

28

Volts

DC

At

60%

Duty

Cycle



Uses

Single-Phase

Input

Power



Overheating

And

Motor

Overload

Protection



Includes

Gun

And

Shielding

Gas

Valve

auto_arc

7/93



ST-i

57

072-A

PRINTED

IN

USA

MILLERS

TRUE

BLUETM

LIMITED

WARRANTY

Effective

January

1,

1995

(Equipment

with

a

serial

number

preface

of

KO

or

newer)

This

limited

wsrrsnty

supersedes

sit

previous

MILLER

wsrrsnties

snd

is

exclusive

with

no

other

gusrsntees

or

wsrrsnties

expressed

or

implied.

LIMITED

WARRANTY



Subject

to

the

terms

snd

conditions

below,

MILLER

Electric

Mtg.

Co.,

Appleton,

Wisconsin,

wsrrsnts

to

its

originsl

retail

purchsser

thst

new

MILLER

equipment

sold

sher

the

effective

dste

ot

this

limited

warrsnty

is

free

ot

de

tects

in

msterisl

snd

workmanship

st

the

time

it

is

shipped by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES,

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRANTIES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

wsrrsnty

periods

listed

below,

MILLER

will

repsir

or

replsce

sny

war

rsnted

psrts

orcomponents

thst

fsil

due

to

such

detects

in

material

or

workmsnship.

MtLLER

must

be

notitied

in

writing

within

thirty

(30)

dsys

ot

such

detect

or

tsilure,

st

which

time

MILLER

will

provide

instructions

on

the

wsrrsnty

clsim

procedures

to

be

followed.

MILLER

shsll

honor

wsrrsnty

clsims

on

wsrrsnted

equipment

listed

below

in

the

event

ot

such

s

tsilure

within

the

wsrrsnty

time

periods.

All

wsrmnty

time

periods

slsrt

on

the

dste

thst

the

equipment

wss

delivered

to

the

original

retsil

purchsser,

or

one

yesr

sher

Ihe

equipment

is

sent

to

s

North

Americsn

distributor

or

eighteen

months

aher

the

equipment

is

sent

to

sn

Internationsl

distributor.

1.

5

Years

Psrts3Yesm

Lsbor



Originst

msin

power

rectitiers

2.

3

Yesrs



Psrts

snd

Lsbor



Trsnsformer/Reclitier

Power

Sources



Ptssms

Arc

Cutting

Power

Sources

*

Semi-Automatic

snd

Automstic

Wire

Feeders

*

Robots

3.

2

Yesrs



Parts

snd

Lsbor

-

Engine

Driven

Welding

Generstors

(NOTE:

Engines

sre

wsrrsnted

sepsrstely

by

the

engine

msnutacturer.)

*

Air

Compressors

4.

1

Yesr



Psrts

snd

Lsbor

-

Motor

Driven

Guns

*

Process

Controllers



IHPS

Power

Sources

*

Wster

Coolsnt

Systems

*

HP

Units

-

Grids

*

Spot

Welders

*

Losd

Bsnks

-

SDX

Trsnsformers



Running

Gesr/Trailers



Plasms

Cutting

Torches

(except

APT,

ZIPCUT

&

PLAZCUT

Models)



Tecumseh

Engines



Deutz

Engines

(outside

North

Americs)

*

Field

Options

(NOTE:

Field

options

sre

covered

under

True

BIuaTM

for

the

remsining

wsrrsnty

period

of

the

product

they

sre

instslled

in,

or

for

s

minimum

of

one

yesr



whichever

is

grester.)

5.

6

Months



Bsneries

6.

g~

Dsys



Psrts

snd

Lsbor



MIG

Guns/TIG

Torches

-

APT,

ZIPCUT

&

PLAZCUT

Model

Plasma

Cutting

Torches



Remote

Controls

*

Accessory

Kits



Replscement

Psrts

MILLERS

True

BIueTM

Limited

Warranty

shall

not

apply

to:

1.

Items

furnished

by

MILLER,

but

msnufactured

by

others,

such

ss

engines

or

trsde

sccessories.

These

items

sre

covered

by

the

manufscturers

warrsnty,

if

sny.

2.

Consumable

components:

such

ss

contsct

tips,

cutting

nozzles,

contsctors

end

relays

or

parts

that

fail

due

to

normal

weer.

