Miller KJ100000 Owner's manual

Miller
Brand
Miller
Model
KJ100000
Category
Welding System
Type
Owner's manual

This manual is also suitable for

OWNERS
MANUAL
OM-210
089A
July
1998
Processes
.
MIG
(GMAW)
Welding
Flux
Cored
(FCAW)
Welding
Description
_______
1~OLSfi
Arc
Welding
Power
Source
And
Wire
Feeder
MW135/MW175
And
GA16C2
Gun
(
I
-
Page is loading ...
TABLE
OF
CONTENTS
SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING
The
following
terms
are
1-1.
Symbol
Usage
1
used
interchangeably
throughout
this
manual:
1-2.
Arc
Welding
Hazards
1
MIG=GMAW
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
Iinstallation,
le
fonctionnement
et
Ia
maintenance
7
1
.4
Principales
normes
de
sØcuritØ
8
1
.5
Information
sur
les
champs
ØlectromagnØtiques
8
SECTION
2
-
SPECIFICATIONS
9
2-1.
Specifications
9
2-2.
Duty
Cycle
And
Overheating
10
2-3.
Volt-Ampere
Curves
11
SECTION
3-
INSTALLATION
12
3-1.
Installing
Welding
Gun
12
3-2.
Changing
Polarity
12
3-3.
Process/Polarity
Table
12
3-4.
Installing
Gas
Supply
13
3-5.
Selecting
A
Location
And
Connecting
Input
Power
For
120
VAC
Model
14
3-6.
Selecting
A
Location
And
Connecting
Input
Power
For
230
VAC
Model
15
3-7.
Electrical
Service
Guide
For
230
VAC
Model
16
3-8.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
16
3-9.
Threading
Welding
Wire
17
SECTION
4-
OPERATION
18
4-1.
Controls
18
4-2.
Weld
Parameters
For
120
VAC
Model
19
4-3.
Weld
Parameters
For
230
VAC
Model
20
SECTION
5-
MAINTENANCE
&TROUBLESHOOTIN~
21
5-1.
Routine
Maintenance
21
5-2.
Overload
Protection
21
5-3.
Changing
Drive
Roll
Or
Wire
Inlet
Guida
22
5-4.
Short
Circuit
Shutdown
22
5-5.
Replacing
Gun
Contact
Tip
22
5-6.
Cleaning
Or
Replacing
GAl
6C2
Gun
Liner
23
5-7.
Troubleshooting
Table
24
SECTION
6-
ELECTRICAL
DIAGRAM
25
SECTION
7-
MIG
WELDING
(GMAW)
GUIDELINE&
28
7-1.
Typical
MIG
Process
Connections
28
7-2.
Typical
MIG
Process
Control
Settings
29
7-3.
Holding
And
Positioning
Welding
Gun
30
7-4.
Conditions
That
Affect
Weld
Bead
Shapa
31
7-5.
Gun
Movement
During
Welding
32
7-6.
Poor
Weld
Bead
Characteristics
32
7-7.
Good
Weld
Bead
Characteristics
32
7-8.
Troubleshooting
Excessive
spatter
33
7-9.
Troubleshooting
Porosity
33
7-10.
Troubleshooting
Excessive
Penetration
34
7-11.
Troubleshooting
Lack
Of
Penetration
34
7-12.
Troubleshooting
Incomplete
Fusion
34
7-13.
Troubleshooting
Burn-Through
35
7-14.
Troubleshooting
-
Waviness
Of
Bead
35
7-15.
Troubleshooting
Distortion
35
7-16.
Common
MIG
Shielding
Gases
36
SECTION
8-
PARTS
LIST
.38
WARRANTY
OM-21
0089A
Page is loading ...
SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING
som
_nd_5/97
1-1
Symbol
Usage
4A
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.
~
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.
r
FUMES
ANb
GASES
can
be
hazardous.
Welding
produces
fumes
and
gases.
Breathing
fl
~i
these
fumes
and
gases
can
be
hazardous
to
your
health.
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.
.
.
