Miller KG177169 Owner's manual

KG177169
Miller
Brand
Miller
Model
KG177169
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
February
1997
Form:
OM-180
6700
Effective
With
Serial
No.
KG177169
OWNER
S
MANUAL
~IILE~
''~~
fl~J~
TO
FOII~~
CE
XMTfi
304
CC
And
CC/CV
Models
For
Multi-Process
Welding
Rated
Welding
Output
Voltage
Range
(CC/CV
Models
Only)
Amperage
Range
Maximum
Open-Circuit
Voltage
DC
IP
Rating
Amperes
Input
at
Rated
Load
Output
50
Hz
400V
KVA
I
KW
300A
@
32
Volts
DC,
60%
Duty
Cycle
1035
5400
90
23
17.0
(0.15*)
12.4
11.5
(0.09)
I
(0.04)
I
*While
idling
cover_om
4/95
ST-801
192
'
1997
MILLER
Electric
Mfg.
Co.
PRINTED
IN
USA
I
<t2
MILLERS
TRUE
BLUEfi
LIMITED
WARRANTY
Effective
January
1,1997
(Equipment
with
a
serial
number
preface
of
KH
or
newer)
This
limited
wsrrsnty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subjecttotheterms
and
conditions
below,
MILLER
Electric
Mfg.
Co.,
Appleton,
Wisconsin,
warrants
to
its
original
retail
purchaaer
that
new
MILLER
equipment
sold
after
the
effective
date
of
this
limited
warranty
is
free
of
de
fects
in
material
and
workmanship
at
the
lime
it
is
shipped
by
MILLER.
ThIS
WAR
RANTY
IS
EXPRESSLY
IN
uEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPUED,
INCLUDING
THE
WARRAN11ES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war-
-ranted
parts
orcomponents
that
fail
due
to
such
defects
in
material
or
workmanship.
MILLER
must
be
notified
in
writing
within
thirty
(30)
days
of
such
defect
or
failure,
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
such
a
failure
within
the
warranty
time
periods.
All
warranty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser;
or
one
year
after
the
equipment
is
sent
to
a
North
American
distributor
or
eighteen
months
after
the
equipment
is
sent
to
an
Intemational
distributor.
1.
5YeamParta-3YearaLabor
*
Original
main
power
rectifiers
*
Invertem
(input
and
output
rectifiers
only)
2.
3
Yeam
Parts
and
Labor
*
Transformer/Rectifier
Power
Sources
*
Plasma
Arc
Cutting
Power
Sources
*
Semi-Automatic
and
Automatic
Wire
Feeders
*
Inverter
Power
Supplies
*
Intetlitig
Robots
(1
year
labor)
*
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
3.
1
Year
Parts
and
Labor
Motor
Driven
Guns
*
Process
Controllers
*
IHPS
Power
Sources
*
Water
Coolant
Systems
*
HFUnits
*
Grids
Spot
Welders
*
Load
Banks
SDXTransformem
*
Miller
Cyclomatic
Equipment
Running
Gear/Trailers
*
Plasma
Cutting
Torches
(except
APT
ZIPCUT
&
PLAZCUT
Models)
Deutz
Engines
(outside
North
America)
Field
Options
(NOTE:
Field
options
are
covered
under
True
Bluefi
for
the
remaining
warranty
period
of
the
product
they
are
installed
in,
orfora
minimum
of
one
year
whichever
is
greater.)
4.
6
Months
Batteries
5.
90
Days
Parts
and
Labor
MIG
GunsTflG
Torches
APT,
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
Remote
Controls
Accessory
Kits
*
Replacement
Parts
(No
labor)
MILLERS
True
Bluefi
Umited
Warranty
shall
not
apply
to:
1.
Items
famished
by
MILLER,
but
manufactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contsctors,
relays,
brushes,
alip
rings,
or
parts
that
fail
due
to
normal
wear.
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip
ment
that
has
been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necesasry
maintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASEAND
USE
BYCOMMER
CIALIINDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
ThE
USE
AND
MAINTENANCE
OF
WELDING
EGUIPMENT.
