Miller KJ031020 Owner's manual

Miller
Brand
Miller
Model
KJ031020
Category
Welding System
Type
Owner's manual

This manual is also suitable for

OM
189
482
August
1998
Processes
189
4828
MIG
(GMAW)
Welding
Flux
Cored
(FCAW)
Welding
Description
1~OLSfi
Arc
Welding
Power
Source
And
Wire
Feeder
MW225
OWNERS
MANUAL
____________
a
TABLE
OF
CONTENTS
The
following
term
is
SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING
1
used
interchangeably
throughout
this
manual:
i~i.
oyflluOi
usage
MIG=GTAW
1-2.
Arc
Welding
Hazards
1
1-3.
Additional
Symbols
for
Installation,
Operation,
and
Maintenance
3
1-4.
Principal
Safety
Standards
3
1-5.
EMF
Information
4
SECTION
1
-
CONSIGNES
DE
SECURITE
-
LIRE
AVANT
UTILISATION
5
1-1.
Signification
des
symboles
5
1-2.
Dangers
relatifs
au
soudage
a
Iarc
5
1-3.
Dangers
supplØmentaires
en
relation
avec
linstallation,
le
fonctionnement
et
a
maintenance
7
1-4.
Principales
normes
de
sØcuritØ
8
1-5.
Information
sur
les
champs
electromagnØtiques
8
SECTION
2
-
INSTALLATION
9
2-1.
Specifications
9
2-2.
Volt-Ampere
Curves
9
2-3.
Duty
Cycle
And
Overheating
10
2-4.
Installing
Work
Clamp
11
2-5.
Installing
Gas
Supply
11
2-6.
Installing
Welding
Gun
12
2-7.
Setting
Gun
Polarity
12
2-8.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
13
2-9.
Changing
Input
Voltage
13
2-10.
Electrical
Service
Guide
14
2-11.
Selecting
A
Location
And
Connecting
Input
Power
14
2-12.
Threading
Welding
Wire
15
2-13.
Weld
Parameter
16
2-14.
Aluminum Weld
Parameter
For
Use
With
Optional
Spoolmate
185
17
SECTION
3
-
OPERATION
18
3-1.
Front
Panel
Controls
18
SECTION
4-
MAINTENANCE
&TROUBLESHOOTING
19
4-1.
Routine
Maintenance
19
4-2.
Circuit
Breakers
CB1
And
CB2
19
4-3.
Changing
Drive
Roll,
Inlet
Wire
Guide
19
4-4.
Cleaning
Or
Replacing
Gun
Liner
20
4-5.
Replacing
Gun
Contact
Tip
21
4-6.
Troubleshooting
21
SECTION
5-
ELECTRICAL
DIAGRA~L
22
SECTION
6-
MIG
WELDING
(GMAW)
GUIDELINES
23
6-1.
Typical
MIG
Process
Connections
23
6-2.
Typical
MIG
Process
Control
Settings
24
6-3.
Holding
And
Positioning
Welding
Gun
25
6-4.
Conditions
That
Affect
Weld
Bead
Shape
26
6-5.
Gun
Movement
During
Welding
27
6-6.
Poor
Weld Bead
Characteristics
27
6-7.
Good
Weld
Bead
Characteristics
27
6-8.
Troubleshooting
-
Excessive
Spatter
28
6-9.
Troubleshooting
-
Porosity
28
6-10.
Troubleshooting
-
Excessive
Penetration
29
6-11.
Troubleshooting
-
Lack
Of
Penetration
29
6-12.
Troubleshooting
-
Incomplete
Fusion
29
6-13.
Troubleshooting
-
Burn-Through
30
6-14.
Troubleshooting
-
Waviness
Of
Bead
30
6-15.
Troubleshooting
-
Distortion
30
6-16.
Common
MIG
Shielding
Gases
31
SECTION
7
-
PARTS
LIST
.32
WARRANTY
OM-189
482-B
SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING
1.1.
Symbol
Usage
som
_nd_5197
AA
Means
Warning
Watch
Out!
There
are
possible
hazards
with
this
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
A
Marks
a
special
safety
message.
g~
Means
Note~
not
safety
related.
1-2.
Arc
Welding
Hazards
A
The
symbols
shown
below
are
used
throughout
this
manual
to
call
attention
to
and
identify
possible
hazards.
When
you
seethe
symbol,
watch
out,
and
followthe
related
instructions
to
avoid
the
hazard.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
found
in
the
Safety
Standards
listed
in
Section
1-4.
Read
and
follow
all
Safety
Standards.
A
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
A
During
operation,
keep
everybody,
especially
children,
away.
ELECTRIC~
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
burns.
