Miller AUTO ARC 255 Owner's manual

AUTO ARC 255
Miller
Brand
Miller
Model
AUTO ARC 255
Category
Welding System
Type
Owner's manual

This manual is also suitable for

AUTO
ARCS
June
1996
Effective
With
Serial
No.
KG171
523
Form:
OM-157066E
OWNERS
MANUAL
Read
and
follow
these
instructions
and
all
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
ii~J
Give
this
manual
to
the
operator.
.
For
help,
call
your
distributor
-.
Call
your
distributor
if
you
do
not
understand
the
directions.
U
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
Auto
Arcfi
Model
255
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-157 072-A
PRINTED
IN
USA
LIMITED
WARRANTY
Effective
February
7,
1996
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
warranty
supersedes
all
previous
manufscturers
warranties
end
is
exclusive
with
no
other
guarsntees
or
wsrrsnties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
temis
end
conditions
below,
wsrrsnts
to
its
MPG
Guns/TIG
Torches
originsl
reteil
purchsser
thst
new
equipment
sold
sfter
the
effective
dste
of
this
lim-
APT
~PCUT
&
PLAZCUT
Model
Plssma
Cuffing
Torches
lted
wsrrsnty
is
free
of
defects
in
msterisl
end
workmsnship
at
the
time
it
is
shipped
*
Rweote
Controls
from
factory
THIS
WARRANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OThER
WAR
RANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MER-
AccessorY
Kits
CHANTABIUTY
AND
FITNESS.
*
Replscsment
Psrts
Within
the
wsrrshty
periods
listed
below,
manufsctumrwill
repsiror
replsce
sny
wsr-
Umited
Wsrranty
shell
not
spply
to:
rented
psits
orcomponents
thstfsit
due
to
such
defects
In
msterisl
orworlonsnship.
Msnufscturer
must
be
notified
in
writing
within
thirly
(30)
dsys
of
such
defect
or
fail
ure,
st
which
tIme
manufscturer
will
provide
instructions
on
the
wsrranty
clsim
pro
cedures
to
be
followed.
Msnufscturer
ehslt
honor
wsrrsnty
clsims
on
wsrrsnted
equipment
listed
below
in
2.
the
event
of
such
s
failure
within
the
werranty
time
periods.
All
wsrrsrrty
time
periods
stsrt
on
the
dste
thst
the
equipment
wss
delivered
to
the
original
retell
purchsser,
or
one
yesr
after
the
equipment
is
sent
to
a
North
American
distributor
or
eighteen
months
efter
the
equipment
is
sent
to
en
Intemationsl
distributor.
1.
5YesrsPsrts3YeamLabor
Original
main
power
rectiftem
Inverters
(input
end
output
rectifiers
onlly)
2.
3
Years
Parts
end
Lsbor
Transfomier/Rectlfier
Power
Sources
Ptsams
Arc
Cuffing
Power
Sources
Semi-Automatic
end
Automstic
Wire
Feeders
Inverter
Power
Supplies
Intellitig
Robots
(1
yesr
labor)
3.
2
Years
Parts
end
Labor
Engine
Driven
Welding
Generetom
(NOTE:
Engines
ere
werranted
seperstely
by
the
engine
msnufacturer.)
*
Air
Compressors
4.
1
Year
Parts
end
Labor
Motor
Driven
Guns
Process
Controllers
*
IHPS
Power
Sources
Water
Coolant
Systems
HF
Units
Grate
Spot
Welders
Load
Banks
SDXTrensformers
Running
Gear/Trailers
Plasma
Cutting
Torches
(except
APT
ZIPCUT
&
PLAZCUT
Models)
Tecumseh
Engines
Deutz
Engines
(outside
North
America)
Field
Options
(NOTE:
Field
options
em
covered
under
the
limited
warranty
for
the
re
maining
warranty
period
of
the
product
they
are
installed
in,
ortor
a
mini
mum
of
one
yesr
whIchever
Is
greater.)
6
Months
Batteries
90
Days
Parts
and
Labor
Consumable
components;
such
as
contact
tips,
cuffing
nozzles,
contactom
and
releya
or
paris
that
fail
due
to
normal
wear.