3.

Equipment

that

hex

been

modified

by

eny

party

other

than

MILLER,

or

equip

ment

that

has

baen

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

COMMER

CIAL/INDUSTRIAL

USERS

AND PERSONS

TRAINED

AND

EXPERIENCED

IN

THE

USE

AND

MAINTENANCE

OF

WELDING

EOUIPMENT.

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

replace

ment

at

an

authorized

MILLER

service

station;

or

(4)

payment

of

or

credit

for

the

pur

chase

price

(less

reasonable

depreciation

based

upon

actual

use)

upon

return

ol

the

goods

at

customers

risk

and

expense.

MILLERS

option

of

repair

or

replacement

will

be

FOB.,

Factory

at

Appleton,

Wisconsin,

or

FOB.

at

a

MILLER

authorized

ser

vice

facility

as

determined

by

MILLER.

Therefore

no

compensation

or

reimburse

ment

for

Iranaportafion

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

CONSEGUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CON

TRACT,

TORT

OR

ANY

OTHER

LEGAL

THEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTATION

ASTO

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

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITH

RESPECT

TO

ANY

AND

ALL

EOUIPMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

slates

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.

Thia

warranty

provides

spe

cific

legal

rights,

and

other

rights

may

be

available,

but

may

vary

from

slate

to

slate.

In

Canada,

legislation

In

some

provinces

provides

for

certain

additIonal

warranties

or

remedies

other

than

as

stated

herein,

and

to

the

estent

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.

r.

1–

I

RECEIVING-HANDLING

Before

unpacking

equipment,

check

carton

for

any

damage

that

may

have

occurred

during

shipment.

File

any

claims

for

loss

or

damagB

with the

delivering

carrier.

Assistance

for

tiling

or

settling

claims

may

be

obtained

from

distributor

and/or

equipmBnt

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.

ThB

information

is

located

on

the

rating

label

or

nameplate.

Model

_________

Serial

or

Style

No.

Date

of

Purchase

muter

4/95

ARC

WELDING

SAFETY

PRECAUTIONS

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.

ARC

WELDING

can

be

hazardous.

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual

and

national,

state,

and

local

codes.

6.

Turn

off

all

equipment

when

not

in

use.

7.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

Do

not

wrap

cables

around

your

body.

Ground

the

workpiece

to

a

good

electrical

(earth)

ground.

Do

not

touch

electrode

while

in

contact

with

the

work

(ground)

circuit.

11.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

12.

Wear

a

safety

harness

to

prevent

falling

if

working

above

floor

level.

1.

Wear

approved

face

shield

or

safety

goggles.

Side

shields

recommended.

2.

Wear

proper

body

protection

to

protect

skin.

4~

WARNING

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.

8.

9.

10.

13.

Keep

all

panels

and

covers

securely

in

place.

L_P

~

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.

1.

2.

3.

4.

5.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

(see

ANSI

Z49.1

listed

in

Safety

Standards)

to

protect

yourface

and

eyes

when

welding

or

watching.

Wear

approved

safety

glasses.

Side

shields

recommended.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

Use

approved

ear

plugs

or

ear

muffs

if

noise

level

is

high.

FUMES

AND

GASES

can

be

hazardous

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

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,

and

cleaners,

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.

WELDING

can

cause

tire

or

explosion.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

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

or

welding

wire

to

metal

objects

can

cause

sparks,

overheating,

or

fire.

6.

7.

8.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

Do

not

weld

on

closed

containers

such

as

tanks

or

drums.

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

1.

Protect

yourself

and

others

from

flying

sparks

and

hot

metal.

hazards.

2.

Do

not

weld

where

flying

sparks

can

strike

flammable

material.

9.

Do

not

use

welder

to

thaw

frozen

pipes.

3.

Remove

all

flammables

within

35

ft

(10.7

m)

of

the

welding

arc.

10.

Remove

stick

electrode

from

holder

or

cut

off

welding

wire

at

If

this

is

not

possible,

tightly

cover

them

with

approved

covers,

contact

tip

when

not

in

use.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

FLYING

SPARKS

AND

HOT

METAL

can

cause

injury.

and

grinding

cause

flying

metal.