The
electrode
and
work
circuit
is
electrically
live
whenever
the
output
is
on.
The
input
power
circuit
and
machine
internal
circuits
are
also
live
when
power
is
on.
In
semiautomatic
or
automatic
wire
welding,
the
wire,
wire
reel,
drive
roll
housing,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
Do
not
touch
live
electrical
parts.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
Do
not
use
AC
output
in
damp
areas,
if
movement
is
confined,
or
if
there
is
a
danger
of
falling.
Use
AC
output
ONLY
if
required
for
the
welding
process.
If
AC
output
is
required,
use
remote
output
control
if
present
on
unit.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
191
0.147
(see
Safety
Standards).
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
Always
verify
the
supply
ground
-
check
and
be
sure
that
input
power
cord
ground
wire
is
properly
connected
to
ground
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet.
When
making
input
connections,
attach
proper
grounding
conductor
first
-
double-check
connections.
Frequently
inspect
input
power
cord
for
damage
or
bare
wiring
-
replace
cord
immediately
if
damaged
-
bare
wiring
can
kill.
Turn
off
all
equipment
when
not
in
use.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
Do
not
drape
cables
over
your
body.
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.
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable
-
do
not
use
work
clamp
or
work
cable.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
Wear
a
safety
harness
if
working
above
floor
level.
Keep
all
panels
and
covers
securely
in
place.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
or
worktable
as
near
the
weld
as
practical.
Insulate
work
clamp
when
not
connected
to
workpiece
to
prevent
contact
with
any
metal
object.
Do
not
connect
more
than
one
electrode
or
work
cable
to
any
single
weld
output
terminal.
SIGNIFICANT
DC
VOLTAGE
exists
after
removal
of
input
power
on
inverters.
Turn
Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions
in
Maintenance
Section
before
touching
any
parts.
I
FUMES
AND
GASES
can
be
hazardous.
-~
=~ul~
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
manufacturers
instructions
for
metals,
consumables,
coatings,
cleaners,
and
degreasers.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
wearing
an
air-supplied
respirator.
Always
have
a
trained
watch-
person
nearby.
Welding
fumes
and
gases
can
displace
air
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
breathing
air
is
safe.
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.
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
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be hazardous
to
your
health.
OM-189
482
Page
1
FIRE
OR
EXPLOSION
hazard.
Do
not
install
or
place
unit
on,
over,
or
near
combustible
surfaces.
Do
not
install
unit
near
flammables.
Do
not
overload
building
wiring
-
be
sure
power
supply
system
is
properly
sized,
rated,
and
protected
to
handle
this
unit.
FALLING
UNIT
can
cause
injury.
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
accessories.
Use
equipment
of
adequate
capacity
to
lift
and
support
unit.
lfusingliftforkstomoveunit,
besureforksare
long
enough
to
extend
beyond
opposite
side
of
unit.
OVERUSE
can
cause
OVERHEATING
Allow
cooling
period;
follow
rated
duty
cycle.
Reduce
current
or
reduce
duty
cycle
before
starting
to
weld
again.
Do
not
block
or
filter
airflow
to
unit.
STATIC
(ESD)
can
damage
PC
boards.
Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
Use
proper
static-proof
bags
and
boxes
to
store,
move,
or
ship
PC
boards.
WELDING
WIRE
can
cause
injury
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.
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
Superinten
dent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
American
Welding
Society
Standard
AWS
F4.1,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
H.F.
RADIATION
can
cause
interference.
High-frequency
(H.F.)
can
interfere
with
radio
navigation,
safety
services,
computers,
and
communications
equipment.
Have
only
qualified
persons
familiar
with
electronic
equipment
perform
this
installation.
The
user
is
responsible
for
having
a
qualified
electrician
promptly
correct
any
interference
problem
resulting
from
the
installation.
If
notified
by
the
FCC
about
interference,
stop
using
the
equipment
at
once.
Have
the
installation
regularly
checked
and
maintained.
Keep
high-frequency
source
doors
and
panels
tightly
shut,
keep
spark
gaps
at
correct
setting,
and
use
grounding
and
shielding
to
minimize
the
possibility
of
interference.
ARC
WELDING
can
cause
interference.
Electromagnetic
energy
can
interfere
with
sensitive
electronic
equipment
such
as
computers
and
computer-driven
equipment
such
as
robots.
Be
sure
all
equipment
in
the
welding
area
is
electromagnetically
compatible.
To
reduce
possible
interference,
keep
weld
cables
as
short
as
possible,
close
together,
and
down
low,
such
as
on
the
floor.
Locate
welding
operation
100
meters
from
any
sensitive
elec
tronic
equipment.
Be
sure
this
welding
machine
is
installed
and
grounded
according
to
this
manual.