Equipment
that
has
been
modified
by
any
party
other
then
manufacturer,
or
equlpmentthst
hen
been
improperly
Installed,
improperly
opersted
or
misused
based
upon
industry
standards,
or
equipment
which
hes
not
had
reasonable
end
necessary
meintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MANUFACTURERS
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMERCIAL/iNDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPE
RIENCED
IN
THE USE
AND
MAINTENANCE
OF
WELDING
EGUIPMENT.
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
mmedies
ahall
be,
at
manufacturers
option:
(1)
repair
or(2)
replacement;
or,
where
authorized
in
writing
by
manufacturer
in
appropriate
cases,
(3)
the
reasonable
coat
of
repair
or
replacement
at
an
authoflzed
service
station;
or
(4)
payment
of
or
credit
for
the
pur
chase
price
hess
reasonable
depreciation
based
upon
actual
use)
upon
retum
of
the
goods
at
customers
risk
and
expense.
Manufacturers
option
of
repair
or
replace
ment
will
be
F.O.B.,
Factory
at
Appleton.
Wisconsin,
or
FOB.
at
an
authorized
ser
vice
facility
as
determined
by
manufecturer.
Therefore
no
compensation
or
reim
bursement
tsr
transportation
coats
of
any
kind
will
be
allowed.
TO ThE
EXTENT
PERMIrrED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
ThE
SDLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MANUFAC
TIJRER
BE
UABLE
FOR
DIRECT,
INDIRECT,
SPECIAL
INCIDENTAL
OR
CON
SEOUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHEThER
BASED
ON
CONTRACt
TORT
OR
ANY
OThER
LEGAL
ThEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
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
MERCHANTABIUTY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITh
RESPECT TO
ANY
AND
ALL
EOUIPMENT
FURNISHED
BY
MANUFACTURER
IS
EXCLUDED
AND
DISCLAIMED
BY
MAN
UFACTURER.
Some
states
In
the
U.S.A.
do
not
allow
limitations
of
how
tong
an
implied
werrenty
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warrenty
provides
ape
cific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
state
to
state.
In
Canade,
legislation
In
some
provlncas
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
prsvidea
epecific
legal
rights,
end
other
rights
may
be
available,
but
may
vary
from
province
to
province.
-I-.
1.
Itemafumlshed
by
manufacturer,
but
manufactured
by
others,
auth
as
engines
ortrsde
accessories.
These
items
are
covered
by
the
manuf
acturers
warranty,
if
any.
5.
{.
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
or
damage
with
the
delivering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
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
Numberof
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No,
Date
of
Purchase
brand_wer
3/96
AUTO
ARCJ
June1996
Form:
OM-157066E
Effective
With
Serial
No.
KG171
523
OWNERS
MANUAL
U
Read
and
follow
these
instructions
and
all
Give
this
manual
to
the
operator.
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
.
U
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the
directions.
1I~fl
U
For
help,
call
your
distributor
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
Auto
Arcfi
Model
255
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
autoam
7/93
ST-i
57
072-A
PRINTED
IN
USA
LIMITED
WARRANTY
Effective
February
7,
1996
(Equipment
with
a
serial
number
praface
of
KD
or
newer)
This
limited
warranty
supemedes
all
previous
manufacturem
warranties
end
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
end
conditions
below,
warrants
to
its
MIG
Guns/TIG
Torches
original
retail
purchaser
thst
new
equipment
sold
after
the
effective
date
of
this
tim-
*
APT,
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
ited
warranty
is
free
of
defects
in
material
and
workmanship
at
the
time
it
is
shipped
Remote
C
from
factory
THIS
WARRANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WAR-
on
ma
RANTIES,
EXPRESS
OR
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MER-
Accessory
Kits
CHANTABILITY
AND
FITNESS.
*
Replacement
Parts
Within
the
warranty
periods
listed
below,
manufacturerwill
repairor
replace
anywar-
Umited
Warranty
ahall
not
apply
to:
rented
parts
orcomponenta
that
fail
due
to
such
defects
in
material
orworkmanahip.
