Miller KF785422 Owner's manual

Brand: Miller

Model: KF785422

Category: Welding System

Type: Owner's manual

This manual is also suitable for

Regency 250

cover 5/94 − ST-121 471-D PRINTED IN USA

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.

For help, call your distributor

or: MILLER Electric Mfg. Co., P.O. Box 1079,

Appleton, WI 54912 414-734-9821

OWNER’S

MANUAL

February 1995 Form: OM-293F

Effective With Serial No. KF785422

Constant Voltage DC Arc Welding Power Source

For GMAW Welding

200 Amperes, 28 Volts DC At 60% Duty Cycle

Uses Single-Phase Input Power

Fan-On-Demand And Receptacle Overload Protection

14-Pin Remote Control Receptacle

For Options And Accessories, See Rear Cover

Regency® 250

miller_war1 6/95

MILLER’S TRUE BLUE® LIMITED WARRANTY

Effective January 1, 1995

(Equipment with a serial number preface of “KD” or newer)

This limited warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.

LIMITED WARRANTY − Subject to the terms and conditions below, MILLER Elec-

tric 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 de-

fects in material and workmanship at 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 warranty periods listed below, MILLER will repair or replace any war-

ranted parts or components that fail due to such defects in material or workman-

ship. MILLER must be notified in writing within thirty (30) days of such defect or fail-

ure, at which time MILLER will provide instructions on the warranty claim proce-

dures 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

* Original main power rectifiers

* Inverters (input and output rectifiers only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources

* Plasma Arc Cutting Power Sources

* Semi-Automatic and Automatic Wire Feeders

* Inverter Power Supplies

* Intellitig

* Robots

3. 2 Years — Parts and Labor

* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

* Air Compressors

4. 1 Year — Parts and Labor

* Motor Driven Guns

* Process Controllers

* IHPS Power Sources

* Water Coolant Systems

* HF Units

* Grids

* Spot Welders

* Load Banks

* SDX Transformers

* Running Gear/Trailers

* Plasma Cutting Torches (except APT, ZIPCUT & PLAZCUT Models)

* Tecumseh Engines

* Deutz Engines (outside North America)

* Field Options

(NOTE: Field options are covered under True Blue® for the remaining

warranty period of the product they are installed in, or for a minimum of

one year — whichever is greater.)

5. 6 Months — Batteries

6. 90 Days — Parts and Labor

* MIG Guns/TIG Torches

* APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches

* Remote Controls

* Accessory Kits

* Replacement Parts

MILLER’S True Blue® Limited Warranty shall not apply to:

1. 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.

2. Consumable components; such as contact tips, cutting nozzles, contactors

and relays or parts that fail due to normal wear.

3. Equipment that has been modified by any party other than MILLER, or equip-

ment 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 opera-

tion 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 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 replace-

ment 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 replace-

ment will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a MILLER autho-

rized service facility as determined by MILLER. Therefore no compensation or re-

imbursement 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 CON-

TRACT, 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, IN-

CLUDING 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 spe-

cific 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.

WHO DO I CONTACT?

For help,

H contact your distributor

For additional information, such as

Technical Manuals (Service And Parts)

Engine Manuals

Circuit And Wiring Diagrams

Process Handbooks

User’s Guides

Distributor Directories

H contact your distributor

To file a claim for loss or damage during

shipment,

H contact the delivering carrier

For assistance in filing or settling claims,

H contact your distributor and/or equipment

manufacturer’s Transportation

Department

Miller Electric Mfg. Co.

H CALL:

414-735-4505

H FAX:

800-637-2348 (in USA), or

414-735-4136 (outside USA)

H WRITE:

Miller Electric Mfg. Co.

P.O. Box 1079

Appleton, WI 54912 USA

Always provide Model Name and Serial or Style Number

OM-293G − 2/95

EMF INFORMATION

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.