As

welds

can

throw

off

slag.

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.

PRINCIPAL

SAFETY

STANDARDS

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

FL

33126

Safefyand

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

Weld

ing

Society

Standard

AWS

F4.1,

from

American

Welding

Society,

550

N.W.

LeJeune

Ad,

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-i,

from

Compressed

Gas

Association,

1235

Jefferson

Davis

Highway,

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

Boulevard,

Rexdale,

Ontario,

Canada

M9W

1

A3.

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

51

B,

from

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

MA

02269.

EMF

INFORMATION

TABLE

OF

CONTENTS

SECTION

1



SAFETY

INFORMATION

1

SECTION

2-

SPECIFICATIONS

1

2-1.

Volt-Ampere

Curves

2

2-2.

Duty

Cycle

2

SECTION

3INSTALLATION

3

3-1.

Installing

Work

Clamp

3

3-2.

Installing

Gas

Supply

4

3-3.

Gun

Polarity

Connections

5

3-4.

Installing

Drive

Rolls

And

Welding

Gun

5

3-5.

Connecting

Input

Power

6

3-6.

Installing

Wire

Spool

And

Adjusting

Hub

Tension

. . . .

8

3-7.

Threading

And

Feeding

Welding

Wire

8

SECTION

4-OPERATION

10

SECTION

5

MAINTENANCE

&

TROUBLESHOOTING

12

5-1.

Routine

Maintenance

12

5-2.

Overload

Protection

13

5-3.

Wire

Drive

Assembly

Maintenance

14

5-4.

Gun

Maintenance

15

5-5.

Troubleshooting

16

SECTION

6-

ELECTRICAL

DIAGRAMS

16

SECTION

7-

PARTS

LIST

17

Figure

7-1.

Main

Assembly

17

Figure

7-2.

MWG-21C

Gun

18

Figure

7-3.

Baffle

w/Cmpts

19

NOTE

~

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

among

those

also

normally

recommended

for

pacemaker

wearers.

Consult

your

doctor

for

complete

information.

modlo

1

4/93

SECTION

1

-

SAFETY

INFORMATION

modl.1

2/93



Read

all

safety

messages

throughout

this

manual.



Obey

all

safety

messages

to

avoid

injury.



Learn

the

meaning

of

WARNING

and

CAUTION.

\4

:1

~

II

~

Figure

1-1.

Safety

Information

SECTION

2-

SPECIFICATIONS

Table

2-1.

Welding

Power

Source

Specifications

-

.

Description

Type

Of

Output

Direct

Current/Constant

Voltage

(DC/CV)

Rated

Weld

Output

200

Amperes,

28

Volts

DC,

60%

Duty

Cycle

(See

Section

2-2)

Type

Of

Input

Power

Single-Phase;

60

Hz;

At

200

Or

230

Volts

AC

Input

Amperes

At

Rated

Output

46

A

At

200

V,

40

A

At

230

V

Maximum

Input

Amperes

While

Idling

1.2

A

At

200

V,

1

A

At

230

V

KVA/KW

Used

At

Rated

Output

9.5

kVAI8.3

kW

Maximum

KVA/KW

Used

While

Idling

0.24

kVAIO.17

kW

Max.

Open-Circuit

Voltage

42

Volts

DC

Control

Circuit

Voltage

At

Gun

24

Volts

DC

Welding

Processes

Gas

Metal

Arc

(GMAW)

And

Flux

Cored

Arc

Welding

(FCAW)

Calculated

Speed

Range

At

No

Load

128

To

.1051

ipm

(3.2

To

266.9

mpm)

Wire Diameter

Range

.030

To

.045

in

(0.8

To

1.1

mm)

Flux

Cored

Wire;

.023

To

.045

in

(0.6

To

1.1

mm)

Hard

Wire

Overall

Dimensions

Length:

37

in

(940

mm);

Width:

19

in

(483

mm);

Height:

30-1/4

in

(768

mm)

Weight

Net:

225

lb

(102

kg);

Ship:

271

lb

(123

kg)

Welding

Gun

Rated

Output

(Air

Cooled)

200

Amperes

At

60%

Duty

Cycle

Using

CO2

Shielding

Gas

(See

Section

2-2)

Cable

Length

15

ft

(4.6

m)

1

2

2

a

CAUTION

/

5

L

~

ELECTRIC

SHOCK

can

kiII~

MOVING

PARTS

can

injure.