Manufacturer
must
be
notified
in
writing
within
thirty
(30)
days
of
such
defect
or
fail-
1.
Itemafumished
by
manufacturer,
but
manufactured
by
othem,
such
as
engines
ure,
at
which
time
manufacturer
will
provide
instructions
on
the
warranty
claim
pro-
ortrade
accessories.
These
items
am
covered
bythe
manufacturerawarranty,
cedures
to
be
followed.
-
if
any.
Manufacturer
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
2.
the
event
of
such
a
failure
within
the
warrentytime
periods.
All
warrantytime
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
aent
to
en
International
distributor.
1.
5veamParts3YeareLsbor
*
Original
main
power
rectiflere
Invertere
(input
and
output
rectifiera
onlly)
2.
3
Yeam
Parts
and
Labor
Transformer/Rectifier
Power
Sources
*
Plasma
Arc
Cutting
Power
Sources
*
Semi-Automatic
and
Automatic
Wire
Feedera
Inverter
Power
Supplies
Intellitig
*
Robots
(1
year
labor)
3.
2
Yeam
Parts
and
Labor
*
Engine
Driven
Welding
Generatore
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
Air
Compreasora
4.
1
YearParts
and
Labor
*
Motor
Driven
Guns
*
Process
Controllera
*
IHPS
Power
Sources
Water
Coolant
Systems
*
HF
Units
Grids
*
Spot
Weldera
Load
Banks
SDXTmnsformem
*
Running
Gearfrrailera
Plasma
Cutting
Torchea
(except
APT
ZIPCUT
&
PLAZCUT
Models)
*
Tecumseh
Engines
Deutz
Engines
(outside
North
America)
*
Field
Options
(NOTE:
Field
options
are
covered
under
the
limited
warranty
for
the
re
maining
warranty
period
of
the
product
they
are
installed
in,
orfor
a
mini
mum
of
one
year
whichever
is
greater.)
6
Months
Batteries
90
Days
Parts
and
Labor
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactora
and
relays
or
parts
that
fail
due
to
normal
wear.
Equipment
that
has
been
modified
by
any
party
other
than
manufacturer,
or
equipmentthat
has
been
improperiy
installed,
improperiy
opemted
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necassary
maintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MANUFACTURERS
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMERCIAL/INDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPE
RIENCED
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
manufactumra
option:
(1)
repair~
or(2)
replacement;
or,
where
authorized
in
writing
by
manufacturer
in
appropriate
cases,
(3)
the
reasonable
coat
of
repair
or
replacement
at
an
authorized
asrvice
atation;
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(lees
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
risk
and
expense.
Manufacturers
option
of
repair
or
replace
ment
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
an
authorized
asr
vice
facility
as
determined
by
manufacturer.
Therefore
no
compensation
or
reim
buraement
for
transportation
costs
of
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARETHE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENTSHALL
MANUFAC
TURER
BE
LIABLE
FOR
DIRECT,
INDIRECT,
SPECtAL,
INCIDENTAL
OR
CON
SEQUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CONTRACT,
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
ANDANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTA11ON
AS
TO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUTFORTHIS
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
MANUFACTURER
IS
EXCLUDED
AND
DISCLAIMED
BY
MAN
UFACTURER.
Some
states
in
the
U.S.A.
do
not
allow
limitationa
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.
a.
I
5.
.E~
r
J
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
Claims
for
loss
or
damage
with
the
delivering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
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
Numberof
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date
of
Purchase
brand_war
3/96
ARC
WELDING
SAFETY
PRECAUTIONS
ELECTRIC
SHOCK
can
kill.
Touching
live
electncal
parts
can
cause
fatal
shocks
or
severe
bums.
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
touchin9
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.
5.
Properiy
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
Turn
off
all
equipment
when
not
in
use.
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.
13.
Keep
all
panels
and
covers
securely
in
place.
1.
Wear
approved
face
shield
or
safety
goggles.
Side
shields
recommended.
AA
WARNING
ARC
WELDING
can
be
hazardous.