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be,
at
MILLERS
option:
(1)
repair;
or
(2)
replacement;
or;
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
mpairor
replace
ment
at
an
authorized
MILLER
service
station;
or(4)
payment
of
orcreditforthe
pur
chase
price
(leas
reasonable
depreciation
based
upon
actual
use)
upon
retum
of
the
goods
at
customers
risk
and
expense.
MILLERS
option
of
repsir
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compenastion
or
reimburse
ment
for
transportation
costs
of
any
kind
will
be
allowed.
TO
ThE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
ThE
SOLEAND
EXCLUSIVE
REMEDIES.
IN
NO
EVENTSHALL
MILLER
BE
UABLE
FOR
DIRECT,
INDIRECt
SPECIAL,
INCIDENTALOR
CONSEGUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CON
TRACt
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTA11ON
ASTO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPUCA11ON,
OPERA11ON
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEALING,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PAR11CULAR
PURPOSE,
WiTh
RESPECT
TO
ANY
AND
ALL
EGUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
state
to
state.
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
other
than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
and
exclusions
set
out
above
may
not
apply.
This
Umitsd
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
WHO
DO
I
CONTACT?
For
help,
To
file
a
claim
for
loss
or
damage
during
Miller
Electric
Mfg.
Co.
contact
your
distributor
For
additional
information,
such
as
Technical
Manuals
(Service
And
Parts)
Engine
Manuals
-
Circuit
And
Wiring
Diagrams
shipment,
contact
the
delivering
carrier
For
assistance
in
filing
or
settling
claims,
contact
your
distributor
and/or
equipment
manufacturers
Transportation
Department
~Sijj~
T~T1
CALL:
414-735-4505
FAX:
800-637-2348
(in
USA),
or
414-7354136
(outside
USA)
Process
Handbooks
Users
Guides
Distributor
Directories
r
D~
=
U
WRITE:
Miller
Electric
Mfg.
Co
contact
your
distributor
P0.
BOX
1079
Appleton,
WI
54912
USA
Always
provide
Model
Name
and
Serial
or
Style
Number
miller_wart
1/97
Declaration
of
Conformity
For
European
Community
(CE)
Products
Manufacturers
Name:
Miller
Electric
Mfg.
Co.
Manufacturers
Address:
1635
W.
Spencer
Street
Appleton,
WI
54914
USA
Declares
that
the
product
XI~IITfi
304
conforms
to
the
following
Directives
and
Standards:
Directives
Electromagnetic
compatibillty
Directives:
89/336/EEC,
92131/EEC
Low
Voltage
Directive:
73/23/EEC
Machinery
Directives:
89/392/EEC,
91/368/EEC,
93/C
133/04,
93/68/EEC
Standards
Electromagnetic
compatibility
(EMC)
Product
standard
for
arc
welding
equipment:
EN50199:
December
1995
Safety
Requirements
forArc
Welding
Equipment
part
1:
EN
60974-1:
1989
Degrees
of
Protection
provided
by
Enclosures
(IP
code):
lEG
529:
1989
Insulation
coordination
for
equipment
within
low-voltage
systems:
Part
1:
Principles,
requirements
and
tests:
IEC
664-1:
1992
European
Contact:
Mr.
Luigi
Vacchini,
Managing
Director
MILLER
Europe
S.P.A.
Via
Privata
Iseo
20098
San
Giuliano
Milanese,
Italy
Telephone:
39(02)98290-1
Fax:
39(02)98281-552
dec_coni
10/95
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
CM-i
80
670C
2/97
safety_somi
4/95
1-1.
Symbol
Usage
j~
Means
Warning!
Watch
Out!
There
are
possib!e
hazards
with
this
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
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.
1-2.
Arc
Welding
Hazards
A~
WARNING
The
symbols
shown
below
are
used
throughout
this
manual
to
call
attention
to
and
identify
possible
hazards.
When
you
see
the
symbol,
watch
out,
and
follow
the
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.
