Miller KE634255 Owner's manual

Brand: Miller

Model: KE634255

Category: Welding System

Type: Owner's manual

This manual is also suitable for

cover 5/94 − ST-800 091 PRINTED IN USA

 1994 MILLER Electric Mfg. Co.

Read and follow these instructions and all

safety blocks carefully.

Have only trained and qualified persons

install, operate, or service this unit.

Call your distributor if you do not understand

the directions.

Give this manual to the operator.

For help, call your distributor

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

Appleton, WI 54912 414-734-9821

OWNER’S

MANUAL

October 1994 Form: OM-278

Effective With Serial No. KE634255

CC/CV DC, 100% Duty Cycle Welding Power Source

For Multiple Welding Processes And CAC-A Cutting/Gouging

650 Amperes At 44 Volts DC

Uses Three-Phase Input Power (See Rating Label)

Overheating And Short Circuit Protection

14-Pin Remote Control Receptacle And Remote Control Terminal Strip

115 Volts AC 15 Amperes Auxiliary Power Receptacle

Dimension 652Dimension 652

OM-278 − 10/94

EMF INFORMATION

The following is a quotation from the General Conclusions Section of

the U.S. Congress, Office of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields −

Background Paper, OTA-BP-E-53 (Washington, DC: U.S.

Government Printing Office, May 1989): “. . . there is now a very large

volume of scientific findings based on experiments at the cellular

level and from studies with animals and people which clearly

establish that low frequency magnetic fields can interact with, and

produce changes in, biological systems. While most of this work is

of very high quality, the results are complex. Current scientific

understanding does not yet allow us to interpret the evidence in a

single coherent framework. Even more frustrating, it does not yet

allow us to draw definite conclusions about questions of possible risk

or to offer clear science-based advice on strategies to minimize or

avoid potential risks.”

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as far away as practical.

5. Connect work clamp to workpiece as close to the weld as

possible.

About Pacemakers:

The above procedures are among those also normally

recommended for pacemaker wearers. Consult your doctor for

complete information.

Considerations About Welding And The Effects Of Low Frequency Electric And

Magnetic Fields

NOTE

mod10.1 4/93

TABLE OF CONTENTS

SECTION 1 − SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Volt-Ampere Curves 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Duty Cycle 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Typical Process Connections 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Selecting A Location And Moving Welding Power Source 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Installing Gas Supply 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. 115 Volts AC Duplex Receptacle 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Selecting And Preparing Weld Output Cables 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Connecting To Weld Output Terminals 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Remote 14 Receptacle Information And Connections 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Terminal Strip 1T Information And Connections 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Connecting Input Power 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − MAINTENANCE & TROUBLESHOOTING 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Overload Protection 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Troubleshooting 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − ELECTRICAL DIAGRAMS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − TUNGSTEN ELECTRODE 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Selecting Tungsten Electrode 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Preparing Tungsten 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − PARTS LIST 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 8-1. Main Assembly 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 8-2. Panel, Front w/Components 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 8-3. Rectifier, Si Diode SR1 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 8-4. Panel, Rear w/Components 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-278 Page 1

SECTION 1 − SAFETY INFORMATION

mod1.1 2/93

Read all safety messages throughout this manual.

Obey all safety messages to avoid injury.

Learn the meaning of WARNING and CAUTION.

1 Safety Alert Symbol

2 Signal Word

WARNING means possible death

or serious injury can happen.

CAUTION means possible minor

injury or equipment damage can

happen.

3 Statement Of Hazard And Re-

sult

4 Safety Instructions To Avoid

Hazard

5 Hazard Symbol (If Available)

6 Safety Banner

Read safety blocks for each sym-

bol shown.

7 NOTE

Special instructions for best oper-

ation − not related to safety.

NOTE

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Disconnect input power before

installing or servicing.

WARNING

READ SAFETY BLOCKS at start of

Section 3-1 before proceeding.

WARNING

1 2

CAUTION

MOVING PARTS can injure.

• Keep away from moving parts.

• Keep all panels and covers closed

when operating.

Turn Off switch when using high frequency.