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.
6.
7.
8.
9.
10.
,~,,
~
-9r.~i
-.
ARC
RAYS
can
burn
eyes
and
skin;
1.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
(see
NOISE
can
damage
hearing.
ANSI
Z49.
1
listed
in
Safety
Standards)
to
protect
your
face
and
eyes
when
welding
or
watching.
Arc
rays
from
the
welding
process
produce
intense
2.
Wear
approved
safety
glasses.
Side
shields
recommended.
heat
and
strong
ultraviolet
rays
that
can
bum
eyes
3.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
skin.
Noise
from
some
processes
can
damage
and
glare;
warn
others
not
to
watch
the
arc.
earing.
4.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
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.
wearing
an
air-supplied
respirator.
Shielding
gases
used
for
Welding
produces
fumes
and
gases.
Breathing
welding
can
displace
air
causing
injury
or
death.
Be
sure
the
these
fumes
and
gases
can
be
hazardous
to
your
breathing
air
is
safe.
health.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
form
highly
toxic
and
irritating
gases.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
7.
Do
not
weld
on
coated
metals,
such
as
galvanized,
lead,
or
3.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
cadmium
plated
steel,
unless
the
coating
is
removed
from
the
4.
Read
the
Material
Safety
Data
Sheets
(MSDSs)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
manufacturers
instruction
for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
and
cleaners,
containing
these
elements
can
give
off
toxic
fumes
if
welded.
WELDING
can
cause
fire
or
explosion.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Sparks
and
spatter
fly
oft
from
the
welding
arc.
The
flying
sparks
and
hot
metal,
weld
spatter,
hot
6.
Be
aware
that
welding
on a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
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.
7.
8.
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.
Chipping
and
grinding
cause
flying
metal.
As
welds
cool,
they
can
throw
off
slag.
2.
Wear
proper
body
protection
to
protect
skin.
SECTION
1
-
SAFETY
INFORMATION
OM-157066E6/96
modl.1
2/93
a
CAUTION
Read
all
safety
messages
throughout
this
manual.
U
Obey
all
safety
messages
to
avoid
injury.
U
Learn
the
meaning
of
WARNING
and
CAUTION.
1
Safety
Alert
Symbol
1
2
2
2
SignalWord
WARNING
means
possible
death
P
.
or
serious
injury
can
happen.
!~!i!t~
:1~II~eU
-3
CAUTION
means
possible
minor
ELECTRIC
SHOCK
can
kiII.f~
MOVING
PARTS
can
injure,
injury
or
equipment
damage
can
~%
Do
not
touch
live
electrical
parts.
Keep
away
from
moving
parts,
happen.
Disconnect
input
power
before
4
Keep
all
panels
and
covers
closed
3
Statement
Of
Hazard
And
installing
or
servicing,
when
operating.
Result
/
4
Safety
Instructions
To
Avoid
5
Hazard
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
~
~
~
~E~r~cSe=t
of
Read
safety
blocks
for
each
sym
7
NOTE
NOTE
~
Turn
Off switch
when
using
high
frequency.
Special
instructions
for
best
oper
ation
not
related
to
safety.
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
KVNKW
Used
At
Rated
Output
9.5
kVAI8.3
kW
Maximum
KVNKW
Used
While
Idling
0.24
kVNO.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:
30-1/4
in
(768
mm);
Width:
19
in
(483
mm);
Height:
37
in
(940
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)
OM-157
066
Page
1
2-1.
Volt-Ampere
Curves
Figure
2-1.
Volt-Ampere
Curves
2-2.
Duty
Cycle
4A
CAUTION
~.
~-
~-
REED
OIJrRJT-1
Figure
2-2.
Duty
Cycle
The
volt-ampere
curves
show
the
50
minimum
and
maximum
voltage
and
amperage
output
capabilities
of
the
welding
power
source.
Curves
of
other
settings
fall
be
tween
the
curves
shown.
~Iz~
g2o
0
I
I I
I
I
0
25
50
75
100
125
150
175
200
225
DC
AMPERES
ssbl.1
10/91
SB-049424-D
WELDING
LONGER
THAN
RATED
DUTY
CYCLE
can
damage
unit
or
gun
and
void
warranty.