If
interference
still
occurs,
the
user
must
take
extra
measures
such
as
moving
the
welding
machine,
using
shielded
cables,
using
line
filters,
or
shielding
the
work
area.
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
R3.
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.
1-3
Additional
Symbols
for
Installation,
Operation,
and
Maintenance
MOVING
PARTS
can
cause
Injury.
Keep
away
from
moving
parts
such
as
fans.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
MOVING
PARTS
can
cause
injury
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
OM-189
482
Page
3
1-5
EMF
Information
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
1.
Keep
cables
close
together
by
twisting
or
taping
them.
Electric
And
Magnetic
Fields
Welding
current,
as
it
flows
through
welding
cables,
will
cause
electro-
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
magnetic
fields.
There
has
been
and
still
is
some
concern
about
such
fields.
However,
after
examining
more
than
500
studies
spanning
17
3.
Do
not
coil
or
drape
cables
around
your
body.
years
of
research,
a
special
blue
ribbon
committee
of
the
National
Research
Council
concluded
that:
The
body
of
evidence,
in
the
4.
Keep
welding
power
source
and
cables
as
far
away
from
opera-
committees
judgment,
has
not
demonstrated
that
exposure
to
power-
tor
as
practical.
frequency
electric
and
magnetic
fields
is
a
human-health
hazard.
However,
studies
are
still
going
forth
and
evidence
continues
to
be
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
examined.
Until
the
final
conclusions
of
the
research
are
reached,
you
possible.
may
wish
to
minimize
your
exposure
to
electromagnetic
fields
when
welding
or
cutting.
About
Pacemakers:
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
Pacemakerwearers
consult
yourdoctorfirst.
If
cleared
byyourdoctor,
procedures:
then
following
the
above
procedures
is
recommended:
OM-189
482
Page
4
SECTION
1
-
CONSIGNES
DE
SECURITE
-
LIRE
AVANT
UTILISATION
1-1.
Signification
des
symboles
som
_nd_Fre
4/97
a
Signifie
Mise
en
garde!
Soyez
vigilant!
Cette
procedure
prØsente
des
risques
de
danger!
Ceux-ci
sont
identifies
par
des
symboles
adjacents
aux
directives.
A
Identifie
un
message
de
sØcuritØ
particulier.
~
Signifie
NOTA
nest
pas
re!atif
A
Ia
sAcuritØ.
1-2
Dangers
relatifs
au
soudage
a
larc
A
Les
symboles
prØsentØs
ci-aprŁs
sont
utilisØs
tout
au
long
du
present
manuel
pour
attirer
votre
attention
et
identifier
les
risques
de
danger.
Lorsque
vous
voyez
un
symbole,
soyez
vigilant
et
suivez
les
directives
mentionnees
afin
dØviter
tout
danger.
Les
consignes
de
sØcuritŁ
prØsentŁes
ci-aprŁs
ne
font
que
rØsumer
linformation
contenue
dans
les
normes
de
sŁcuritØ
ØnumŁrØes
a
Ia
section
1-5.
Veuillez
lire
et
respecter
toutes
ces
normes
de
sØcuritØ.
A
Linstallation,
Iutilisation,
lentretien
et
les
reparations
ne
doi
vent
Œtre
conflØs
qu
des
personnes
qualifiŁes.
A
Au
cours
de
lutilisation,
tenirtoute
personne
a
lØcartet
plus
par
ticuliŁrement
les
enfants.
UN
CHOC
ELECTRIQUE
peuttuer
Un
simple
contact
avec
des
piŁces
Łlectriques
peut
provoquer
une
electrocution
ou
des
blessures
graves.
Lelectrode
et
le
circuit
de
soudage
sont
sous
tension
des
que
lappareil
est
sur
ON.
Le
circuit
dentrŁe
et
les
circuits
internes
de
lappareil
sont
Łgalement
sous
tension
ace
moment-l.
En
soudage
semi-automatique
ou
automatique,
le
fil,
le
dŁvidoir,
le
logement
des
galets
dentraInement
et
les
piŁces
mŁtalliques
en
contact
avec
le
fil
de
soudage
sont
sous
tension.
Des
matŁriels
mal
installŁs
ou
mal
mis
a
Ia
terre
prŁsentent
un
danger.
Ne
jamais
toucher
les
piŁces
Łlectriques
sous
tension.
Porter
des
gants
et
des
vŁtements
de
protection
secs
ne
comportant
pas
de
trous.
Sisoler
de
Ia
piŁce
et
de
Ia
terre
au
moyen
de
tapis
ou
dautres
moyens
isolants
suffisamment
grands
pour
empŁcherle
contact
phy
sique
Łventuel
avec
Ia
piŁce
ou
Ia
terre.