Considerations About Welding And The Effects Of Low Frequency Electric And

Magnetic Fields

NOTE

mod10.1 4/93

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 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Installing Handles 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Selecting A Location And Moving Welding Power Source 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Selecting And Preparing Weld Output Cables 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Connecting To Weld Output Receptacles 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Remote 14 Receptacle Information And Connections 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Connecting Input Power 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − MAINTENANCE & TROUBLESHOOTING 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Overload Protection 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − ELECTRICAL DIAGRAMS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − PARTS LIST 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-1. Main Assembly 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-2. Panel, Front w/Components 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-3. Switch, Selector 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 7-4. Panel, Rear w/Components 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-293 Page 1

SECTION 1 − SAFETY INFORMATION

mod1.1 2/93

Read all safety messages throughout this manual.

Obey all safety messages to avoid injury.

Learn the meaning of WARNING and CAUTION.

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 Re-

sult

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.

NOTE

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Disconnect input power before

installing or servicing.

WARNING

READ SAFETY BLOCKS at start of

Section 3-1 before proceeding.

WARNING

1 2

CAUTION

MOVING PARTS can injure.

• Keep away from moving parts.

• Keep all panels and covers closed

when operating.

Turn Off switch when using high frequency.

Figure 1-1. Safety Information

SECTION 2 − SPECIFICATIONS

Table 2-1. Welding Power Source

Specification Description

Type Of Output Constant Voltage DC

Rated Weld Output 200 Amperes, 28 Volts DC At 60% Duty Cycle (See Section 2-2)

Type Of Input Power Single-Phase; 200, 230, 460, 575 Volts AC; 60 Hz

Input Amperes At Rated Output 46 A At 200 V, 40 A At 230 V, 20 A At 460 V, 16 A At 575 V

Input Amperes While Idling 1.2 A At 200 V, 1.0 A At 230 V, 0.5 A At 460 V

KVA/KW Used At Rated Output 9.15 kVA/8.3 kW

KVA/KW Used While Idling 0.244 kVA/0.134 kW

Max. Open-Circuit Voltage 42 Volts DC

Welding Process Gas Metal Arc Welding (GMAW)

Input Power Cord 8 ft (2.4 m)

Work Cable 10 ft (3 m)

Overall Dimensions See Figure 3-3

Weight Net: 168 lb (76 kg); Ship: 172 lb (78 kg)

OM-293 Page 2

2-1. Volt-Ampere Curves

ssb1.1 10/91 − ST-049 424-D

The volt-ampere curves show the

minimum and maximum voltage

and amperage output capabilities of

the welding power source. Curves

of other settings fall between the

curves shown.

Figure 2-1. Volt-Ampere Curves

2-2. Duty Cycle

CAUTION

WELDING LONGER THAN RATED DUTY CYCLE can damage unit and void warranty.

• Do not weld at rated load longer than shown below.

warn7.1 8/93

Duty Cycle is percentage of 10

minutes that unit can weld at

rated load without overheating.

sb1.2 8/93 − ST-155 647

Minutes

60% Duty Cycle At 200 Amperes

Definition Chart

6 Minutes Welding 4 Minutes Resting

Figure 2-2. Duty Cycle Chart

SECTION 3 − INSTALLATION

3-1. Installing Handles

ST-155 896-A

1 Wrapper

2 Hexhead Screw

3 Handle

Install handle using screws on

wrapper. Repeat for left side of unit.

Tools Needed:

3/8 in

Figure 3-1. Installing Handles

OM-293 Page 3

3-2. Selecting A Location And Moving Welding Power Source

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Disconnect input power conductors from de-

energized supply line BEFORE moving welding

power source.

FIRE OR EXPLOSION can result from

placing unit on, over, or near com-

bustible surfaces.

• Do not locate unit on, over, or near combustible

surfaces.

• Do not install unit near flammables.

BLOCKED AIRFLOW causes over-

heating and possible damage to unit.

• Do not block or filter airflow.

Warranty is void if any type of filter is used.

FUMES can be hazardous; LACK OF

FRESH AIR AND PROPER VEN-

TILATION can be harmful.

• Do not breathe welding fumes.

• Place unit only where there is a good fresh air supply

and proper ventilation.

FALLING EQUIPMENT can cause

serious personal injury and equipment

damage.

• Use lifting eye to lift unit only, NOT running gear, gas

cylinders, or any other accessories.