Only
qualified
persons
shc~uld
install,
operate,
maintain,
and
repair
this
unit.
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.
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
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockoul/tagout
input
power
according
to
OSHA
29
CFR
1910.147
(see Safety
Standards).
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
6.
Always
verity
the
supply
ground
check
and
be
sure
that
input
Dower
cord
around
wire
is
~
~
to
around
VVUII4JI~(.,~
vv,JIr,L~uIe
~
.
.~.

ARC
RAYS
can
burn
eyes
and
skin;
ARC
RAYS
NOISE
can
damage
hearing;
FLYING
SLAG
OR
SPARKS
can
injure
eyes.
2.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Arc
rays
from
the
welding
process
produce
intense
Z49.1
and
Z87.1
listed
in
Safety
Standards).
visible
and
invisible
(ultraviolet
and
infrared)
rays
3.
Wear
approved
safety
glasses
with
side
shields.
that
can
burn
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
Chipping,
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
grinding,
and
welds
cooling
throw
off
pieces
of
metal
or
slag.
and
glare;
warn
others
not
to
watch
the
arc.
NOISE
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
material
(wool
and
leather)
and
foot
protection.
FUMES
AND
GASES
can
be
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
hazardous
to
your
health.
wearing
an
air-supplied
respirator.
Always
have
a
trained
Welding
produces
fumes
and
gases.
Breathing
watchperson
nearby.
Welding
fumes
and
gases
can
displace
air
these
fumes
and
gases
can
be
hazardous
to
your
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
health,
breathing
air
is
safe.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes,
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
form
highly
toxic
and
irritating
gases.
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
(MSDS5)
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
cleaners,
and
degreasers.
containing
these
elements
can
give
off
toxic
fumes
if
welded.
A
Marks
a
special
safety
message.
~
Means
NOTE;
not
safety
related.
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properiy
grounded
receptacle
outlet.
7.
When
making
input
connections,
attach
proper
grounding
conductor
first
double-check
connections.
8.
Frequently
inspect
input
power
cord
for
damage
or
bare
wiring
replace
cord
immediately
if
damaged
bare
wiring
can
kill.
9.
Turn
off
all
equipment
when
not
in
use.
10.
Do
not
use
worn,
damaged,
undersized,
or
pooriy
spliced
cables.
11.
Do
not
drape
cables
over
your
body.
12.
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable
do
not
use
work
clamp
or
work
cable.
13.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
14.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
15.
Wear
a
safety
harness
if
working
above
floor
level.
16.
Keep
all
panels
and
covers
securely
in
place.
17.
Clamp
work
cable
with
good
metal-to-metal
contact
to
nr
~~---
n~ar
th~
w~Ir~
~q
OM-180
670
Page
1
CYLINDERS
can
explode
if
damaged.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
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.
1.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
2.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
5.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
6.
Never
weld
on
a
pressurized
cylinder
explosion
will
result.
7.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
8.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
9.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
10.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
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
bums.
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.
4.
Be
alert
that
welding
sparks
and
hot
materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
6.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
7.
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).
8.
Connect
work
cable
to
the
work
as
close
to
the
welding
area
as
practical
to
prevent
welding
currentfrom
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
hazards.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
10.
Remove
stick
electrode
from
holder
or
cut
oft
welding
wire
at
contact
tip
when
not
in
use.
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as
a
butane
lighteror
matches,
from
your
person
before
doing
any
welding.
1-3.
Additional
Installation,
Operation,
And
Maintenance
Hazards
EXPLOSION
can
result
from
unit
on,
over,
or
near
Do
not
locate
unit
on,
over,
or
near
combustible
surfaces.
Do
not
install
unit
near
flammables.
FALLING
EQUIPMENT
can
cause
serious
personal
injury
and
equipment
damage.
1.
Use
lifting
eye
to
lift
unit
only,
NOT
running
gear,
gas
cylinders,
or
any
other
accessories.
Use
equipment
of
adequate
capacity
to
lift
unit.
If
using
lift
forks
to
move
unit,
be
sure
forks
are
long
enough
to
extend
beyond
opposite
side
of
unit.