Do
n
ot
weld
at
rated
load
longer
than
shown
below.
wfwam8.2
8/93
0
Definition
~
Duty
Cycle
is
percentage
of
10
10
weld
at
rated
load
without
over-
minutes
that
unit
or
gun
can
Minutes
heating.
UNIT
60%
Duty
Cycle
At
200
Amperes
g
6
Minutes
Welding
4
Minutes
Resting
Chart
GUN
6
minutes
Welding
4
minutes
Resting
w
-
-
-
100
-
-
-
.i
-
-
00
00 40
00
00
JO
1010100
~fGUN
60%
Duty
Cycle
At
180
Amperes
Using
Mixed
Gas
X
DJTY
~
6
minutes
Welding
4
minutes
Resting
sbl.3
8/93SB-150
215
OM-157
066
Page
2
3-1.
Installing
Work
Clamp
Figure
3-1.
Installing
Work
Clamp
SECTION
3-
INSTALLATION
5
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.
ST-154
630-A
OM-157
066
Page
3
3-2.
Installing
Gas
Supply
a
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.
-
~..
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
1r
Shut
off
shielding
gas
supply
when
not
in
use.
wam4.1
9/91
1
Cylinder
Bracket
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.
Tools
Needed:
5/8,1-1/Bin
ssb3.1
-
5/94
ST-154 623
/
ST-158 697-A
10
Flow
Adjust
Typical
flow
rate
is
20
cfh
(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-nng
between
regulator/flowmeter
and
CO2
cylinder.
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.
3-4.
Installing
Drive
Rolls
And
Welding
Gun
swaml.1
2./93
Shown
As
Shipped
Set
For
Electrode
Positive
(DCEP)
For
Solid
Steel
Or
Aluminum
Wires
(GMAW
Process).
Wire
Drive
Assembly
Lead
To
Positive
(+)
Output
Terminal
5
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
S-14.4
449-C
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:
~z=Z~
3/4,11/l6in
Ref.
ST-153
874-B
Figure
3-3.
Gun
Polarity
Connections
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.
lighten
knob.
8
Gun
Trigger
Plug
Insert
into
receptacle,
and
tighten
threaded
collar.
Close
pressure
assembly.
Close
door.
ST-
154
621
/
Ref.
ST-154
624-A
.7
Tools
Needed:
6
Figure
3-4.
Gun
Connections
OM-1
57066
Page
5
3-5.
Connecting
Input
Power
A.
Positioning
Jumper
Links
Figure
3-5.
Input
Voltage
Jumper
Links
Location
Jumper
links
allow
operation
on
different
input
voltages
and
are
factory
set
for
the
highest
input
voltage.
Check
input
voltage
available
at
site.
1
Input
Voltage
Label
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.
swam3.1
2193
200
VOLTS
230
VOLTS
S-153
980
I
Look
at
jumper
links
and
compare
link
position
with
applicable
label.
2
Screw
3
Access
Door
To
change
link
position,
remove
screw
and
pivot
door
up.
4
Input
Voltage
Jumper
Links
Location
Move
links
to
match
input
voltage.
For
example,
use
200
volts
posi
tion
when
200
volts
input
power
is
available.
Close
door
and
secure
with
screw.
Close
side
door.
Tools
Needed:
c::~::rJ==iJ
3/8
in
ssb5.i
2192
/
Ref.
ST-i
54
626-B
/
Ref.
ST-i54
628-B
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
Tum
oft
unit
Power
switch,
and
connect
plug
to
wall
receptacle.
ssb2.2
12/94
Ref.
ST-i
54
619-B
/
Ret.
ST-i
49 405-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
AWG/Kcmil
8
10
These
values
are
calculated
from
the
1996
edition
of
the
National
Electrical
Code
(NEC).
S-0092-H
5
3
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
a
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,
other
stationary
support.
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
The
welding
wire,
drive
rolls,
drive
assembly,
and
a
metal
parts
touching
the
welding
wire
are
electricall
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
Iswam2.1
9191
1
Turn
Off
unit.