• Use equipment of adequate capacity to lift the unit.

swarn11.1 3/93

ssb9.1* 5/94 − ST-800 402 / ST-121 471-D

1 Lifting Handles

2 Lifting Forks

Use lifting handles or lifting forks to

move unit.

If using lifting forks, extend forks

beyond opposite end of unit.

3 Rating Label

Use rating label to determine input

power needs.

4 Line Disconnect Device

Locate unit near correct input

power supply.

Movement

Location And Airflow

18 in

(460 mm)

18 in

(460 mm)

Special installation may be

required where gasoline or

volatile liquids are present −

see NEC Article 511 or CEC

Section 20.

Figure 3-2. Movement And Location Of Welding Power Source

OM-293 Page 4

Overall dimensions (A, B, and C) include lifting eye, handles, hardware, etc.

NOTE

ST-155 897-A

Inches Millimeters

A 23-1/4 591

B 16 406

C 22-3/4 578

D 13 330

E 12-1/4 311

F 3/4 19

G 16-1/16 408

H 14-29/32 379

J 5-13/32 137

K 13/32 10

L 7/16 Dia. 11 Dia.

6 Holes 6 Holes

Front

Figure 3-3. Overall Dimensions And Base Mounting Hole Layout

3-3. Selecting And Preparing Weld Output Cables

Ref. S-0336

1 Weld Output Cable

Determine total cable length in weld

circuit and maximum welding am-

peres. Use Table 3-1 to select prop-

er cable size.

Use shortest cables possible.

Do not use damaged cables.

2 Terminal Lug

Use lugs of proper amperage ca-

pacity and hole size for connecting

to work clamp and wire feeder.

3 Wire Feeder

Install according to manufacturer’s

instructions.

4 Work Clamp

Install onto work cable.

5 Male Camlok Connector

Install onto weld cable as shown in

Figure 3-5.

Tools Needed:

10 ft (3 m)

Total Cable

Length In Weld

Circuit = 20 ft (6 m)

10 ft (3 m)

For Example,

Figure 3-4. Selecting And Preparing Weld Output Cables

OM-293 Page 5

Table 3-1. Weld Cable Size*

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Welding

Amperes

10 To 60%

Duty Cycle

60 Thru 100%

Duty Cycle

10 Thru 100% Duty Cycle

100 4 4 4 3 2 1 1/0 1/0

150 3 3 2 1 1/0 2/0 3/0 3/0

200 3 2 1 1/0 2/0 3/0 4/0 4/0

250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0

300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0

*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. S-0007-D

sb6.4 11/92 − ST-155 015

1 Weld Output Cable

Strip insulation as shown.

2 Copper Strip (Two Included)

3 Connector Body

Wrap strip around bare weld cable

(use two on small diameter cable),

and insert into connector body.

4 Setscrew

Tighten setscrew against copper

strip.

5 Handle

6 Pin

Slide handle over connector body

so holes align; secure by tapping

pin into place.

If job requires cable larger than 3/0

AWG, use 2 ft. (610 mm) or shorter

piece of 3/0 AWG cable for Camlok

connector installation. Connect

other end of short cable to larger

weld cable.

1 in

(26 mm)

Tools Needed:

7/32 in

Figure 3-5. Male Camlok Connector Assembly

OM-293 Page 6

3-4. Connecting To Weld Output Receptacles

WARNING

ELECTRIC SHOCK can kill; ARCING can burn skin or damage electrical equipment.

• Do not touch live electrical parts.

• Turn Off welding power source before making any weld output connections.

• Do not change position of welding cable connectors while welding.

• Be sure connectors are secure in receptacles before welding.

swarn12.2 2/93

Ref. ST-159 395-A

1 Positive (+) Weld Output

Receptacle

2 Negative (−) Weld Output

Receptacle

For Electrode Positive (DCEP),

connect work cable to negative (−)

receptacle and electrode cable

from wire feeder to positive (+)

receptacle.

For Electrode Negative (DCEN),

reverse cable connections.