HOT
PARTS
can
cause
severe
burns.
1.
Do
not
touch
hot
parts
bare
handed.
2.
Allow
cooling
period
before
working
on
gun
or
torch.
MOVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts
such
as
fans.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
1.
Pacemaker
wearers
keep
away.
2.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
operations.
MOVING
PARTS
can
cause
injury.
1.
Keep
away
from
moving
parts.
2.
Keep
away
from
pinch
points
such
as
drive
rolls.
FLYING
PIECES
OF
METAL
or
DIRT
can
injure
eyes.
1.
Wear
safety
glasses
with
side
shields
or
face
shield.
WELDING
WIRE
can
cause
puncture
wounds.
1.
Do
not
press
gun
trigger
until
instructed
to
do
so.
2.
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
orany
metal
when
threading
welding
wire.
HIGH-FREQUENCY
RADIATION
can
interfere
with
radio
navigation,
safety
services,
computers,
and
communications
equipment.
1.
Have
only
qualified
persons
familiar
with
electronic
equipment
perform
this
installation.
2.
The
user
is
responsible
for
having
a
qualified
electrician
promptly
correct
any
interference
problem
resulting
from
the
installation.
3.
If
notified
by
the
FCC
about
interference,
stop
using
the
equipment
at
once.
4.
Have
the
installation
regularly
checked
and
maintained.
5.
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.
1.
2.
3.
FIRE
OR
placing
combustible
surfaces.
OM-180
670
Page
2
OVERUSE
can
cause
OVERHEATED
SIGNIFICANT
DC
VOLTAGE
exists
after
EQUIPMENT.
Allow
cooling
period.
Reduce
current
or
reduce
duty
cycle
before
starting
to-weld
again.
Follow
rated
duty
cycle.
STATIC
ELECTRICITY
can
damage
parts
on
circuit
boards.
1.
Put
on
grounded
wrist
strap
BEFORE
handling
boards
or
parts.
Use
proper
static-proof
bags
and
boxes
to
store,
move,
or
ship
PC
boards.
removal
of
input
power
on
inverters.
1.
Turn
Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions
in
Maintenance
Section
before
~hing
any
parts.
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
1.
Shut
oft
shielding
gas
supply
when
not
in
use.
1-4.
Principal
Safety
Standards
1-5.
EMF
Information
Safely
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
Superintendent
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.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway,
Suite
501,
Ariington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wil
7.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protection,
ANSI
Standard
Z87.1,
from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
SiB,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
procedures:
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
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
mostof
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
ofter
clear
science-based
advice
on
strategies
to
minimize
or
avoid
potential
risks.
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
also
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
OM-180
670
Page
3
SECTION
2-
DEFINITIONS
2-1.
Manufacturers
Warning
Label
Definitions
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
1
Electric
shock
from
welding
electrode
or
wiring
can
kill.
1.1
Wear
dry
insulating
gloves.
Do
not
touch
electrode
with
bare
hand.
Do
not
wear
wet
or
damaged
gloves.
1.2
Protect
yourself
from
electric
shock
by
insulating
yourself
from
work
and
ground.
1.3
Disconnect
input
plug
or
power
before
working
on
machine.
2
Breathing
welding
fumes
can
be
hazardous
to
your
health.
2.1
Keep
your
head
out
of
the
fumes.
2.2
Use
forced
ventilation
or
local
exhaust
to
remove
the
fumes.
2.3
Use
ventilating
fan
to
remove
fumes.
3
Welding
sparks
can
cause
explosion
or
fire.
3.1
Keep
flammables
away
from
welding.
Do
not
weld
near
flammables.
3.2
Welding
sparks
can
cause
fires.
Have
a
fire
extinguisher
nearby,
and
have
a
watchperson
ready
to
use
it.
3.3
Do
not
weld
on
drums
or
any
closed
containers.
4
Arc
rays
can
bum
eyes
and
injure
skin.
4.1
Wear
hat
and
safety
glasses.
Use
ear
protection
and
button
shirt
collar.