Figure 1-1. Safety Information

SECTION 2 − SPECIFICATIONS

Table 2-1. Welding Power Source

Specification Description

Type Of Output CC/CV DC (Constant Current/Constant Voltage Direct Current)

Rated Weld Output NEMA Class I (100) − 650 Amperes, 44 Volts DC At 100% Duty Cycle (See Section 2-2)

Type Of Input Power Three-Phase; 230, 460, Or 575 Volts AC; 60 Hz

Input Amperes At Rated Output 126 A At 230 V, 63 A At 460 V, 50.4 A At 575 V

Input Amperes While Idling 3.8 A At 230 V, 1.9 A At 460 V, 1.4 A At 575 V

KVA/KW Used At Rated Output 50 kVA/34.8 kW

KVA/KW Used While Idling 1.52 kVA/0.76 kW

Max. Open-Circuit Voltage CC Mode: 72 Volts DC; CV Mode: 70 Volts DC

Welding Processes Shielded Metal Arc (SMAW), Gas Tungsten Arc (GTAW), Gas Metal Arc (GMAW), Flux Cored Arc

(FCAW), And Submerged Arc Welding (SAW); Air Carbon Arc Cutting And Gouging (CAC-A)

Overall Dimensions See Figure 3-3

Weight Net: 545 lb (247 kg); Ship: 561 lb (254 kg)

OM-278 Page 2

2-1. Volt-Ampere Curves

ssb1.1* 10/91 − ST-168 916 / ST-168 917

The volt-ampere curves show the

minimum, mid, and maximum volt-

age and amperage output capabili-

ties of the welding power source.

Curves of other settings fall be-

tween the curves shown.

A. CC Mode B. CV Mode

Figure 2-1. Volt-Ampere Curves

2-2. Duty Cycle

CAUTION

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

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

warn7.1 8/93

Duty Cycle is percentage of 10

minutes that unit can weld at

rated load without overheating.

Continuous Welding

sb1.1 8/93 − Ref. ST-168 918

Minutes

100% Duty Cycle At 650 Amperes

Definition Chart

Figure 2-2. Duty Cycle

OM-278 Page 3

SECTION 3 − INSTALLATION

3-1. Typical Process Connections

See also operator booklet on unit for additional process connection information.

NOTE

Welding

GMAW

Power Source

Work

Welding

GTAW

Power Source

Work

HF Unit

Welding

GMAW

Power Source

Work

Push-Pull

Feeder

Wire Feeder

14 Pin

Remote

Control

Welding

SMAW

Power Source

Work

14 Pin

POLARITY

TYPICAL

Figure 3-1. Typical Process Connections

OM-278 Page 4

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

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Disconnect input power conductors from deener-

gized supply line BEFORE moving welding power

source.

FIRE OR EXPLOSION can result from

placing unit on, over, or near combus-

tible surfaces.

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

faces.

• Do not install unit near flammables.

FUMES can be hazardous; LACK OF

FRESH AIR AND PROPER VENTILA-

TION can be harmful.

• Do not breathe welding fumes.

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

and proper ventilation.

FALLING EQUIPMENT can cause seri-

ous personal injury and equipment

damage.

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

cylinders, or any other accessories.

• Use equipment of adequate capacity to lift the unit.

swarn11.1* 3/93

1 Lifting Eye

2 Lifting Forks

Use lifting eye or lifting forks to

move unit.

If using lifting forks, extend forks

beyond opposite side of unit.

3 Rating Label (Under Access

Door)

Use rating label to determine input

power needs.

4 Line Disconnect Device

Locate unit near correct input pow-

er supply.

Movement

Location And Airflow

18 in

(460 mm)

18 in

(460 mm)

ssb9.1 12/93 − ST-800 402 / ST-800 091

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

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

NOTE

Ref. ST-153 556-A

Inches Millimeters

A 27-1/4 692

B 22-1/4 565

C 36 914

D 33 838

E 1-1/2 38

F 20 508

G 1-1/8 29

H 7/16 Dia 11 Dia

4 Holes 4 Holes

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

OM-278 Page 5

3-3. Installing Gas Supply

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.