1 2

Figure 3-6. Weld Output Connections

3-5. Remote 14 Receptacle Information And Connections

sb7.1* 12/93 − ST-121 471-D / Ref. S-0004-A / S-0750

1 Remote 14 Receptacle RC3

(See Table 3-2)

2 Keyway

3 Plug

4 Threaded Collar

To connect to receptacle, align

keyway, insert plug, and tighten

threaded collar.

Figure 3-7. Remote 14 Connections

OM-293 Page 7

Table 3-2. Remote 14 Socket Information

A 24 volts ac. Protected by circuit breaker CB2.

B Contact closure to A completes 24 volts ac contactor control circuit.

I 115 volts ac. Protected by circuit breaker CB1.

J Contact closure to I completes 115 volts ac contactor control circuit.

G Circuit common for 24 and 115 volts ac circuits.

K Chassis common.

Socket Information

*The remaining sockets are not used.

Socket*

3-6. Connecting Input Power

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

ssb5.1* 2/92 - S-0279-B

Jumper links allow operation on dif-

ferent input voltages and are facto-

ry set for the highest input voltage.

Check input voltage available at

site.

Remove wrapper to check jumper

links.

1 Input Voltage Label − Only

One Is On Unit

Look at jumper links and compare

link position with unit label.

2 Input Voltage Jumper Links

Move links to match input voltage.

For example, use 230 volts position

when 230 volts input power is avail-

able.

Reinstall wrapper or go on to Figure

3-9.

Tools Needed:

3/8 in

S-153 408-A

200V 230V 460V

230 V 460V 575V

S-047 734-A

Figure 3-8. Input Voltage Jumper Links Location

S-0092-G

OM-293 Page 8

B. Connecting Input Power

Have only qualified persons make

this installation.

1 Line Disconnect Device Of

Proper Rating

2 Grounding Conductor − Green

Or Green With Yellow

Stripe(s)

3 Input Conductors

Install grounding conductor and

input conductors from unit to

deenergized line disconnect

device.

Connect grounding conductor first,

then line input conductors.

Be sure grounding conductor goes

to an earth ground.

4 Overcurrent Protection

Select type and size using

Table 3-3. Install into deenergized

line disconnect device (fused

disconnect switch shown).

ssb2.3 11/93 − ST-155 895-A

Tools Needed:

Figure 3-9. Input Power Connections

Table 3-3. Electrical Service Requirements*

Input Voltage

200 230 460 575

Input Amperes At Rated Output

46 40 20 16

Recommended Standard Fuse Or Circuit Breaker

Rating In Amperes

70 60 30 25

Input Conductor Size In AWG/Kcmil

8 8 12 14

Max Input Conductor Length In Feet (Meters)

89 (27) 118 (36) 188 (57) 191 (58)

Grounding Conductor Size In AWG/Kcmil

8 10 12 14

These values are calculated from the 1993 edition of the National Electrical Code (NEC).

1 Recommended fuse or circuit breaker size is that closest to 150% of rated input amperage of the welding power source. Article 630-12(a) of NEC

allows fuse or circuit breaker sizing up to 200% of rated input amperage.

2 Input conductor size is for insulated copper wire with 75°C rating with not more than three single current-carrying conductors in a cable or raceway

(Table 310-16 of NEC).

3 Maximum length is to prevent more than a 3% voltage drop between service entrance and input terminals of the welding power source (Articles

210-19(a) and 215-2(b) of NEC).

4 The grounding conductor shall be colored or identified as specified in the NEC. Grounding conductor size for copper wire is not required to be larger

than input conductor (Article 250-95 of NEC).

OM-293 Page 9

SECTION 4 − OPERATION

WARNING

ELECTRIC SHOCK can kill.

• Always wear dry insulating gloves.

• Insulate yourself from work and ground.

• Do not touch live electrical parts.

• Keep all panels and covers securely in place.

FUMES AND GASES can be hazardous

to your health.

• Keep your head out of the fumes.

• Ventilate area, or use breathing device.

• Read Material Safety Data Sheets (MSDSs) and

manufacturer’s instructions for material used.

WELDING can cause fire or explosion.

• Do not weld near flammable material.