Use
welding
helmet
with
correct
shade
of
filter.
Wear
complete
body
protection.
5
Become
trained
and
read
the
instructions
before
working
on
the
machine
or
welding.
6
Do
not
remove
or
paint
over
(cover)
the
label.
1/96
OM-180
670
Page
4
d??4~
~L=<6O0
~
p~
1
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
2
Electric
shock
from
wiring
can
kill.
3
Disconnect
input
plug
or
power
before
working
on
machine.
4
Hazardous
voltage
remains
on
input
capacitors
after
power
is
turned
off.
Do
not
touch
fully
charged
capacitors.
5
Always
wait
60
seconds
after
power
is
turned
off
before
working
on
unit,
OR
6
Check
input
capacitor
voltage,
and
be
sure
it
is
near
0
before
touching
any
parts.
4/96
/
1
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
/
/
2
When
power
is
applied
failed
parts
can
explode
or
cause
other
parts
to
explode.
/
I
~
I?L~
~
?S~AI
3
Flying
pieces
of
parts
can
cause
injury.
Always
wear
a
face
shield
when
servicing
unit.
4
Always
wear
long
sleeves
and
button
your
collar
when
servicing
unit.
5
After
taking
proper
precautions
as
shown,
connect
power
to
unit.
I)
4/96
4A1
1
Warning!
Watch
Out!
There
are
possible
hazards
as
shown
by
the
symbols.
2
Falling
equipment
can
cause
injury
and
damage
to
unit.
3
Always
lift
and
support
unit
using
both handles.
Keep
angle
of
lifting
device
less
than
60
degrees.
4
Use
a
proper
cart
to
move
unit.
5
Do
not
use
one
handle
to
lift
or
support
unit.
3
\
5
1/96
OM-180
670
Page
5
2-2.
Manufacturers
Rating
Labels
For
CC/CV
Models
~-
~JQY___
400A
36V
rr
,
~I
X
30%
60%
100%
Uo
851
12
400
fU2
36
300
250
32
30
V
Ui
400
Ii
max
I
IOV
IP
~
7A
xlOO%
Ii
elf
3~40
I~
2~d\~50W
31
17
QD~I~-
I
CE
I
EN
60974-1
~-
14
50A
by
Uo
85
400A
36V
x
12
U2
30%
no
34
60%
~nfl
29
100%
2cfl
27
I1~
Y~60~
v
~
LJ1400
umax
heft
29
16
UP
23
2x1\50
F~
I
ii
OV
7A
x
100%
2-3.
Manufacturers
Rating
Label
For
CC
Models
DI~E
ICE
1EN60974-1
ti.
Uo85
X
I
30%
12
I
400
60%
300
100%
250
U21
36
32
30
J)i>
~
v
H
U1400
umax
heft
31
17
UP
23
2x1\~5OKz
I
11OV
7A
xlOO%
~I~1J1*~
ICE
1EN60974-1
Ref.
S-182
226
Ref.
S-183 310
OM-180
670
Page
6
2-4.
Symbols
And
Definitions
OM-180
670
Page
7
3-1.
Selecting
A
Location
SECTION
3-INSTALLATION
Dimensions
And
Weight
87
lb
(39.5
kg)
24
In
17
in
(432
mm)
Movement
1
Location
18
in
(460
mm)
A
Do
not
move
or
operate
unit
where
it
could
tip.
1
Lifting
Handles
Use
handles
to
lift
unit.
2
Hand
Cart
Use
cart
or
similar
device
to
move
unit.
3
Plate
Label
Use
label
to
determine
input
power
needs.
4
Line
Disconnect
Device
Locate
unit
near
correct
input
power
supply.
A
Special
installation
may
be
required
where
gasoline
or
volatile
liquids
are
present
see
NEC
Article
511
or
CEC
Section
20.
Ioc_2
3/96
-
ST-8O1
192
12-1/2
in
(318
18
in
(460
mm)
STOCK
NO.
SERIAL
NO.
OM-180
670
Page
8
3-2.