Ne
pas
se
servir
de
source
Łlectrique
courant
Łlectrique
dans
les
zones
humides,
dans
les
endroits
continŁs
ou
l
o
on
risque
de
tomber.
Se
servir
dune
source
Łlectrique
courant
Łlectrique
UNIQUEMENT
si
le
procŁdŁ
de
soudage
le
demande.
Si
lutilisation
dune
source
Łlectrique
Łcourant
Łlectrique
savŁre
nŁces
saire,
se
servir
de
Ia
fonction
de
tŁlŁcommande
si
rappareil
en
est
ŁquipŁ.
Couper
lalimentation
ou
arrŁter
le
moteuravantde
procŁder
a
linstal
lation,
a
Ia
reparation
ou
a
lentretien
de
lappareil.
DŁverrouiller
lalimentation
selon
Ia
norme
OSRA
29
CFR
1910.147
(voir
normes
de
sŁcuritŁ).
lnstalleretmettre
a
laterrecorrectement
cetappareil
conformŁment
son
manuel
dutilisation
et
aux
codes
nationaux,
provinciaux
et
municipaux.
Toujours
verifier
laterre
du
cordon
dalimentation
-
Verifier
et
sassu
rer
que
le
fil
de
terre
du
cordon
dalimentation
est
bien
raccordŁ
a
Ia
borne
de
terre
du
sectionneurou
que
Ia
fiche
du
cordon
est
raccordŁe
a
une
prise
correctement
mise
a
Ia
terre.
En
effectuant
les
raccordements
dentrŁe
fixer
dabord
le
conducteur
de
mise
a
Ia
terre
appropriŁ
et
contre-vŁrifier
les
connexions.
Verifier
frŁquemment
le
cordon
dalimentation
pour
voir
sil
nest
pas
endommagŁ
ou
dŁnudŁ
-
remplacer
le
cordon
immŁdiatement
sil
est
endommagŁ
-
un
cable
dŁnudŁ
peut
provoquer
une
electrocution.
Mettre
lappareil
hors
tension
quand
on ne
lutilise
pas.
Ne
pas
utiliser
des
cables
uses,
endommagŁs,
de
grosseur
insufti
sante
ou
mal
ŁpissŁs.
Ne
pas
enrouler
les
cables
autour
du
corps.
Si
Ia
piŁce
soudŁe
doit
Łtre
mise
a
laterre,
letaire
directement
avec
un
cable
distinct
-
ne
pas
utiliser
le
connecteur
de
piŁce
ou
le
cable
de
retour.
Ne
pas
toucher
lŁlectrode
quand
on
est
en
contact
avec
Ia
piŁce,
Ia
terre
ou
une
electrode
provenant
dune
autre
machine.
Ce
groupe
de
symboles
signifie
Mise
en
garde
Soyez
vigilant~
II
y
a
des
risques
de
danger
relies
aux
CHOCS
ELECTRIQUES,
aux
PIECES
EN
MOUVEMENTetaux
PIECES
CHAUDES.
Reportez-vousauxsymboles
etauxdirectives
ci-dessous
afin
de
connaitre
les
mesures
a
prendre
pour
Łviter
tout
danger.
Nutiliser
quun
materiel
en
bon
Łtat.
Reparer
ou
remplacer
sur-le
champ
les
piŁces
endommagŁes.
EntretenirlappareilconformŁment
ace
manuel.
Porter
un
harnais
de
sŁcuritŁ
quand
on
travaille
en
hauteur.
Maintenir
solidement
en
place
tous
es
panneaux
et
capots.
Fixer
le
cable
de
retourde
faon
a
obtenir
un
bon
contact
mŁtal-mŁtal
avec
Ia
piŁce
a
souder
ou
a
table
de
travail,
le
plus
prŁs
possible
de
Ia
soudure.
Isoler
Ia
pince
de
masse
quand
pas
mis
a
Ia
piŁce
pour
Łviter
le
contact
avec
tout
obiet
metallique.
liv
a
DU
COU
RANT
CONTINU
IMPORTANT
dans
les
convertisseurs
aprŁs
Ia
suppression
de
lalimenta
tion
Ølectrique.
ArrŁter
les
convertisseurs,
debrancher
le
courant
Łlectrique,
et
de
charger
les
condensateurs
dalimentation
selon
Ies
instructions
indiquŁes
dans
Ia
partie
entretien
avant
de
toucher
les
piŁces.
~4b~LLEsFUMEEsET
LESGAZ
peuvent
:etre
dangereux.
Le
soudage
genere
des
fumŁes
et
des
gaz.
Leur
=9
t~
.....J
inhalation
peut
Łtre
dangereux
pour
votre
sante.