• Watch for fire; keep extinguisher nearby.

• Do not locate unit over combustible surfaces.

• Do not weld on closed containers.

• Allow work and equipment to cool before handling.

ARC RAYS can burn eyes and skin;

NOISE can damage hearing.

• Wear welding helmet with correct shade of filter.

• Wear correct eye, ear, and body protection.

MOVING PARTS can cause injury.

• Keep away from moving parts.

• 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.

See Safety Precautions at beginning of manual for ba-

sic welding safety information.

swarn6.1 10/91

ST-121 470-B

1 Voltage Range Receptacles

2 Range Selector Jack Plug

3 Voltage Adjustment Switch

4 Power Switch

5 Pilot Light

Figure 4-1. Controls

Wear the following while welding:

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

123

Figure 4-2. Safety Equipment

OM-293 Page 10

1 Work Clamp

Connect work clamp to a clean,

paint-free location on workpiece, as

close to weld area as possible.

Use wire brush or sandpaper to

clean metal at weld joint area. Use

chipping hammer to remove slag

after welding.

sb4.1 2/93

Tools Needed:

Figure 4-3. Work Clamp

CAUTION

ARCING can damage contact surfaces.

• Do not change Voltage Range selector plug position while welding.

Arcing can damage contacts, making plug connection inoperative.

warn5.1* 2/93

Ref. ST-159 395-A

1 Voltage Range Selector Plug

Use plug position to select open-

circuit voltage range.

2 High 20-30 V Range

Receptacle

3 Low 10-20 V Range

Receptacle

To connect to a receptacle, insert

plug and turn clockwise.

Figure 4-4. Voltage Range Selector Plug

OM-293 Page 11

CAUTION

ARCING can damage switch.

• Do not change Voltage Adjustment switch position while welding.

Arcing inside switch can damage contacts, causing switch to fail.

warn5.1 2/93

1 Voltage Adjustment Switch

Use switch to adjust open-circuit

voltage within range selected by

Voltage Range selector plug. Each

position of the switch represents a

change of 2 volts.

Figure 4-5. Voltage Adjustment Switch

1 Power Switch

2 Pilot Light

Use switch to turn unit and pilot light

On and Off.

3 Fan Controlled By Thermostat

Fan motor is thermostatically

controlled and only runs when

cooling is needed.

Figure 4-6. Power Switch And Pilot Light

OM-293 Page 12

Begin Welding

ssb6.1 9/92

Install &

Connect

Equipment

Install & Prepare

Wire Feeding

System

Put On

Personal Safety

Equipment

Set Controls

Turn On

Shielding Gas

Turn On Feeder

And Welding

Power Source

Figure 4-7. Sequence Of Gas Metal Arc Welding (GMAW)

SECTION 5 − MAINTENANCE & TROUBLESHOOTING

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.

MOVING PARTS can cause injury.

• Keep away from moving parts.

Maintenance to be performed only by qualified persons.

swarn8.1 2/93

5-1. Routine Maintenance

Turn Off all power before maintaining.

ST-121 471-D

3 Months

Blow Out

Vacuum

Inside

6 Months

Clean

And

Tighten Weld

Connections

Replace

Unreadable

Labels

Tape Or

Replace

Cracked

Cables

3 Months

See

Section

3-4

− −

During Heavy Service,

Clean Monthly

Figure 5-1. Maintenance Schedule

OM-293 Page 13

5-2. Overload Protection

READ SAFETY BLOCKS at start of

Section 5 before proceeding.

WARNING

A. Overheating

minutes

When overheated, cooling fan begins

to run, and output may stop.

Let fan run for

15 minutes.

Start welding.

ssb10.1 1/94 − ST-121 471-D

Figure 5-2. Overheating

Thermostats TP1 and TP2 protect the unit from damage due to overheating. If main transformer T1 and/or rectifier

assembly SR3 get too hot, TP1 and/or TP2 close and fan motor energizes. The fan keeps running until the transformer

and rectifier are cool.

Under normal operation, the fan may not run.

Thermostat TP3 also protects the unit from damage due to overheating. If rectifier assembly SR3 gets too hot, TP3

opens and weld output stops. Wait several minutes before trying to weld.