Do

not

touch

live

electrical

parts.

~



Keep

away

from

moving

parts.

I



Disconnect

input

power

betoreJJ

4



Keep

all

panels

and

covers

closed

I

installing

or

servicing.

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

~j

NOTE

~

Turn

Off

switch

when

using

high

frequency.

4

Safety

Instructions

To

Avoid

Hazard

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.

OM-157

066

Page

1

2-1.

Volt-Ampere

Curves

Figure

2-1.

Volt-Ampere

Curves

2-2.

Duty

Cycle

£~

CAUTION

300

250-

Q,

200-

uJ

a.

<

0

~1

w

RATED

O(.IrPUT







 

-

I----





-

20

30

40 60 00

70

0000

150

Figure

2-2.

Duty

Cycle

Cl)

0

>

0

0

50

40

30

20

10

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

be

tween

the

curves

shown.

ssbl.1

10/91

S8~049424-D

0

25

50

75

100

125

150

175

200

225

DC

AMPERES

WELDING

LO



Do

not

weld

at

r

NGER

THAN

RATED

DUTY

CYCLE

can

damage

unit

or

gun

and

void

warranty.

ated

load

longer

than

shown

below.

wfwarn8.2

8/93

0

Definition

~

Duty

Cycle

is

percentage

of

10

~IE~E~

10

~~minutes

that

unit

or

gun

can

weld

at

rated

load

without

over

Minutes

heating.

UNIT

60%

Duty

Cycle

At

200

Amperes

g

6

Minutes

Welding

4

Minutes

Resting

Chart

GUN

~f=

GUN

%

DUTY

CYCLE

6

minutes

Welding

4

minutes

Resting

sD1.3

8/93

5B-150

215

60%

Duty

Cycle

At

180

Amperes

Using

Mixed

Gas

OM-157

066

Page

2

3-1.

Installing

Work

Clamp

Figure

3-1.

Installing

Work

Clamp

SECTION

3-

INSTALLATION

1

Work

Cable

2

Boot

Slide

boot

onto

work

cable.

Route

cable

out

front

panel

opening

from

inside.

3

Negative

()

Output

Terminal

Connect

cable

to

terminal

and

cov

er

connection

with

boot.

4

Hardware

4

5

Work

Clamp

Route

cable

through

clamp

handle

and

secure

to

top

of

clamp

with

hardware.

Close

door.

Tools

Needed:

r

1/2,

3/4

in

Ref.

51-154

630-A

2

3

OM-157

066

Page

3

3-2.

Installing

Gas

Supply

AA

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.

2

~

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.



Shutoff

shielding

gas

supply

when

not

in

use.

1

Cylinder

Bracket

warn4.1

9/91

2

S-Hook

Crimp

between

small

hole

in

brack

et

and

chain.

3

Chain

4

Snap

Crimp

onto

open

end

of

chain.

Obtain

gas

cylinder

and

chain

to

running

gear.

5

Cap

6

Cylinder

Valve

Remove

cap,

stand

to

side

of

valve,

and

open

valve

slightly.

Gas

flow

blows

dust

and

dirt

from

valve.

Close

valve.

7

Cylinder

8

Regulator/Flowmeter

Install

so

face

is

vertical.

9

Gas

Hose

Connection

Fitting

has

5/8-18

right-hand

threads.

Obtain

and

install

gas

hose.

10

Flow

Adjust

Typical

flow

rate

is

20

Cf

h

(cubic

feet

per

hour).

Check

wire

man

ufacturers

recommended

flow

rate.



Make

sure

flow

adjust

is

closed

-

when

opening

cylinder

to

avoid

damage

to

the

flowmeter.

11

CO2

Adapter

12

0-Ring

Install

adapter

with

0-ring

between

regulator/flowmeter

and

CO2

cylinder.

Tools

Needed:

~

5/8,1-1/8in

8sb3.1

5/94



ST-154

623

/

ST-158

697-A

Figure

3-2.

Typical

Regulator/Flowmeter

Installation

OM-157

066

Page

4

3-3.

Gun

Polarity

Connections

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.