• Shut off shielding gas supply when not in use.

warn4.1 9/91

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 Gas Hose Connection

Fitting has 5/8-18 right-hand

threads. Obtain and install gas

hose.

6 Flow Adjust

Typical flow rate is 20 cfh (cubic feet

per hour). Check wire manufactur-

er’s recommended flow rate.

7CO

Adapter

8 O-Ring

Install adapter with O-ring between

regulator/flowmeter and CO

cylinder.

ssb3.1* 6/93 − ST-158 697-A

Tools Needed:

5/8, 1-1/8 in

Gas

7 8

Argon Gas

Figure 3-4. Typical Regulator/Flowmeter Installation

3-4. 115 Volts AC Duplex Receptacle

Ref. ST-800 101-B

1 115 Volts AC Duplex Recep-

tacle

This welding power source sup-

plies up to 15 amperes of 115 volts

ac power.

Power output is shared between

this receptacle and the Remote 14

receptacle or terminal strip 1T (see

Sections 3-7 and 3-8).

Receptacle is protected from over-

load by circuit breaker CB1 (see

Section 5-2).

Close door.

Figure 3-5. Connecting To 115 Volts AC Duplex Receptacle

OM-278 Page 6

3-5. Selecting And Preparing Weld Output Cables

sb6.5 11/92 − S-0752

1 Weld Output Cable

Determine total cable length in weld

circuit and maximum welding am-

peres. Use Table 3-1 to select prop-

er cable size.

Use shortest cables possible.

Do not use damaged cables.

2 Terminal Lug

Use lugs of proper amperage

capacity and hole size for connect-

ing to work clamp, wire feeder or

electrode holder, and weld output

terminals.

3 Wire Feeder

4 Insulated Electrode Holder

5 GTAW Torch

Install according to manufacturer’s

instructions.

6 Work Clamp

Install onto work cable.

Tools Needed:

10 ft (3 m)

Total Cable

Length In Weld

Circuit = 20 ft (6 m)

10 ft (3 m)

For Example,

OR OR

Figure 3-6. Selecting And Preparing Weld Output Cables

Table 3-1. Weld Cable Size*

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Welding

Amperes

10 To 60%

Duty Cycle

60 Thru 100%

Duty Cycle

10 Thru 100% Duty Cycle

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

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

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

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

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

350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0

400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0

500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0

600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0

700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0

800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0

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

OM-278 Page 7

3-6. Connecting To Weld Output Terminals

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Turn Off welding power source, and disconnect

input power before making any weld output

connections.

USING BOTH POSITIVE (+) WELD

OUTPUT TERMINALS AT SAME TIME

can cause serious electric shock and

arcing hazards.

• Both positive (+) terminals are live at the same time.

• Do not use both positive (+) weld output terminals at

the same time.

• Remove any cable not being used.

swarn12.1* 2/93

Ref. ST-800 101-B / ST-162 508-A

1 Positive (+) High Inductance

Weld Output Terminal

2 Positive (+) Low Inductance

Weld Output Terminal

While in the GMAW mode (see

Figure 4-4), use positive (+) weld

output terminal that provides the

best welding arc and weld puddle

properties for application.

When connected to Low terminal,

low inductance results in a stiff,

fast-responding arc, and small,

fast-freezing puddle.

When connected to High terminal,

high inductance results in a soft,

slower-responding, low spatter arc,

and more fluid weld puddle.

While in SMAW mode (see

Figure 4-4), use positive (+) High

Inductance weld output terminal.

3 Negative (−) Weld Output Ter-

minal

For Electrode Positive (DCEP),

connect work cable to negative (−)

terminal and electrode holder or

wire feeder cable to proper positive

(+) terminal.

For Electrode Negative (DCEN),

reverse cable connections.

Close door.

Tools Needed:

3/4 in

Use ONLY one positive

(+) weld output terminal

at a time. Remove any

cable not being used.