____________
Eloigner
votre
tŒte
des
fumŁes.
Ne
pas
respirer
les
fumees.
A
lintŁrieur,
ventiler
Ia
zone
etlou
utiliser
un
echappement
au
ni
veau
de
larc
pour
lŁvacuation
des
fumŁes
et
des
gaz
de
soudage.
Si
Ia
ventilation
est
insuffisante,
utiliser
un
respirateur
a
alimenta
tion
dair
homologuŁ.
Lire
les
spŁcificationsdesŁcuritŁdes
matŁriaux
(MSDSs)
et
es
ins
tructions
du
fabricant
concernant
les
mŁtaux,
lea
consommables,
les
revŒtements,
les
nettoyants
et
les
degraisseurs.
Travailler
dans
un
espace
fermŁ
seulement
siI
est
bien
ventile
ou
en
portent
un
respirateur
a
alimentation
dair.
Demander
toujours
a
un
surveillant
dOment
formŁ
de
se
tenir
a
proximitŁ.
Des
fumŁes
et
des
gaz
de
soudage
peuvent
dŁplacer
lair
et
abaisser
le
niveau
doxygŁne
provoquant
des
blessures
ou
des
accidents
mortels.
Sassurer
que
lair
de
respiration
ne
presente
aucun
danger.
Ne
pas
souderdans
des
endroits
situŁs
a
proximitŁ
dopŁrations
de
dŁgraissage,
de
nettoyage
ou
de
pulverisation.
La
chaleur
et
les
rayons
de
Iarc
peuvent
rŁagir
en
presence
de
vapeurs
et
former
des
gaz
hautement
toxiques
et
irritants.
Ne
pas
souder
des
mŁtaux
munis
dun
revŒtement,
tels
que
lacier
galvanisŁ,
plaque
en
p10mb
ou
au
cadmium
a
moms
que
le
revŒte
ment
nait
ŁtŁ
enlevŁ
dens
Ia
zone
de
soudure,
que
lendroit soit
bien
ventilŁ,
et
si
necessaire,
en
portant
un
respirateur
a
alimenta
tion
dair.
Lea
revŁtements
et
tous
les
metaux
renfermant
ces
ele
ments
peuvent
degager
des
fumŁes
toxiques
en
cas
de
soudage.
OM-189
482
Page
5
Ne
pas
placer
lappareil
sur,
au-dessus
ou
a
proximitØ
de
surfaces
infllammables.
Ne
pas
installer
lappareil
a
proximitØ
de
produits
inflammables
Ne
pas
surcharger
installation
Ølectrique
-
sassurer
que
lalimen
tation
est
correctement
dimensionnØ
et
protØgØ
avant
de
mettre
lappareil
en
service.
LA
CHUTE
DE
LAPPAREIL
peut
bIesser~
Utiliser
lanneau
de
levage
uniquement
pour
sou
lever
lappareil,
NON
PAS
les
chariot,
es
bouteil
les
de
gaz
ou
tout
autre
accessoire.
Utiliser
un
engin
dune
capacitØ
appropriee
pour
soulever
lappareil.
En
utilisant
des
fourches
de
levage
pour
dØplacer
lunitØ,
sassurer
que
lesfourches
sont
suffisamment
longues
pourdØpasserdu
ctØ
oppose
de
lappareil.
LEMPLOI
EXCESSIF
peut
SURCHAUFFER
LEQULPEMENT.
PrØvoir
une
pØriode
de
refroidissement,
respec
ter
le
cycle
opØratoire
nominal.
RØduire
le
courantou
le
cycle
opØratoire
avantde
recommancer
le
soudage.
Ne
pas
obstruer
les
passages
dair
du
poste.
LES
CHARGES
ELECTROSTATIQUES
peuveAt
endommager
les
circuits
im
primes.
Etablir
Ia
connexion
avec
Ia
barrette
de
terre
avant
de
manipuler
des
cartes
ou
des
pieces.
Utiliser
des
pochettes
et
des
boites
antistatiques
pour
stocker,
deplacer
ou
expØdier
des
cartes
de
circuits
imprimes.
DES
RGANES
MOBILES
pØuvent
provoquerdesbiessures.
Ne
pas
sapprocher
des
organes
mobiles.
Ne
pas
sapprocher
des
points
de
coincement
tels
que
des
rouleaux
de
commande.
LES
FILS
DE
SOUDAGE
peuvent
pro
voquer
des
blessures.
Ne
pas
appuyer
sur
Ia
gachette
avant
den
avoir
recu
linstruction.
Ne
pas
diriger
le
pistolet
vers
soi,
dautres
per
sonnes
ou
toute
piece
mecanique
en
engageant
le
fil
de
soudage.