___________________

swaml.1

2193

Shown

As

Shipped



Set For

Electrode

Positive

(DCEP)

For

Solid

Steel

Or

Aluminum

Wires

(GMAW

Process).

Wire

Drive

Assembly

Lead

To

Positive

(+)

Output

Terminal

Work

Clamp

Lead

To

Negative

()

Output

Terminal

GUN

POLARITY

CHANGEOVER

CONNECTIONS

Reverse

Lead

Connections



For

Electrode

Negative

(DCEN)

For

Flux

Cored

Wires

(FCAW

Process).

Drive

Assembly

Becomes

Negative

1

Polarity

Changeover

Label

2

Wire

Drive

Assembly

3

Positive

(+)

Output

Terminal

4

Negative

()

Output

Terminal

Always

read

and

follow

wire

man

ufacturers

recommended

polarity.

5

Circuit

Breaker

CB1

(see

Section

5-2).

Tools

Needed:

~

3/4,11/l6in

Rot.

ST-153

874-B

S-144

449-c

3

Figure

3-3.

Gun

Polarity

Connections

4

3-4.

Installing

Drive

Rolls

And

Welding

.Gun

5

1

Pressure

Adjustment

2

Pressure

Assembly

3

Drive

Roll

4

Securing

Screw

Install

correct

drive

roll

for

wire

size

and

type

using

supplied

screws.

5

Wire

Drive

Assembly

6

Gun

Securing

Knob

7

Gun

End

Loosen

securing

knob.

Insert

gun

end

through

opening

until

it

bot

toms

against

drive

assembly.

Tighten

knob.

8

Gun

Trigger

Plug

Insert

into

receptacle,

and

tighten

threaded

collar.

Close

pressure

assembly.

Close

door.

ST-

154

621

/

Ret.

ST-154

624-A

7

Tools

Needed:

6

Figure

3-4.

Gun

Connections

OM-157

066

Page

5

3-5.

Connecting

Input

Power

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.



Have

only

qualified

persons

install

unit.



Installation

must

meet

National

Electrical

Code

and

all

other

codes.

swarn3.1

2/93

A.

Positioning

Jumper

Links

Figure

3-5.

Input

Voltage

Jumper

Links

Location

OM-157

066

Page

6

B.

Connecting

Input

Power

Have

only

qualified

persons

make

this

installation.

1

Line

Disconnect

Device

Of

Proper

Rating

2

230

Volts

AC

Wall

Receptacle

3

Input

Conductors

4

Grounding

Conductor

Select

size

and

length

using

Table

3-1.

Conductor

rating

must

comply

with

national,

state,

and

local

electrical

codes.

Install

and

connect

grounding

conductor

and

input

conductors

in

conduit

or

equivalent

between

wall

receptacle

and

deenergized

line

disconnect

device.

Connect

grounding

conductor

first,

then

line

input

conductors.

Be

sure

grounding

conductor

goes

to

an

earth

ground.

5

Overcurrent

Protection

Select

type

and

size

using

Table

3-1.

Install

into

deenergized

line

disconnect

device

(fused

dis

connect

switch

shown).

6

Input

Power

Plug

Turn

off

unit

Power

switch,

and

connect

plug

to

wall

receptacle.

ssb2.2

12/94



Ret.

ST-154 619-B

I

Ref.

ST-149

405-B

Figure

3-6.

Input

Power

Connections

Table

3-1.

Electrical

Service

Requirements*

Input

Voltage

200 230

input

Amperes

At

Rated

Output

46

40

Recommended

Standard

Fuse

Or

Circuit

Breaker

Rating

In

Amperes

70

60

Mm

Input

Conductor

Size

In

AWGIKcmiI

8

8

Max

Input

Conductor

Length

In

Feet

(Meters)

89

(27)

117(36)

Mm

Grounding

Conductor

Size

In

AWGIKcmiI

8

10

*

These

values

are

calculated

from

the

1993

edition

of

the

National

Electrical

Code

(NEC).

5-0092-H

Tools

Needed:

OM.157

066

Page

7

3-6.

Installing

Wire

Spool

And

Adjusting

Hub

Tension

Figure

3-7.

Installing

Wire

Spool

And

Adjusting

Hub

Tension

3-7.