POSITIVE

NEGATIVE

Wire

Feeder

Workpiece Workpiece

Welding Power Source

GMAW or SAW Connections (DCEP) − For

SMAW Connections (DCEP)

POSITIVE

NEGATIVE

Welding Power Source

POSITIVE

NEGATIVE

FCAW Use Low Inductance Weld Output Terminal

Figure 3-7. Weld Output Connections

OM-278 Page 8

3-7. Remote 14 Receptacle Information And Connections

sb7.1* 12/93 − ST-800 693-A / Ref. S-0004-A / S-0750

1 Remote 14 Receptacle RC8

(See Table 3-2)

2 Keyway

3 Plug

4 Threaded Collar

To connect to receptacle, align

keyway, insert plug, and tighten

threaded collar. Close door.

If remote control plug does not fit

receptacle, go to Figure 3-9 to wire

cord to terminal strip 1T.

Figure 3-8. Remote 14 Connections

Table 3-2. Remote 14 Socket Information

A 24 volts ac. Protected by circuit breaker CB2.

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

I 115 volts ac. Protected by circuit breaker CB1.

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

G Circuit common for 24 and 115 volts ac circuits.

C Command reference; CV: +10 volts dc or CC: 0 to +10 volts dc.

D Remote control circuit common.

E 0 to +10 volts dc input command signal from remote control.

K Chassis common.

F Current feedback; 0 to +10 volts dc, 1 volt per 100 amperes.

H Voltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts.

Socket Information

*The remaining sockets are not used.

Socket*

OM-278 Page 9

3-8. Terminal Strip 1T Information And Connections

WARNING

ELECTRIC SHOCK can kill; UNEXPECTED OUTPUT can cause serious injury.

• Do not touch live electrical parts.

• Turn Off welding power source, and disconnect input power before making any internal inspection or connections.

• Do not connect to Remote 14 receptacle and terminal strip at the same time.

Output (Contactor) can be energized from either the receptacle or terminal strip. Use only one remote control method.

Terminal Information:

Remote Contactor

A, B Contact closure completes the 24 volts ac contactor control circuit. Protected by circuit breaker CB2.

Remote Amperage/Voltage Control

C Command reference; CV: +10 volts dc or CC: 0 to +10 volts dc.

D Control circuit common.

E Input command signal (potentiometer wiper or 0-10 volts dc source); 0 to +10 volts dc.

115 Volts AC

I, J Contact closure completes the 115 volts ac contactor control circuit. Protected by circuit breaker CB1.

Remote Power On/Off

K GND (chassis common).

L, M Remote power on/off connections.

Remote Voltage Sensing Signal

N Voltage sensing signal from Negative (−) weld output terminal.

P Voltage sensing signal from Positive (+) weld output terminal.

Ref. ST-800 170-C

Turn Off welding power source.

1 Remote Control Cord

2 Terminal Strip Access Panel

Remove screws and tip access

panel forward.

3 Strain Relief (Customer

Supplied)

Install strain relief. Route leads

through strain relief.

4 Terminal Strip 1T

5 Terminal Strip Label

Connect leads to 1T using terminal

information below.

Secure cord in strain relief. Rein-

stall and secure access panel.

Close door.

Tools Needed:

In some cases, Terminal Strip 1T letter designators

do not match Remote 14 Receptacle RC8. Read

descriptions below before making connections.

Turn Off power before

opening terminal strip

cover.

REMOTE

OUTPUT

CONTROL

115 VAC 24VAC

REMOTE

VOLTAGE

SENSE

GND REMOTE

POWER ON/OFF

S-162 895-B

EDI J ABNPK ML

REMOTE

CONTACTOR CONTACTOR

Figure 3-9. Terminal Strip 1T Connections

OM-278 Page 10

3-9. Connecting Input Power

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Turn Off welding power source, and disconnect input power before inspecting or installing.

• Have only qualified persons install unit.

• Installation must meet National Electrical Code and all other codes.

swarn3.1 2/93

A. Positioning Jumper Links

ssb5.1* 2/92 − ST-800 104-A

Jumper links allow operation on dif-

ferent input voltages and are facto-

ry set for the highest input voltage.

Check input voltage available at

site.

Open rear panel access door to

check jumper links.

1 Input Voltage Label

Look at jumper links and compare

link position with unit label.

2 Input Voltage Jumper Links

Move links to match input voltage.

For example, use 230 volts position

when 230 volts input power is avail-

able.