OM-210
089
Page
1
ARC
RAYS
can
bum
eyes
and
skin
Arc
rays
from
the
welding
process
produce
intense
visible
and
invisible
(ultraviolet
and
infrared)
rays
that
can
burn
eyes
and
skin.
Sparks
fly
off
from
the
weld.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Z49.1
and
Z87.1
listed
in
Safety
Standards).
Wear
approved
safety
glasses
with
side
shields
under
your
helmet.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(leather
and
wool)
and
foot
protection.
WELDING
can
cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can
cause
them
to
blow
up.
Sparks
can
fly
off
from
the
welding
arc.
The
flying
sparks,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
to
metal
objects
can
cause
sparks,
explosion,
overheating,
or
fire.
Check
and
be
sure
the
area
is
safe
before
doing
any
welding.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
Do
not
weld
on
closed
containers
such
as
tanks,
drums,
or
pipes,
unless
they
are
properly
prepared
according
to
AWS
F4.1
(see
Safety
Standards).
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
hazards.
Do
not
use
welder
to
thaw
frozen
pipes.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
FLYING
METAL
can
injure
eyes.
Welding,
chipping,
wire
brushing,
and
grinding
cause
sparks
and
flying
metal.
As
welds
cool,
they
can
throw
off
slag.
Wear
approved
safety
glasses
with
side
shields
even
under
your
welding
helmet.
BUILDUP
OF
GAS
can
injure
or
kill
Shut
off
shielding
gas
supply
when
not
in
use.
Always
ventilate
confined
spaces
or
use
approved
air-supplied
respirator.
HOT
PARTS
can cause
severe
burns
Do
not
touch
hot
parts
bare
handed.
Allow
cooling
period
before
working
on
gun
or
torch.
MAGNETIC
FIELDS
can
affect
pacemakers.
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
NOISE
can
damage
hearing.
Noise
from
some
processes
or
equipment
can
damage
hearing.
Wear
approved
ear
protection
if
noise
level
is
high.
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to
treat
them
carefully.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
Never
drape
a
welding
torch
over
a
gas
cylinder.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
Never
weld
on
a
pressurized
cylinder
explosion
will
result.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
.
.
OM-210
089
Page
2
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.
If
using
lift
forks
to
move
unit,
be
sure
forks
are
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.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
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.
MOVING
PARTS
cncause
injury.
Keep
away
from
moving
parts
such
as
fans.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
H.F.
RADIATION
can
cause
interferene.
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.i,
from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
SiB,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
1-3
Additional
Symbols
for
Installation,
Operation,
and
Maintenance
OM-210
089
Page
3
1-5
EMF
Information
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
Welding
current,
as
it
flows
through
welding
cables,
will
cause
electro
magnetic
fields.
There
has
been
and
still
is
some
concern
about
such
fields.
However,
after
examining
more
than
500
studies
spanning
17
years
of
research,
a
special
blue ribbon
committee
of
the
National
Research
Council
concluded
that:
The
body
of
evidence,
in
the
committees
judgment,
has
not
demonstrated
that
exposure
to
power-
frequency
electric
and
magnetic
fields
is
a
human-health
hazard.
However,
studies
are
still
going
forth
and
evidence
continues
to
be
examined.
Until
the
final
conclusions
of
the
research
are
reached,
you
may
wish
to
minimize
your
exposure
to
electromagnetic
fields
when
welding
or
cutting.
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
your
body.
4.
Keep
welding
power
source
and
cables
as
far
away
from
opera
tor
as
practical.
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
About
Pacemakers:
Pacemaker
wearers
consult
your
doctor
first.
If
cleared
by
your
doctor,
then
following
the
above
procedures
is
recommended.
OM-210
089
Page
4
Page is loading ...
Page is loading ...
Page is loading ...
Safety
in
Welding
and
Cutting,
norme
ANSI
Z49.
1,
de
American
Wel
ding
Society,
550
N.W.
Lejeune
Rd,
Miami
FL
33126
Safetyand
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
American
Welding
Society,
550
N.W.
Lejeune
Ad,
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
Ølectrique
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
Pape,
OTA-BP-E-53
(Washington
DC:
U.S.