1
Wire
Spool
2
Gun
Contact
lip
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/l6in
Ref.
ST-154 626-B
/
Ref.
ST-072
573-B
OM-157
066
Page
8
1
Wire
Spool
2
Welding
Wire
3
Inlet
Wire
Guide
4
Pressure
Adjustment
Knob
5
Pressure
Assembly
Drive
Roll
Outlet
Wire
Guide
Gun
Conduit
Cable
Lay
gun
cable
out
straight.
Close
and
tighten
pressure
assembly,
and
let
go
of
wire.
/
Press
gun
trigger
until
wire
comes
out
of
gun.
Reinstall
contact
tip
and
nozzle.
Remove
gun
nozzle
and
contact
tip.
Feed
wire
to
check
drive
roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
I
Cut
off
wire.
Close
and
latch
door.
Figure
3-8.
Threading
And
Feeding
Welding
Wire
ST-800
739-A
/
ST.154
251
/
S-0627-A
6
7
8
2
3
6
7
Hold
wire
tightly
to
keep
it
from
unraveling.
Open
pressure
assembly.
Pull
and
hold
wire;
cut
oft
end.
Push
wire
thru
guides
into
gun;
continue
to
hold
wire.
-4
=~
I~
-4~
00FF
Set
switch.
El
I
I
OM-1
57
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
(MSDS5)
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
ARCING
can
damage
switch.
Do
not
change
Voltage
switch
position
while
welding.
Arcing
inside
switch
can
damage
contacts,
causing
switch
to
fail.
y
:9//,~
~
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
S
Wear
welding
helmet
with
correct
shade
of
filter.
Wear
correct
eye,
ear,
and
body
protection.
,~
~
e
MOVING
PARTS
can
cause
injury.
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.
swam6.2
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
bettercontrol
of
wire
speed
use
Low
position
when
wire
speed
is
between
90
and
670
1pm.
Use
Full
position
when
wire
speed
is
be
tween
150
1pm
and
1030
ipm.
2
Voltage
Range
Selector
Place
switch
in
desired
position.
See
inside
rear
cover
for
settings.
Ref.
ST-i
53
874-B
/
S-i
71
601
Figure
4-2.
Center
Baffle
Controls
OM-157
066
Page
10
Tools
Needed:
Figure
4-3.
Front
Panel
Controls
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
Oft.
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
workpiece,
as
close
as
possible
to
weld
area.
Ref.
ST-i
54
622-B
/
ST-17i
639/Ref.
ST-i
54251
1
2
OM-157
066
Page
11
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Oft
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.
5-1.
Routine
Maintenance
41b
M
OVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
*~
Maintenance
and
troubleshooting
to
be
performed
only
by
qualified
persons.
swam8
2*
2/93
Turn
Off
all
power
before
maintaining.
Figure
5-1.
Maintenance
Schedule
OM-157
066
Page
12
5-2.
Overload
Protection
READ
Sectio
SAFETY
n
5
befor
BLOCKS
at
start
of
e
proceeding.
A.
Circuit
Br
eaker
CB1
1
I
4?
~
1
Circuit
Breaker
CB1
If
CB1
opens,
wire
feed
stops.
Check
gun
liner
for
blockage
or
binding
drive
gear,
or
misaligned
dnve
rolls.
Allow
a
cooling
period
before
resetting
CB1.
kinks,
and
check
for
jammed
wire,
Ref.
ST-153
874-B
Figure
5-2.
Circuit
Breaker
CB1
B.
Fuses
Fl
And
F2
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
____
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
Figure
5-5.
Wire
Drive
Assembly
Maintenance
Turn
Off
unit
and
disconnect
input
power.
Ref.
ST-i
54
626-B
/
SA-145
763
/
ST-154
633
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
Inlet
Guide
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
Am,
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:
OM-157
066
Page
14
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Miller AUTO ARC 255 Owner's manual

AUTO ARC 255
Miller
Brand
Miller
Model
AUTO ARC 255
Category
Welding System
Type
Owner's manual
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