Rester
a
lØcart
des
organes
mobiles
comme
le
ventilateur.
Maintenir
fermØs
et
fixement
en
place
les
portes,
panneaux,
recouvrements
et
dispositifs
de
protection.
LE
RAYONNEMENT
HAUTE
FRE
QUENCE
(H.F.)
risque
de
provoquer
des
interferences.
Le
rayonnementhautefrequence
peutprovoquer
des
interferences
avec
les
equipements
de
ra
dio-navigationetdecommunication,
lesservices
de
sØcuritØ
et
les
ordinateurs.
Demander
seulement
a
des
personnes
qualifiØes
familiarisØes
avec
des
Øquipements
electroriiques
de
faire
fonctionner
installa
tion.
Lutilisateur
est
tenu
de
faire
corriger
rapidement
par
un
Ølectricien
qualifie
les
interferences
resultant
de
linstallation.
Si
le
FCC
signale
des
interferences,
arrŒter
immØdiatement
lappa
reil.
Effectuer
rØguliŁrement
le
contrle
et
lentretien
de
linstallation.
Maintenir
soigneusement
fermØs
les
portes
et
les
panneaux
des
sources
de
haute
frØquence,
maintenir
les
Øclateurs
a
une
distance
correcte
et
utiliser
une
terre
et et
un
blindage
pour
rØduire
les
inter
fØrences
Øventuelles.
LE
SOUDAGE
A
LARC
risque
de
:provoquer
des
interferences.
Lenergie
electromagnetique
risque
de
provoquer
des
interferences
pour
lequipement
electronique
sensible
tel
que
les
ordinateurs
et
lØquipement
commandØ
par
ordinateur
tel
que
les
robots.
Veiller
ace
que
tout
lequipement
de
Ia
zone
de
soudage
soit
com
patible
ØlectromagnØtiquement.
Pour
rØduire
Ia
possibilitØ
dinterfØrence,
maintenir
les
cables
de
soudage
aussi
courts
que
possible,
es
grouper,
et
les
poser
aussi
bas
que
possible
(ex.
par
terre).
Veiller
a
souder
a
une
distance
de
100
metres
de
tout
equipement
electronique
sensible.
Veiller
~
ce
que
Ce
poste
de
soudage
soit
pose
et
mis
a
Ia
terre
conformØment
a
Ce
mode
demploi.
En
cas
dinterfØrences
aprŁs
avoir
pris
es
mesures
precØdentes,
il
incombe
a
lutilisateur
de
prendre
des
mesures
supplØmentaires
telles
que
le
dØplacement
du
poste,
lutilisation
de
cables
blindØs,
lutilisation
de
filtres
de
ligne
ou
Ia
pose
de
protecteurs
dans
Ia
zone
de
travail.
LESCHAMPS
MAGNETIQUES
peuvent
affecter
les
stimulateurs
cardiaques.
Porteurs
de
stimulateur
cardiaque,
restez
~
dis
tance.
Les
porteurs
dun
stimulateur
cardiaque
doivent
dabord
consulter
leur
mØdecin
avant
de
sappro
cher
des
operations
de
soudage
a
larc,
de
gou
geage
ou
de
soudage
par
points.
1-3
Dangers
supplementaires
en
relation
avec
linstallation,
le
fonctuonnement
et
Ia
maintenance.
Risque
DiNCENDIE
OU
DES
ORGANES
MOBILES
peuvent
DEXPLOSION.
provoquer
des
blessures.
OM-189
482
Page
7
1-4
Prunc~paIes
normes
de
securite
Safety
in
Welding
and
Cutting,
normeANSl
Z49.1,
delAmericanWel
ding
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.
Recommended
Safe
Practice
for
the
Preparation
for
Welding
and
Cut
ting
of
Containers
That
Have
Held
Hazardous
Substances,
norme
AWS
F4.1,
de
IAmerican
Welding
Society,
550
N.W.
Lejeune
Rd,
Mia
mi
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
de
Ia
National
Fire
Pro
tection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
DonnØes
sur
le
soudage
electrique
et
sur
les
effets,
pour
lorganisme,
des
champs
magnØtiques
basse
frequence
Lextrait
suivant
est
tire
des
conclusions
generales
du
document
intitu
lØ
Biological
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
-
Background
Paper,
OTA-BP-E-53
(Washington
DC:
U.S.
Govern
ment
Printing
Office,
mai
1989),
publiØ
par
le
Office
of
Technology
Assessment
du
Congres
amØricain:
...
il
existe
maintenant
dabon
dantes
donnØes
scientifiques
compilØes
a
Ia
suite
dexpØriences
sur
Ia
cellule
ou
dØtudes
sur
des
animaux
et
des
humains,
qui
montrent
clairement
que
les
champs
ØlectromagnØtiques
basse
frØquence
peu
vent
avoir
des
effets
sur
lorganisme
et
mØme
y
produire
des
transformations.