Govern
ment
Printing
Office,
mai
1989),
publiØ
par
le
Office
of
Technology
Assessment
du
CongrŁs
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
frequence
peu
vent
avoir
des
effets
sur
lorganisme
et
mŒme
y
produire
des
transformations.
MŒme
sil
sagit
de
travaux
de
trŁs
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
es
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.
RŁgles
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
OccupationAndEducational
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.
Atm
de
rØduire
es
champs
ØlectromagnØtiques
dans
lenvironnement
de
travail,
respecter
les
consignes
suivantes
1
Garder
les
cables
ensembles
en
les
torsadant
ou en
les
attachant
avec
du
ruban
adhØsif.
2
Mettre
tous
les
cables
du
ctØ
oppose
de
lopØrateur.
3
Ne
pas
courber
pas
et
ne
pas
entourer
pas
les
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
prØcØdemment
font
partie
de
celles
desti
flees
aux
personnes
ayant
recours
a
un
stimulateur
cardiaque.
Veuillez
consulter
votre
mØdecin
pour
obtenir
plus
de
details.
1
4
Principales
normes
de
securitØ
1
5
Information
sur
les
champs
Ølectromagnetiques
.
OM-21
0
088
Page
8
SECTION
2-
SPECIFICATIONS
2-1.
Specifications
A.
12OVAC
Model
Rated
Welding
Output
Amperage
Range
Maximum
Open-
Circuit
Voltage
DC
Amperes
Input
at
Rated
Load
Output
120
V,
60
Hz,
Single-Phase
~A
KW
Weight
WI
Gun
Overall
Dimensions
90
A
@
19
Volts
DC,
30%
Duty
Cycle
75
A
@
19
Volts
DC,
20%
Duty
Cycle*
30130
28
24
20*
2.88
2.40*
2.45
2.04*
67
lb
(30
kg)
Length:
19-1/8
in
(489
mm)
Width
10-1/2
in
(267
mm)
Height:
14-1/2
in
(368
mm)
Wire
Type
And
Dia
Solid/
Stainless
Flux
Cored/
Aluminum
Wire
Feed
Speed
Range
At
No
Load
.023
-
.030
in
(0.6
0.8
mm)
.030
-
.035
~fl
(0.8
0.9
mm)
160
-870
1PM
(4.1
22.5
m/min)
*
CSA
Rating
5.
230
VAC
Model
Rated
Welding
Output
Amperage
Range
Maximum
Open-
Circuit
Voltage
DC
Amperes
Input
at
Rated
Load
Output
230
V,
50/60
Hz,
Single-Phase
~A
KW
Weight
W/
Gun
Overall
Dimensions
130
A
@
20
Volts
DC,
30%
Duty
Cycle
At
60Hz
Input
20%
Duty
Cycle
At
50
Hz
Input
30
175
30
19.5
4.49
3.83
70
lb
(31.8
kg)
Length:
19-1/8
in
(489
mm)
Width:
10-1/2
in
(267
mm)
Height.
14-1/2
in
(368
mm)
Wire
Type
And
Dia
Solid/
Stainless
Flux
Cored/
Aluminum
Wire
Feed
Speed
Range
At
No
Load
.023
.030
in
(0.6
0.8
mm)
.030
-
.035
in
(0.8
0.9
mm)
160
-954
1PM
(4.1
-24
m/min)
OM-210
089
Page
9
2-2.
Duty
Cycle
And
Overheating
30%dutycycle
at
90
amps
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
duty
cycle
before
welding.
A
Exceeding
duty
cycle
can
damage
unit
or
gun
and
void
warranty.
B.
230
VAC
Model
%
DUlY CYCLE
30%dutycycle
at
130
amps,
60
Hz
20%
duty
cycle
at
130
amps,
50
Hz
S
A.
120
VAC
Model
S
~5
~.)
.~5
30
4,)
50
50
80
%
DUTY
CYCLE
3
Minutes
Welding
7
Minutes
Resting
3
Minutes
Welding
7
Minutes
Resting
dutyl
4/95
SA-802
090
/
SA-802
091
OM-210
089
Page
10
2-3.