Threading

And

Feeding

Welding

Wire

£~

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

instructed

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.

swarn5.1

10/91

/swarn2.1

9/91

Turn

Off

unit.

1

Wire

Spool

2

Gun

Contact

Tip

If

necessary,

cut

welding

wire

off

at

contact

tip,

and

retract

wire

onto

spool

and

secure.

3

Retaining

Ring

4

Compression

Spring

Remove

ring

and

pull

off

spool.

Compression

spring

is

used

with

8

in

(200

mm)

spools.

5

Hub

6

Hub

Pin

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.

Thread

welding

wire

(see

Section

3-7).

Close

door.

Tools

Needed:

~

15/16

in

Ref.

ST-i

54

626~B

/

Ref.

ST-072

573-B

9

OM-157

066

Page

8

1

Wire

Spool

2

Welding

Wire

3

Inlet

Wire

Guide

4

Pressure

Adjustment

Knob

5

Pressure

Assembly

6

Drive

Roll

7

Outlet

Wire

Guide

8

Gun

Conduit

Cable

Lay

gun

cable

out

straight.

Close

and

tighten

pressure

assembly,

and

let

go

of

wire.

Remove

gun

nozzle

and

contact

tip.

/

Press

gun

trigger

until

wire

comes

out

of

gun.

Reinstall

contact

tip

and

nozzle.

Feed

wire

to

check

drive

roll

pressure.

Tighten

knob

enough

to

prevent

slipping.

/

Cutoff

wire.

Close

and

latch

door.

Figure

3-8.

Threading

And

Feeding

Welding

Wire

ST-800

739-A

I

ST-i

54

251

/

S-0627-A

Hold

wire

tightly

to

keep

it

from

unraveling.

Open

pressure

assembly.

Pull

and

hold

wire;

cut

off

end.

Push

wire

thru

guides

into

gun;

continue

to

hold

wire.

-4

~

I0~~

POWER

~

QOFF

Set

switch.

-4

(

I

-4

OM-157

066

Page

9

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

(MSDSs)

and

manufacturers

instructions

for

material

used.

WELDING

can

cause

tire

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

ARCING

can

damage

switch.



Do

not

change

Voltage

switch

position

while

welding.

Arcing

inside

switch

can

damage

contacts,

causing

switch

to

fail.

t1

~

~

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing.

I

Wear

welding

helmet

with

correct

shade

of

filter.



Wear

correct

eye,

ear,

and

body

protection.

,~

~

~

MOVING

PARTS

can

cause

injury.

S

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

8/92

Wear

the

following

while

welding:

2

3

/

1

Dry,

Insulating

Gloves

2

Safety

Glasses

With

Side

Shields

3

Welding

Helmet

With

Correct

Shade

Of

Filter

(See

ANSI

Z49.1)

sb3.1

1/94

Figure

4-1.

Safety

Equipment

1

Wire

Mode

Switch

For

better

control

of

wire

speed

use

Low

position

when

wire

speed

is

between

90

and 670

ipm.

Use

Full

position

when

wire

speed

is

be

tween

150

ipm

and

1030

ipm.

2

Voltage

Range

Selector

Place

switch

in

desired

position.

See

inside

rear

cover

for

settings.

Ret.

ST-153

874-B

/

S-171

601

Figure

4-2.

Center

Battle

Controls

OM-157

066

Page

10

Tools

Needed:

1

Wire

Speed

Control

Use

control

to

set

wire

feed

speed.

2

Voltage

Control

Use

control

and

Voltage

Range

Selector

(see

Figure

4-2)

to

set

arc

voltage.

Step

6

of

Low

range

and

Step

1

of

High

range

overlap.

3

Pilot

Light

4

Power

Switch

Use

switch

to

turn

unit

On

and

Off.

The

pilot

light

comes

on

when

unit

is

turned

on.

5

Work

Clamp

Use

wire

brush

or

sandpaper

to

clean

metal

at

weld

joint

area.

Connect

work

clamp

to

clean,

paint-free

location

on

workplece,

as

close

as

possible

to

weld

area,

3

4

Figure

4-3.

Front

Panel

Controls

Ref.

ST-154

622-B

/

ST-171

639/Ref.

ST-154

251

OM-157

066

Page

11

SECTION

5-

MAINTENANCE

&

TROUBLESHOOTING

LA

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.