Close rear panel access door or go

on to Figure 3-11.

Tools Needed:

3/8 in

230 VOLTS

S-168 940

460 VOLTS 575 VOLTS

Figure 3-10. Input Voltage Jumper Links Location

OM-278 Page 11

B. Connecting Input Power

Have only qualified persons make

this installation.

Open rear access door.

1 Line Disconnect Device Of

Proper Rating

2 Input Conductors

3 Grounding Conductor

Select size and length using

Table 3-3. Conductor rating must

comply with national, state, and lo-

cal electrical codes. Use lugs of

proper amperage capacity and cor-

rect hole size.

4 Strain Relief Connector

Insert conductors through strain

relief.

5 Line Terminals

6 Welding Power Source

Ground Terminal

Connect grounding conductor to

ground terminal on base of unit first.

Then connect input conductors to

contactor.

7 Disconnect Device Ground

Terminal

Install and connect grounding

conductor and input conductors in

conduit or equivalent to deener-

gized line disconnect device.

Connect grounding conductor first,

then line input conductors.

Be sure grounding conductor goes

to an earth ground.

Close access door.

8 Overcurrent Protection

Select type and size using

Table 3-3. Install into deenergized

line disconnect device (fused dis-

connect switch shown).

ssb2.4* 1/94 − ST-800 103-A

S-162 681

IMPORTANT

Three-Phase Input Power Connections

GND/

Green Or

Green With

Yellow Stripe(s)

Input

Contactor

Cut All Conductors To Same Length, And Loop Back

Excess Grounding Conductor. Always Connect Input

Grounding Conductor To GND/PE Stud Near

Contactor On Base First.

Tools Needed:

3/8 in

Figure 3-11. Input Power Connections

S-0092-G

OM-278 Page 12

Table 3-3. Electrical Service Requirements*

Input Voltage

230 460 575

Input Amperes At Rated Output

126 63 51

Recommended Standard Fuse Or Circuit Breaker

Rating In Amperes

200 90 80

Input Conductor Size In AWG/Kcmil

1 6 6

Max Input Conductor Length In Feet (Meters)

180 (55) 284 (87) 444 (135)

Grounding Conductor Size In AWG/Kcmil

6 8 8

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

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

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

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

(Table 310-16 of NEC).

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

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

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

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

SECTION 4 − OPERATION

WARNING

ELECTRIC SHOCK can kill.

• Always wear dry insulating gloves.

• Insulate yourself from work and ground.

• Do not touch live electrical parts.

• Keep all panels and covers securely in place.

FUMES AND GASES can be hazardous

to your health.

• Keep your head out of the fumes.

• Ventilate area, or use breathing device.

• Read Material Safety Data Sheets (MSDSs) and

manufacturer’s instructions for material used.

WELDING can cause fire or explosion.

• Do not weld near flammable material.

• Watch for fire; keep extinguisher nearby.

• Do not locate unit over combustible surfaces.

• Do not weld on closed containers.

• Allow work and equipment to cool before handling.

ARC RAYS can burn eyes and skin;

NOISE can damage hearing.

• Wear welding helmet with correct shade of filter.

• Wear correct eye, ear, and body protection.

MOVING PARTS can cause injury.

• Keep away from moving parts.

• Keep all doors, panels, covers, and guards closed

and securely in place.

MAGNETIC FIELDS FROM HIGH CUR-

RENTS can affect pacemaker operation.

• Pacemaker wearers keep away.

• Wearers should consult their doctor before going

near arc welding, gouging, or spot welding opera-

tions.

See Safety Precautions at beginning of manual for ba-

sic welding safety information.

swarn6.1 10/91

1 Output (Contactor) Switch

2 Arc Force (Dig) Control

3 Remote Amperage/Voltage

Control Switch

4 Process Selector Switch

5 Amperage/Voltage Adjustment

Control

6 Digital Voltmeter

7 Digital Ammeter

8 Power Switch/Pilot Light

9 High Temperature Shutdown

Light

34267

Ref. ST-800 101-B

Figure 4-1. Controls

OM-278 Page 13

Wear the following while welding:

1 Dry, Insulating Gloves

2 Safety Glasses With Side

Shields

3 Welding Helmet With Correct

Shade Of Filter (See ANSI

Z49.1)

sb3.1 1/94

123

Figure 4-2. Safety Equipment

1 Work Clamp

Connect work clamp to a clean,

paint-free location on workpiece, as

close to weld area as possible.