Volt-Ampere
Curves
A.
12OVAC
Model
30
27.5
25
22.5
20
17.5
15
12.5
10
7.5
2.5
0
The
volt-ampere
curves
show
the
minimum
and
maximum
voltage
and
amperage
output
capabilities
of
the
welding
power
source.
Curves
of
other
settings
fall
be
tween
the
curves
shown.
0
20
40
60
80 100
120
140
160
180
B.
230
VAC
Model
Cl)
0
0
-J
U
a
AMPS
RANGE
4
RANGE
3
RANGE
2
RANGE
I
3W
25-
20-
15-
~-.------..
~
~
-~----------------~
10-
5-
A-
RANGE
4
RANGE
3
RANGE
2
RANGE
1
ssbl.1
10/91
-ST-802
082/ST-802
089
0
50
100
DC
LOAD
AMPS
150
OM-210
089
Page
11
SECTION
3-
INSTALLATION
1
Drive
Assembly
2
Gun
Securing
Thumbscrew
3
Gun
End
3-3.
Process/Polarity
Table
Facing
Interior
Panel
with
door
open
Process
Polarity
Cable
Connections
Cable
To
Gun
Cable
To
Work
GMAW
Soild
wire
with
shield-
ing
gas
DCEP
Reverse
polarity
Connect
to
positive
(+)
out-
put
terminal
Connect
to
negative
()
output
terminal
FCAW
Self-shielding
wire
no
shielding
gas
DCEN
Straight
Polarity
Connect
to
negative
()
output
terminal
Connect
to
positive
(+)
output
terminal
3-1.
Installing
Welding
Gun
S
Loosen
thumbscrew.
Insert
gun
end
through
opening
until
it
bot
toms
against
drive
assembly.
Tighten
thumbscrew.
4
Gun
Trigger
Leads
Insert
leads,
one
at
a
time,
through
small
grommet
on
front
panel.
Connect
female
friction
terminals
to
matching
male
terminals
in
unit.
Polarity
is
not
important.
3-2.
Changing
Polarity
Close
door.
Ref.
ST-802
024
S6e
nualibt
40~
'
L~_~
Lead
Connections
For
Direct
Current
Electrode
Positive
(DCEP)
2
Lead
Connections
For
Direct
Current
Electrode
Negative
(DCEN)
Always
read
and
follow
wire
manufacturers
recommended
po
larity,
and
see
Section
3-3.
Close
door.
POLAR~TV
CHANGEOVER
u~
Fk~.
2
DcEP
Bectrodo
Podtrve
Sold
W~,
OM-210
089
Page
12
3-4.
Installing
Gas
Supply
Tools
Needed:
~
5/8,1-1/8in
Obtain
gas
cylinder
and
chain
to
running
gear,
wall,
or
other
station
ary
support
so
cylinder
cannot
fall
and
break
off
valve.
1
Cap
2
Cylinder
Valve
Remove
cap,
stand
to
side
of
valve,
and
open
valve
slightly.
Gas
flow
blows
dust
and
dirt
from
valve.
Close
valve.
3
Cylinder
4
Regulator/Flowmeter
Install
so
face
is
vertical.
5
Regulator/Flowmeter
Gas
Hose
Connection
6
Welding
Power
Source
Gas
Hose
Connection
Connect
customer
supplied
gas
hose
between
regulator/llowmeter
gas
hose
connection,
and
fitting
on
rear
of
welding
power
source.
7
Flow
Adjust
Typical
flow
rate
is
20
cfh
(cubic
feet
per
hour).
Check
wire
man
ufacturers
recommended
flow
rate.
8
CO2
Adapter
(Customer
Sup
plied)
9
0-Ring
(Customer
Supplied)
Install
adapter
with
0-ring
between
regulator/flowmeter
and
CO2
cylinder.
ri~~H
4
2
3
Argon
Gas
5
2
ST-802
028/
ST-802
086
3
//
CO2
Gas
:j00000000000
]OOaODtJD0000
]cIOiJcI0000000
]OEJD~JDDDDDDD
]DOD0000
]UcJ00000
]DOD0000
1~DI~
oaool
6
OM-210
089
Page
13
3-5.