Weld
Output
Terminals
And
Selecting
Cable
Sizes
1060%
Duty
Cycle
60100%
Duty
Cycle
3-3.
Remote
14
Receptacle
Information
24
VOLTS
AC
~
OUTPUT
(CONT~TOR)
A
24
volts
ac.
Protected
by
circuit
breaker
CB2.
B
Contact
closure
to
A
completes
24
volts
ac
con
tactor
control
circuit.
115
VOLTS
AC
~
ouTPur
(OONT~TOR)
I
115
volts
ac.
Protected
by
circuit
breaker
CB1.
J
Contact
closure
to
I
completes
115
volts
ac
con
tactor
control
circuit.
REMOTE
OUTPUT
CONTROL
C
Output
to
remote
control;
0
to
+10
volts
dc,
+10
volts
dc
in
MIG
mode.
D
Remote
control
circuit
common.
E
0
to
+10
volts
dc
input
command
signal
from
re
mote
control.
A/V
AMPERAGE
VOLTAGE
H
Voltage
feedback;
+1
volt
dc
per
10
output
recep
tacle
volts.
F
Current
feedback;
+1
volt
dc
per
100
amperes.
M
CC/CV
select
(CC/CV
models
only).
4~
A
ARC
WELDING
can
cause
Electromagnetic
Interference.
To
reduce
possible
interference,
keep
weld
cables
as
short
as
possible,
close
together,
and
down
low,
such
as on
the
~=~?i
floor.
Locate
welding
operation
100
meters
from
any
sensitive
electronic
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.
Total
Cable
(Copper)
Length
In
Weld
Circuit
Not
Exceeding
100
ft
(30
m)
Or
Less
150
~
(45
m)
200
ft
j_(60_m)
250
~
1
(70
m)
300
ft
j_(90_m)
350
ft
I
~
(105
m)
(120
m)
10
100%
Duty
Cycle
Output
Receptacles
4
4
4
3
2
1
1/0
1/0
3 3
2
1
1/0
2/0
3/0
3/0
3
2
1
1/0
2/0
3/0
4/0
4/0
2
1
1/0
2/0
3/0
4/0
2-2/0
2-2/0
1
1/0
-
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
1/0
2/0
3/0
4/0
2-2/0
2-3/0 2-3/0
2-4/0
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-4/0
2-4/0
2/0 3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-3/0
3/0
4/0
2-2/0
2-3/0
2-4/0
3-3/0
3-4/0
3-4/0
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.
~JREMO~
S-0007-D
Socket*
Socket
Information
ST-801
192
The
remaining
sockets
are
not
used.
GND
G
K
Circuit
common
for
24
and
115
volts
ac
circuits.
Chassis
common.
OM-180
670
Page
9
3-4.
110
Volt
AC
Duplex
Receptacle
(Optional
For
CC
Model)
3-5.
Electrical
Service
Guide
N
OTE
~
Actual
input
voltage
cannot
exceed–
10%
of
indicated
required
input
voltage.
If
actual
input
voltage
is
outside
of
this
range,
no
output
is
available.
Input
Voltage
400
Input
Amperes
At
Rated
Output
17.0
Max
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes
30
Mm
Input
Conductor
Size
in
AWGIKcmiI*
14
Max
Recommended
Input
Conductor
Length
In
Feet
(Meters)*
116(35)
Mm
Grounding
Conductor
Size
in
AWGIKcmil*
14
This
infonnation
is
provided
for
customers
who
wish
to
add
an
extension
to
the
input
power
cable
supplied
with
the
unit.
Lengths
are
for
combined
length
of
supplied
input
power
cord
and
extension.
Reference:
1993
National
Electrical
Code
(NEC).
S-0092.J
1
11OV7AAC
Receptacle
Power
is
shared
between
duplex
receptacle
and
Remote
14
recep
tacle
(see
Section
3-3).
2
Circuit
Breaker
CB1
3
Circuit
Breaker
CB2
CB1
protects
110
volt
ac
portion
of
duplex
receptacle
and
Remote
14
receptacle
from
overload.