Use wire brush or sandpaper to

clean metal at weld joint area. Use

chipping hammer to remove slag

after welding.

sb4.1 2/93

Tools Needed:

Figure 4-3. Work Clamp

1 Process Selector Switch

Use switch to select type of weld

output. Use SMAW (Hot Start On)

position for Shielded Metal Arc

Welding and Air Carbon Arc Cut-

ting/Gouging processes. Use

GMAW position for Gas Metal Arc

and Flux Cored Arc Welding pro-

cesses. Use SMAW (Hot Start Off)

position for Gas Tungsten Arc

Welding process.

Switch position determines opera-

tion of Amperage/Voltage Adjust-

ment control (see Figure 4-5) and

Arc Force (Dig) control (see

Figure 4-6).

With switch in SMAW (Hot Start

On) position, unit automatically pro-

vides a starting amperage higher

than set value.

Ref. ST-162 500-A

Figure 4-4. Process Selector Switch

OM-278 Page 14

1 Amperage/Voltage Adjustment

Control

2 Volts Scale

3 Amps Scale

Use Process Selector switch (see

Figure 4-4) to select weld amper-

age or voltage. Use Volts scale for

GMAW and FCAW processes. Use

Amps scale for SMAW and GTAW

processes.

4 Remote Amperage/Voltage

Control Switch

Use switch to select way of control-

ling amperage and voltage adjust-

ment.

For front panel control, place switch

in the Panel position.

For remote control, place switch in

Remote position. See Examples in

Figure 4-9 and Figure 4-10.

36 40

Figure 4-5. Amperage/Voltage Adjustment Control And Switch

1 Arc Force (Dig) Control

This control is used for SMAW,

SAW, or CAC-A, and only works

when Process Selector switch (see

Figure 4-4) is in the SMAW (Hot

Start On) position.

Control increases short-circuit am-

perage to help start an arc or make

vertical or overhead welds.

When set at 0, short-circuit amper-

age is the same as normal welding

amperage.

As setting increases, short-circuit

amperage increases to help arc

starting. See Figure 2-1.

Select setting best suited for appli-

cation. Numbers around control are

for reference only.

Turn control to 0 (zero) for GTAW process.

Figure 4-6. Arc Force (Dig) Control

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Do not touch weld output terminals when contactor is energized.

• Do not touch electrode and work clamp at the same time.

swarn7.1 10/91

1 Output (Contactor) Switch

Use switch to select way of control-

ling unit output.

For weld output, place switch in On

position.

For remote output control, connect

to Remote 14 receptacle or terminal

strip as instructed in Sections 3-7

and 3-8, and place switch in Re-

mote position.

Weld output terminals are

energized when switch is

On and Power is On.

Figure 4-7. Output (Contactor) Switch

OM-278 Page 15

1 Digital Voltmeter

Voltmeter displays voltage (to 0.1

volt) at the weld output terminals,

but not necessarily the welding arc

due to cable resistance, poor con-

nections, etc.

2 Digital Ammeter

Ammeter displays weld amperage

output of unit.

Both meters hold last weld value for

5 seconds after welding ends.

Figure 4-8. Voltmeter And Ammeter

4. Adjust Remote Control

2. Set Switches

1. Set Process

Ref. ST-162 500-A

EXAMPLE Of Combination Remote Amperage Control For GTAW Welding

Min (0 A DC)

Max (450 A DC)

36 40

3. Set Desired Maximum Amperage For Application

Figure 4-9. Remote Amperage Control Example

OM-278 Page 16

2. Set Switches

1. Set Process

3. Front Panel Amperage/Voltage

Control Does Not Work

REMOTE VOLTAGE

Min

(0 V)

Max

EXAMPLE Of Full Remote Voltage Control For GMAW Welding

36 40

(60 V)

Ref. ST-162 500-A

4. Set Percentage On Remote

Voltage Control Of Wire Feeder

Figure 4-10. Remote Voltage Control Example

1 Power Switch/Pilot Light

Use switch to turn unit on and off.