Selecting
A
Location
And
Connecting
Input
Power
For
120
VAC
Model
.
18
in
Rating
Label
I
2
Grounded
Receptacle
A
120
volt,
20
ampere
individual
branch
circuit
protected
by
time-
delay
fuses
or
circuit
breaker
is
required.
3
Plug
From
Unit
Select
extension
cord
of
14
AWG
for
up
to
50
ft
(15
m)
or
12
AWG
for
50
up
to
200
ft
(61
m).
A
Special
installation
may
be
required
where
gasoline
or
volatile
liquids
are
present
see
NEC
Article
511
or
CEC
Section
20.
OM-210
089
Page
14
3-6.
Selecting
A
Location
And
Connecting
Input
Power
For
230
VAC
Model

S
1
Rating
Label
Supply
correct
input
power.
2
Plug
3
Receptacle
Connect
plug
to
receptacle.
4
Line
Disconnect
Device
See
Section
3-7.
4
Li
A
Special
installation
may
be
required
where
gasoline
or
volatile
liquids
are
present
see
NEC
Article
511
or
CEC
Section
20.
A
Always
connect
grounding
conductor
first.
=
GNDIPE
A
Do
not
move
or
operate
unit
where
it
could
tip.
ssb2.2
1/94
-
Ref.
ST-802
179
OM-2i0
089
Page
15
3-7.
Electrical
Service
Guide
For
230
VAC
Model
Input
Voltage
230
Input
Amperes
At
Rated
Output
19.5
Max
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes
30
Mm
Input
Conductor
Size
In
AWG/Kcmil
14
Max
Recommended
Input
Conductor
Length
In
Feet
(Meters)
66
(20)
Mm
Grounding
Conductor
Size
In
AWG/KcmiI
14
Reference:
1996
National
Electrical
Code
(NEC)
S-0092-J
.
3-8.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
OM-210
089
Page
16
3-9.
Threading
Welding
Wire
Tools
Needed:
1
Wire
Spool
2
Welding
Wire
3
Inlet
Wire
Guide
4
Pressure
Adjustment
Knob
5
Drive
Roll
6
Outlet
Wire
Guide
7
Gun
Conduit
Cable
Lay
gun
cable
out
straight.
Hold
wire
tightly
to
keep
it
from
unraveling.
~6in~
(150
mm)
Open
pressure
assembly.
Pull
and
hold
wire;
cut
off
end.
Push
wire
thru
guides
into
gun;
continue
to
hold
wire.
ON
I
INPUT
POWER
-e
Close
and
tighten
pressure
assembly,
and
let
go
of
wire.
Remove
gun
nozzle
and
contact
tip.
Turn
power
on.
Press
gun
trigger
until
wire
comes
out
of
gun.
1111
I
II
(~!.
Feed
wire
to
check
drive
roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
Cut
off
wire.
Close
and
latch
door.
ReL
ST-802
081
I
Ref.
ST-205
837
-4
-4
-4
Reinstall
contact
tip
and
nozzle.
OM-210
089
Page
17
SECTION
4-OPERATION
4-1.
Controls
,
~
1
Voltage
Switch
The
higher
the selected
number,
the
thicker
the
material
that
can
be
welded
(see
weld
setting
label
in
welding
power
source
or
Sections
4-2
and
4-3,
as
applicable).
Do
not
switch
under
load.
2
Voltage
Switch
-
Purge
0
Position
In
purge
position,
fan
runs
but
there
is
no
weld
output.
3
Wire
Speed
Control
Use
control
to
select
a
wire
feed
speed.
As
Voltage
switch
setting
increases,
wire
speed
range
also
increases
(see
weld
setting
label
in
welding
power
source
or
Sections
4-2
or
4-3,
as
applicable).
Ref.
S~2O5
3~
.
II~
/
7/
/P~ST~
I
R
a.,
44~:
~
OM-210
089
Page
18
4-2.
Weld
Parameters
For
120
VAC
Model
205406A
Welding
Guide
Settings
are
approximate.