CB2
protects
24
volt
ac
portion
of
Remote
14
receptacle
from
overload.
Press
button
to
reset
breaker.
Ref.
ST-SQl
245-A
OM-180
670
Page
10
3-6.
Connecting
Input
Power
~~=GNDIPE
1
Check
input
voltage
available
at
site.
1
Input
And
Grounding
Conductors
2 Line
Disconnect
Device
Select
type
and
size
of
overcurrent
protection
using
Section
3-5.
A
Always
connect
green/yel
low
wire
to
supply
ground
ing
terminal,
never
to
a
line
terminal.
Tools
Needed:
Ref.
ST-14-4flh/ST-801
192
2
Li
(U)
12(V)
L3
(W)
Green/Yellow
A
Always
connect
grounding
conductor
first.
OM-180
670
Page
11
SECTION
4-
OPERATION
4-1.
Front
Panel
Controls
For
CC/CV
Model
_____
A!
ST-uS
275
1
Power
On/Oft
Switch
~
The
fan
motor
is
thermostatically
controlled
and
only
runs
when
cooling
is
needed.
2
Voltmeter
(see
Section
4-3)
3
Ammeter
(see
Section
4-3)
4
Voltage/Amperage
Adjustment
Control
5
Mode
Switch
The
Mode
switch
setting
determines
both
the
process
and
output
On/Off
control
(see
Section
4-4.
Source
of
control
(panel
or
re
mote)
for
the
amount
of
output
is
selected
on
the
Voltage/Amperage
Control
switch.
For
Air
Carbon
Arc
(CAC-A)
cutting
and
gouging,
place
switch
in
Stick
position.
For
best
results,
place
Inductance/Dig
control
in
the
maximum
position.
6
Voltage/Amperage
Control
Switch
For
front
panel
control,
place
switch
in
Panel
position.
For
remote
control,
make
connections
to
Re
mote
14
receptacle,
and
place
switch
in
Remote
position.
In
most
modes,
remote
control
is
a
percent
of
the
Voltage/Amperage
Adjustment
control
setting
(the
value
se
lected
on
Voltage/Amperage
Adjustment
control
is
maximum
available
on
remote).
In
the
MIG
mode,
remote
control
provides
full
range
of
unit
output
regardless
of
V/A
Adjust
control
setting.
7
Inductance/Dig
Control
Control
adjusts
Dig
when
a
Stick
(SMAW)
welding
position
is
selected
on
mode
switch.
When
set
lower,
short-circuit
amperage
at
low
arc
voltage
is
the
same
as
normal
weld
ing
amperage.
When
set
higher,
short-circuit
amperage
is
increased
at
low
arc
voltage
to
assist
with
arc
starts
as
well
as
reduce
sticking
while
welding
(see
volt-ampere
curves
in
Section
4-8).
Select
setting
best
suited
for
application.
Control
adjusts
inductance
when
a
MIG
(GMAW)
position
is
selected
on
the
mode
switch.
Inductance
determines
the
wet
ness
of
the
weld
puddle.
When
set
higher,
wetness
(puddle
fluidity)
increases.
When
pulsed
MIG,
or
one
of
the
TIG
(GTAW)
processes
is
selected,
this
control
is
not
functional.
-fi
0
OM-180
670
Page
12
4-2.
Front
Panel
Controls
For
CC
Model
___
A
Power
On/Off
Switch
The
fan
motor
is
thermostatically
cont
rolled
and
only
runs
when
cooling
is
needed.
2
Voltmeter
(see
Section
4-3)
3
Ammeter
(see
Section
4-3)
4
Amperage
Adjustment
Control
5
Mode
Switch
The
Mode
switch
setting
determines
both
the
process
and
output
On/Oft
control
(see
Section
4-4.
Source
of
control
(panel
or
re
mote)
for
the
amount
of
output
is
selected
on
the
Voltage/Amperage
Control
switch.
For
Air
Carbon
Arc
(CAC-A)
cutting
and
gouging,
place
switch
in
Stick
position.