Maintenance

and

troubleshooting

to

be

performed

only

by

qualified

persons.

swarns.2

2/93



M

OVING

PARTS

can

cause

injury.



Keep

away

from

moving

parts.

4~



Keep

away

from

pinch

points

such

as

drive

rolls.

4~

5-1.

Routine

Maintenance

a

Turn

Off

all

power

before

maintaining.

3

Months

Replace

Unreadable

Labels

Clean

_

~

1~ghten

3-1

t~~e)

Terminals



-

14-Pin

Cord

Gas

Hose

Gun

Cable

Figure

5-1.

Maintenance

Schedule

OM-157

066

Page

12

5-2.

Overload

Protection

£~

WARNING

A.

Circuit

Breaker

CB1

B.

Fuses

Fl

And

F2

READ

SAFETY

BLOCKS

at

start

of

Section

5

before

proceeding.

1

Circuit

Breaker

CB1

If

CB1

opens,

wire

feed

stops.

Check

gun

liner

for

blockage

or

kinks,

and

check

for

jammed

wire,

binding

drive

gear,

or

misaligned

drive

rolls.

Allow

a

cooling

period

before

resetting

CB1.

Ref.

ST-153

874-B

Figure

5-2.

Circuit

Breaker

CB1

Turn

Off

unit

and

disconnect

input

power.

1

Fuse

Fl

(See

Parts

List

For

Rating)

Fl

protects

the

115

volts

ac

wind

ing

of

transformer

Ti.

If

Fl

opens,

all

weld

output

stops

and

pilot

light

PL1

goes

out.

2

Fuse

F2

(See

Parts

List

For

Rating)

F2

protects

the

24

volts

ac

winding

of

transformer

Ti.

If

F2

opens,

all

weld

output

stops.

Ref.

ST-800

928-B

C.

Overheating

Figure

5-3.

Fuse

Location

Figure

5-4.

Overheating

OM-157

066

Page

13

5-3.

Wire

Drive

Assembly

Maintenance

4~

WARNING

READ

SAFETY

BLOCKS

at

start

of

Section

5

before

proceeding.

Figure

5-5.

Wire

Drive

Assembly

Maintenance

Turn

Off

unit

and

disconnect

Input

power.

1

Wire

Spool

2

Gun

Contact

Tip

Cut

welding

wire

off

at

contact

tip.

Retract

wire

onto

spool

and

Se-

cure.

3

Drive

Roll

Alignment

Bolt

Turn

in

or

out

until

groove

lines

up

with

wire

guide.

4

Drive

Roll

5

Wire

lnletGuide

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.

6

Pressure

Roll

Arm

7

Cotter

Pin

8

Pin

9

Screw

10

Bearing

Remove

bearing

as

shown.

Install

new

bearing

and

secure

with

screw.

Reinstall

arm

onto

pin

and

secure

with

cotter

pin.

Thread

welding

wire

(see

Section

3-7).

Close

door.

Tools

Needed:

Ret.

ST-154

626-B

I

SA-145

T6~

I

ST-~54

633

OM-157

066

Page

14

5-4.

Gun

Maintenance

I~hd~~

READ

SAFETY

BLOCKS

at

start

of

Section

5

before

proceeding.

FLYING

METAL

CHIPS

AND

DIRT

can

cause

injury

and

damage

equipment.



Point

gun

away

from

people

and

in

a

safe

direction

when

blowing

out

with

compressed

air.

Figure

5-6.

Gun

Maintenance

swarnlO.1

10191

Turn

Off

unit

and

disconnect

input

power.

1

Wire

Spool

Cut

welding

wire

off

at

contact

tip.

Retract

wire

onto

spool

and

se

cure.

2

Gun

Securing

Knob

Loosen

knob

and

remove

gun

and

trigger

plug.

Reassemble

gun.

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.

Reinstall

gun

(see

Section

3-4).

Thread

welding

wire

(see

Section

3-7).

Close

door.

Ret.

ST.154 624-A

/

ST-801

149

7

7

Remove

nozzle,

contact

tip,

and

liner

collet.

out

gun

casin

Gun/Feeder



COnnector

7

-

Remove

liner.

1~

Tools

Needed:

~

3/8

in

OM-157

066

Page

15

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