Adjust
as
required.
TO
WELD:
THICKNES
(Inches/
Gauge)
WIRE
TYPE\SIZE
GAS
GAS
FLOW
(Cubic
Ft/Hr)
POLARIT~
WELDING
VOLTAGE
WIRE
SPEEI
WIRE
STICKOU
(Inches)
Auto
Body
Lawnmower
Handles,
Waaons,
Tricycles
Duct
Wo~k,
Auto
Door
Brackets,
Tailpipes,
Bicycles
Wheelbarrows,
Lawnmower
Decks,
Basketball
Posts,
Galvanized
Roofing,
Trailer
Sides,
Garage
Door
Tracks,
Tailpipes,
Motorcycles
.022
24
GA.
3/64
18
GA.
1/16
16
GA.
HB28
(.024)
HB-28
(.024)
HB28
(.030)
co2
or
C25
CO2
or
C25
CO2
or
C25
20
20
20
DCEP
DCEP
DCEP
1
2
2
34
34
23
1/4
1/4
5/16
Fabshield
21B
(.035)
HB-28
(.024)
CO2
orC25
20
DCEN
DCEP
1
2
23
3-4
1/4
5/16
HB-28
(.030)
CO2
or
C25
20
DCEP
2
2-3
5/16
HB-28
(.035)
CO2
or
C25
20
DCEP
2
34
5/16
Fabshield
21B
(.035)
DCEN
1
2-3
1/4
Fabshield
21B
(.045)
DCEN
1
1/2
Fencing,
Lawnmower
Decks,
Trailers,
Trailer
Frames,
Wheelbarrows,
Garage
Door
Brackets
Grain
Waaons,
Bailers,
ombines,
~umpers
1/8
11GA.
HB-28
(.024)
CO2
or
C25
20
DCEP
3
45
5/16
HB28
(.030)
CO2
orG25
20
DCEP
3
1/2
HB-28
(.035)
CO2
or
C25
20
DCEP
3
34
1/2
Fabshield
21B
(.035)
DCEN
2
3-4
1/4
Fabshield
21
B
(.045)
DCEN
2
3
3/4
Trailer
Hitches,
Door
Hinge
Brackets,
Axles
A
Frames,
Farm
Equipmeni
Frames,
Basketball
Rimsand
Brackets
3/16
7
GA.
HB28
(.024)
CO2
or
C25
20
DCEP
4
6-7
1/2
HB28
(.030)
CO2
or
C25
20
DCEP
4
1/2
HB-28
(.035)
CO20rC25
20
DCEP
4
4-5
45
1/2
Fabshield
21B
(.035)
DCEN
3
1/2
Fabshield
21
B
(.045)
DCEN
4
4
3/4
Stainless
Steel
Fryers,
Counter
Tops,
Kitchen
Equipment
1/16
16
GA.
1/8
11
GA.
Solid
Stainless
(.030)
C25
20
DCEP
2
4-5
5/16
C25
20
DCEP
4
6
1/2
Aluminum
1/16
16
GA.
5356
(.035)
ARGON
20
DCEP
1
8
1/4
CO2
=
Carbon
Dioxide
C25
=
Argon
+
25%
Carbon
Dioxide
205
406-A
OM-210
089
Page
19
4-3.
Weld
Parameters
For
230
VAC
Model
.
.
Welding
Guide
Settings
are
approximate.
Adjust
as
required.
205424A
TO
WELD:
THICKNES
(Inches!
Gauge)
WIRE
TYPE\SIZE
GAS
GAS
FLOW
(Cubic
Ft/Hr)
POLARIT~
WELDING
VOLTAGE
WIRE
PEE
WIRE
STICKOU1
(Inches)
Auto
Body
.022
24
GA.
HB28(.024)
CO2
orC25
20
DCEP
1
4.55.5
1/4
Lawnmower
Handles,
Waaons,
Tricycles
Duct
Worl<,
Auto
Door
Brackets,
Tailpipes,
Bicycles
3/64
18
GA.