MŒme
sil
sagit
de
travaux
de
trØs
grande
qualitØ,
les
rØsultats
sont
complexes.
Cette
dØmarche
scientifique
ne
nous
per-
met
pas
dØtablir
un
tableau
densemble
coherent.
Pire
encore,
elle
ne
nous
permet
pas
de
tirer
des
conclusions
finales
concernant
les
ris
ques
Øventuels,
ni
doffrir
des
conseils
sur
les
mesures
a
prendre
pour
rØduire
sinon
Øliminer
les
risques
Øventuels.
(Traduction
libre)
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
de
Ia
Compressed
Gas
Association,
1235
Jefferson
Davis
High
way,
Suite
501,
Arlington,
VA
22202.
ROgles
de
sØcuritØ
en
soudage,
coupage
et
procØdØs
connexes,
nor-
me
CSA
Wi
17.2,
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
Protec
tion,
norme
ANSI
Z87.1,
de
lAmerican
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
and
Welding
Processes,
norme
NFPA
51
B,
de
Ia
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Afin
de
rØduire
les
champs
electromagnØtiques
dans
lenvironnement
de
travail,
respecter
les
consignes
suivantes
1
Garder
les
cables
ensembles
en
es
torsadant
ou en
les
attachant
avec
du
ruban
adhØsif.
2
Mettre
tous
es
cables
du
cOtØ
oppose
de
lopØrateur.
3
Ne
pas
courber
pas
et
ne
pas
entourer
pas
es
cables
autour
de
vous.
4
Garder
le
poste
de
soudage
et
les
cables
le
plus
loin
possible
de
vous.
5
Relier
Ia
pince
de
masse
le
plus
prŁs
possible
de
Ia
zone
de
soudure.
Consignes
relatives
aux
stimulateurs
cardiaques
Les
consignes
mentionnØes
prØcØdemmentfont
partie
de
celles
desti
nØes
aux
personnes
ayant
recours
a
un
stimulateur
cardiaque.
Veuillez
consulter
votre
mØdecin
pour
obtenir
plus
de
details.
1-5.
Information
sur
les
champs
ØlectromagnØtiques
OM-189
482
Page
8
2-1.
Specifications
SECTION
2-
INSTALLATION
Rated
Welding
Output
Amperage
Range
Maximum
Open-Circuit
Voltage
DC
Amperes
Input
at
Rated
Load
Output,
60
Hz,
Weight
Overall
Dimensions
Single-
200V
Phase
230V
KVA
KW
150
A
@
23
Volts
DC,
60%
Duty
Cycle
30
-
165
33
30
(1
.6)*
26
(1
.4)*
6
(0.27)*
5
(0.1
3)*
165
lb
(75
kg)
Length:
36
in
(915
mm)
Width:
18
in
(457
mm)
Height:
27
in
(686
mm)
Wire
Type
And
Diameter
Calculated
Wire
Speed
Range
At
No
Load
138
-
795
1PM
(3.5
-
20.3
rn/mm)
Max
Wire
Feed
Speed
While
Welding
650
1PM
(16.5
m/min)
Solid
Steel
I
I
Flux
Cored
I
Aluminum
Stainless
Steel
I
I
.023
-
.035
in
I
.030
-
.045
in
I
.030
-
.035
in
(0.6
-
0.9
mm)
(0.8
-
1.2
mm)
(0.8
-
0.9
mm)
~WhiIe
idling
2-2.
Volt-Ampere
Curves
Volt-ampere
curves
show
mini
mum
and
maximum
voltage
and
amperage
output
capabilities
of
unit.
Curves
of
other
settings
fall
between
curves
shown.
Cl)
~
0
>
uJ
0
<
li
0
>
c
<
0
-J
0
50
100
150
200
LOAD
CURRENT,
AMPS
vacurvel
4/95
-
SB-180
824
35
30
25
20
15
10
OM-189
482
Page
9
2-3.
Duty
Cycle
And
Overheating
200
U,
w
w
~150
0
-J
w
Overheating
60%
Duty
Cycle
At
150
Amperes
6
Minutes
Welding
Duty
Cycle
is
percentage
of
10
minutes
that
unit
can
weld
at
rated
load
without
overheating.
If
unit
overheats,
thermostat(s)
opens,
output
stops,
and
cooling
fan
runs.
Wait
fifteen
minutes
for
unit
to
cool.
Reduce
amperage
or
voltage,
or
duty
cycle
before
welding.