B. Circuit Breakers CB1 And CB2

Ref. ST-159 395-A

1 Circuit Breaker CB1

CB1 protects the 115 volts ac wind-

ing of transformer T1 from over-

load. If CB1 opens, the 115 volts ac

output to the Remote 14 receptacle

stops.

2 Circuit Breaker CB2

CB2 protects the 24 volts ac wind-

ing of transformer T1 from over-

load. If CB2 opens, the 24 volts ac

output to the Remote 14 receptacle

stops.

Press button to reset a breaker.

Figure 5-3. Circuit Breakers CB1 And CB2

OM-293 Page 14

5-3. Troubleshooting

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Turn Off welding power source, and disconnect

input power before inspecting, maintaining, or

servicing.

HOT PARTS can cause severe burns.

• Allow cooling period before servicing.

MOVING PARTS can cause injury.

• Keep away from moving parts.

Troubleshooting to be performed only by qualified

persons.

swarn9.1 2/93

Table 5-1. Welding Trouble

Trouble Remedy Section

No weld output; unit completely inopera-

tive; pilot light not on.

Place Power switch in On position. − −

Place line disconnect device in On position. 3-6

Check and replace fuse(s) if necessary. 3-6

Check for proper input connections. 3-6

Erratic weld output. Check weld output and input power connections. 3-4, 3-6

Secure Voltage Range Selector Plug in receptacle. Figure 4-4

No open-circuit voltage; pilot light on;

wire does not feed.

Secure gun trigger connections or see gun Owner’s Manual. − −

Secure plug in Remote 14 receptacle RC3. 3-5

No open-circuit voltage; pilot light on;

wire feeds.

Secure Voltage Range Selector Plug in receptacle. Figure 4-4

Thermostat TP3 open (overheating). Allow unit to cool. 5-2

Have Factory Authorized Service Station/Service Distributor

check contactor W.

− −

Open-circuit voltage normal; pilot light

on; wire does not feed.

Check gun or wire feeder Owner’s Manual. − −

No 115 volts ac output at Remote 14

receptacle RC3.

Reset circuit breaker CB1, if necessary. 5-2

No 24 volts ac output at Remote 14 re-

ceptacle RC3.

Reset circuit breaker CB2, if necessary. 5-2

OM-293 Page 15

SECTION 6 − ELECTRICAL DIAGRAMS

SB-119 335

Figure 6-1. Circuit Diagram For Welding Power Source

OM-293 Page 16

Figure 6-2. Wiring Diagram For Welding Power Source

SC-121 384-B

OM-293 Page 17

SECTION 7 − PARTS LIST

456

Fig 7-2

Fig 7-4

ST-121 583-C

Figure 7-1. Main Assembly

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 7-1. Main Assembly

Quantity

1 +047 167 WRAPPER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 134 327 LABEL, warning general precautionary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 081 588 HANDLE, lifting 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 038 620 LINK, jumper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 TE1 038 779 BLOCK, term 30A 5P 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 070 765 STRIP, mtg term block 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Z 171 712 STABILIZER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

022 391 STRIP, polyest gl lam .062 x 1.500 x 3.125 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Fig 7-4 PANEL, rear w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 071 906 CORD SET, 8-10ga 3/c 8ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 C7 156 517 CAPACITOR, elctlt 15000uf 45VDC 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 081 594 ANGLE, mtg RH capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 081 590 STRIP, mtg center capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 081 592 ANGLE, mtg LH capacitor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 080 509 GROMMET, scr No. 8/10 panel hole 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 TP1 123 317 THERMOSTAT, NO 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 T1 153 406 TRANSFORMER, pwr main 200/230/460 (consisting of ) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 153 407 COIL, pri/sec 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 T1 122 326 TRANSFORMER, pwr main 230/460/575 (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 119 317 COIL, pri/sec 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 081 586 BASE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 039 629 PLUG, male twlk insul 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 Fig 7-2 PANEL, front w/components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 +049 150 PANEL, side 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109 035 LABEL, warning electric shock can kill 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

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