HB-28
(.024)
CO2
or
C25
20
DCEP
2
4-5.5
1/4
HB28
(.030)
CO2
or
C25
20
DCEP
2
455.5
5/16
Fabshield
21B
(.035)
DCEN
1
45
1/4
Wheelbarrows,
Lawnmower
Decks,
Basketball
Posts,
Galvanized
Roofing,
Trailer
Sides,
Garage
Door
Tracks,
Tailpipes,
Motorcycles
1/16
16
GA.
HB-28
(.024)
CO2
or
C25
20
DCEP
2
4-5.5
5/16
HB-28
(.030)
CO2
or
C25
20
DCEP
2
4.55.5
5/16
HB-28
(.035)
CO2
or
C25
20
DCEP
2
5/16
Fabshield
21B
(.035)
DCEN
1
45
1/2
Fabshield
21B
(.045)
DCEN
1
55.~
1/2
Fencing,
Lawnmower
Decks,
Trailers,
Trailer
Frames
Wheelbarrows,
GarageDoor
Brackets
Grain
Waaons,
Bailers,
Combines,
bumpers
1/8
11
GA.
HB-28
(.024)
CO2
or
C25
20
DCEP
3
~i~T
5/16
HB-28
(.030)
CO2
or
C25
20
DCEP
3
4.55.~
3/8
HB28
(.035)
CO2
or
C25
20
DCEP
3
3/8
Fabshield
21B
(.035)
DCEN
2
1/2
Fabshield
21B
(.045)
DCEN
2
45
1/2
Trailer
Hitches,
Door
Hinge
Brackets,
Axles
A
Frames,
Farm
Equipmen~
Frames,
Basketball
Rims
and
Brackets
3/16
.187
io
1/4
.250
HB28
(.024)
CO2
or
C25
20
DCEP
4
78
1/2
HB28(.030)
CO2orC25
20
DCEP
4
1/2
HB28
(.035)
Fabshield
21B
(.035)
CO2
or
C25
20
DCEP
DCEN
4
3or4
4_S
5
1/2
1/2
Fabshield
21B
(.045)
DCEN
3or4
45
3/4
Stainless
Steel
Fryers,
Counter
Tops,
Kitchen
Equipment
1/16
16
GA.
1/8
11
GA.
3/16tol/4
.187to.250
Solid
Stainless
(.030)
TRIMIX
20
DCEP
2
4.5-5.:
3/8
TRI-MIX
20
DCEP
3
6-7
3/8
TRI-MIX
20
DCEP
4
67
3/8
Aluminum
1/16
16
GA.
5356
(.035)
ARGON
20
DCEP
1
9
1/2
3/32
14
GA.
5356
(.035)
ARGON
20
DCEP
2
9
9-10
1/2
1/8
11
GA
5356
(.035)
ARGON
20
DCEP
3
1/2
1/4
5356
(.035)
ARGON
20
DCEP
4
10
1/2
CO2
=
Carbon
Dioxide
C25
=
Argon
+
25%
Carbon
Dioxide
TRI-MIX=
90%
HELIUM
+
7-1/2%
ARGON
+
2-1/2%
CARBON
DIOXIDE
205
424-A
OM-210
089
Page
20
SECTION
5-
MAINTENANCE
&TROUBLESHQOTING
5-1.
Routine
Maintenance
5-2.
Overload
Protection
120
VAC
And
230
VAC
(CSA)
Models
3
1
Circuit
Breaker
CB
Circuit
breaker
CB
protects
wire
feed
motor
from
overload.
If
circuit
breaker
opens,
wire
stops
feeding.
2
Circuit
Breaker
CB1
(CSA
Model)
CB1
protects
unit
from
overload.
If
CB1
opens,
unit
shuts
down.
3
Circuit
Breaker
CB2
(CSA
Model)
Circuit
breaker
CB2
protects
wire
feed
motor
from
overload.
If
circuit
breaker
opens,
wire
stops
feeding.
Reset
breaker.
Ref.
ST-802
081
2
120
VAC
(CSA)
Model
OM-210
089
Page
21
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Miller KJ100000 Owner's manual

Miller
Brand
Miller
Model
KJ100000
Category
Welding System
Type
Owner's manual
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