The switch lights when power is on.

2 High Temperature Shutdown

Light

Lights when unit internal tempera-

ture has reached maximum rated

temperature. Unit output shuts

down, but thermostatically con-

trolled fan motor runs as long as

cooling is needed.

Figure 4-11. Power Switch/Pilot Light, And High Temp Light

OM-278 Page 17

WARNING

BUILDUP OF SHIELDING GAS can harm health or kill.

• Shut off shielding gas supply when not in use.

warn1.1 9/91

1 Shielding Gas Cylinder

2 Valve

3 Gun Trigger

4 Foot Control

5 Finger Tip Control

Open valve on cylinder just before

welding.

Gun trigger, finger tip control, or foot

control turns weld output and gas

flow on and off.

Close valve on cylinder when fin-

ished welding.

sb5.2* 2/92 − S-0621-C

Figure 4-12. Shielding Gas

Begin Welding

ssb7.1 9/92

Install &

Connect

Equipment

Select

Electrode

Put On

Personal Safety

Equipment

Set Controls

Insert

Electrode

Into Holder

Turn On

Welding Power

Source

Figure 4-13. Sequence Of Shielded Metal Arc Welding (SMAW)

Begin Welding

ssb6.1 9/92

Install &

Connect

Equipment

Install & Prepare

Wire Feeding

System

Put On

Personal Safety

Equipment

Set Controls

Turn On

Shielding Gas

Turn On Feeder

And Welding

Power Source

Figure 4-14. Sequence Of Gas Metal Arc Welding (GMAW)

Install &

Connect

Equipment

Install & Prepare

Wire Feeding

System

Put On

Personal Safety

Equipment

Set Controls

Turn On Feeder

And Welding

Power Source

Begin Welding

ssb6.1* 9/92

Figure 4-15. Sequence Of Flux Cored Arc Welding (FCAW)

Install &

Connect

Equipment

Install & Prepare

Wire Feeding

System

Install & Prepare

Flux System

Begin Welding

Turn On

Flux System

Put On

Personal Safety

Equipment

Set Controls

Turn On Feeder

And Welding

Power Source

Figure 4-16. Submerged Arc Welding (SAW)

OM-278 Page 18

Turn On

Shielding Gas

ssb8.1 12/92

Install &

Connect

Equipment

Install & Connect

High-Frequency

Unit

Select

Tungsten

(See Section 7)

Insert

Tungsten

Into Torch

Put On

Personal Safety

Equipment

Set Controls

Turn On

High-Frequency

Unit

Turn On

Welding Power

Source

Begin Welding

Figure 4-17. Sequence Of Gas Tungsten Arc Welding (GTAW)

Install &

Connect

Equipment

Begin

Cutting Or

Gouging

Turn On

Welding Power

Source

Turn On

Compressed Air

Supply

Connect

Compressed Air

Supply

Select

Carbon Electrode

Put On

Personal Safety

Equipment

Set Controls

Insert Electrode

Into Torch

Figure 4-18. Air Carbon Arc Cutting And Gouging (CAC-A)

SECTION 5 − MAINTENANCE & TROUBLESHOOTING

WARNING

ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Turn Off welding power source, and disconnect

input power before inspecting, maintaining, or

servicing.

HOT PARTS can cause severe burns.

• Allow cooling period before maintaining or servicing.

MOVING PARTS can cause injury.

• Keep away from moving parts.

Maintenance to be performed only by qualified persons.

swarn8.1 2/93

5-1. Routine Maintenance

Turn Off all power before maintaining.

3 Months

Clean

And

Tighten

Weld

Terminals

Replace

Unreadable

Labels

6 Months

Tape Or

Replace

Cracked

Weld

Cable

During Heavy Service,

Clean Monthly

Blow Out

Vacuum

Inside

ST-800 091

Figure 5-1. Maintenance Schedule

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Miller KE634255 Owner's manual

Brand: Miller

Model: KE634255

Category: Welding System

Type: Owner's manual

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