A
Exceeding
duty
cycle
can
damage
unit
and
void
warranty.
~AorV
Reduce
Duty
Cycle
dutyl
4/95
-
SB-181
009
RATED
OUTPUT~
-~
iiiiiiii~iiiii
ii
100
30
40
50
60
70
80
90100
%
DUTY
CYCLE
4
Minutes
Resting
,
-*
I-,
Minutes
OM-189
482
Page
10
2-6.
Installing
Welding
Gun
2-7.
Setting
Gun
Polarity
Tools
Needed:
~
r
3/4,11/161n
1
Polarity
Changeover
Label
(Located
Near
Drive
Assembly)
Always
read
and
follow
manufac
tures
recommended
polarity.
1
.2
3
1
Drive
Assembly
2
Gun
Securing
Knob
3
Gun
End
Loosen
securing
knob.
Insert
gun
end
through
opening
until
it
bot
toms
against
drive
assembly.
Tighten
nut.
4
Gun
Trigger
Plug
Insert
plug
into
receptacle,
and
tighten
threaded
collar.
Close
door.
Ref.
ST-801
936
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
s1444490
OM-189
482
Page
12
~6in~
(150
mm)
Open
pressure
assembly.
Pull
and
hold
wire;
cut
off
end.
Push
wire
thru
guides
into
gun;
continue
to
hold
wire.
Press
gun
trigger
until
wire
comes
out
of
gun.
1111
II
Feed
wire
to
check
drive
roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
Cut
off
wire.
Close
and
latch
door.
Ref.
ST-801
938)
Ref.
ST-149
326-A
2-12.
Threading
Welding
Wire
Tools
Needed:
-4
Close
and
tighten
pressure
assembly,
and
let
go
of
wire.
-*
Remove
gun
nozzle
and
contact
tip.
ON
POWER
00FF
I
/
Turn
On.
Cut
off
wire.
Close
and
latch
door.
I
-4
Reinstall
contact
tip
and
nozzle.
OM-189
482
Page
15
2-13.
Weld
Parameter
Wire
Type,
Shielding
Gas,
And
Flow
Rate
Wire
Diameter
(inch)
Operator
Ofl
ro
~
Material
Thickness
3/Bin
(9.5
mm)
1/4
in
(6.4
mm)
3/l6in
(4.6
mm)
1/Sin
(3.2
mm)
12
ga
14
ga
16
ga
18
ga
20
ga
22
ga
E7OS-6
Co2
20
cfh+
.023
Vottage
Tap
- -
6
5
4
3
3
2
1
1
-
-
Wire
Speed
-
-
100
90
70
65
60
40
25
20
- -
.030
Voltage
Tap
- -
4
4
3
2
2
2
1
-
-
- -
Wire
Speed
- -
70
60
50
45 40
30
25
-
- -
-
.035
Voltage
Tap
6
4
4
3
3
2
2
1
-
-
-
-
Wire
Speed
80
65
40
35
30
25
30
10
-
-
- -
E70S6
75%
Argon
~
.023
Voltage
Tap
- -
3
4
3
3 2
2
1
1
1
WireSpeed
--
80
90
70
60
70
40
45
25
12
.030
Voltage
Tap
6
4
4
3
3 2 2
1
1
- -
Wire
Speed
90 58
70
55 50
48
45
30
5
- -
.035
Voltage
Tap
6
4
4
3
-
3
2
2
1 1
- -
Wire
Speed
80
48
60 50
35
27 30
11
3
-
-
E71T-GS
Flux
Core
.030
VoltageTap
5
4
4
3
2
2
1
1
--
--
Wire
Speed
80
65
65
50
30 30
10
5
-
-
- -
.035
Voltage
Tap
5
4
3
2 2
2
1 1
-
-
-
-
Wire
Speed
50
50 40
30 25
20
10
0
-
-
- -
ER
308
Stainless
Steel
TC~
.023
VoltageTap
5
4
4
4
3
3
3
2 2 2
Wire
Speed
95
85
80
60 50
50
50
30 20 20
030
Voltage
Tap
5 5
4
3
3
2
2 2
1
-
-
Wire
Speed
70
70
70
50
45
50
45
40
0
-
-
.035
VoltageTap
6
5
5
4
3 2
2
2
-- --
Wire
Speed
65
40
40
30 30
25
20
10
-
-
- -
*Do
not
change
Voltage
switch
position
while
welding
Wire
Speed
value
in
Table
is
a
starting
value
only,
and
Wire
Speed
control
setting
can
be
fine
tuned
during
welding.
S-181
020-A
OM-189
482
Page
16
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Miller KJ031020 Owner's manual

Miller
Brand
Miller
Model
KJ031020
Category
Welding System
Type
Owner's manual
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