For
best
results,
place
Dig
control
in
the
maxi
mum
position.
6
Amperage
Control
Switch
For
front
panel
control,
place
switch
in
Panel
position.
For
remote
control,
make
connections
to
Re
mote
14
receptacle,
and
place
switch
in
Remote
position.
Remote
control
is
a
per
cent
of
Amperage
Adjustment
control
set
ting.
Value
selected
on
Amperage
Adjust
ment
control
is
maximum
available
on
remote.
7
Dig
Control
Control
adjusts
Dig
when
a
Stick
(SMAW)
welding
position
is
selected
on
mode
switch.
When
set
lower,
short-circuit
amperage
at
low
arc
voltage
is
the
same
as
normal
weld
ing
amperage.
When
set
higher,
short-circuit
amperage
is
increased
at
tow
arc
voltage
to
assist
with
arc
starts
as
well
as
reduce
sticking
while
welding
(see
volt-ampere
curves
in
Section
4-8).
Select
setting
best
suited
for
application.
When
a
TIG
(GTAW)
process
is
selected,
this
control
is
not
functional.
-e
0
ST-i
83
303
OM-180
670
Page
13
4-3.
Meter
Functions
N
OTE
~
The
meters
display
the
actual
weld
output
values
for
approximately
three
seconds
I
after
the
arc
is
broken.
Mode
Meter
Reading
At
Idle
Lift-Arc
TIG
(GTAW)
V
A
7.0
85
I
Actual
Volts
Preset
Amps
~r4~
Lift-Arc
Trigger
Hold
TIG
(GTAW)
V
A
I
I
85
I
I
Blank
Preset
Amps
Q
TIG
(GTAW)
V
A
1
85
Blank
Preset
Amps
ifr~
MIG(GMAW)
V A
24.5
Preset
Volts
Blank
Pulsed
MIG
(GMAW-P)
V A
I
I
Pulse
Display
Pulse
Display
Remote
Control
SMAW
V
A
I
I
85
I
I
Blank
Preset
Amps
Et
Panel
Control
I
SMAW
V
A
80.0
85
I
Actual
Volts
(OCV)
Preset
Amps
OM-180
670
Page
14
4-4.
Mode
Switch
Settings
NOTE
~
The
SMAW
modes
provide
the
Adaptive
Hot
StartTM
feature,
which
automatically
increases
the
outputamperage
at
the
start
of
a
weld
should
the
start
require
it.
This
eliminates
electrode
sticking
at
arc
start.
Mode
Output
Control
Lift-Arc
TIG
(GTAW)
Select:
or
~Arnp
Weld
~
I
9~
Lift-Arc
Trigger
Hold
TIG
(GTAW)
or
Amp
Select:
Requires:
~]
(3~
Control
TIG
(GTAW)
With
HFUnit,
Pulsing
Device,
Or
Remote
Control
Select:
or
Amp
 
Requires:
~
(34
Control
MIG(GMAW)
Se~ct0
Requires:
Feeder
ILIL
(GMAW-P)
Pulsed
MIG
(Requires
an
external
pulsing
device.)
Select:
E?J
Volt
Requires:
~
Feeder
or
Control
.
~E
Remote
Control
SMAW
Select:
or
Amp
Requires:
]
()*
Control
~E
PanelControl
SMAW
Select:
Weld
~
I
OM-180
670
Page
15
4-5.
Lift-Arc
TUG
~
4-6.
Lift-Arc
Trigger
Hold
TUG
~.~ri
12
Seconds
~1
2
Touch
S~cor~ds
T..P\00.
With
Process
Switch
in
the
Lift-Arc
TIG
position,
start
an
arc
as
follows:
1
TIG
Electrode
2
Workpiece
Touch
tungsten
electrode
to
work-
piece
at
weld
start
point,
hold
electrode
to
workpiece
for
1-2
seconds,
and
slowly
lift
electrode.
An
arc
will
form
when
electrode
is
lifted.
Normal
open-circuit
voltage
is
not
present
before
tungsten
electrode
touches
workpiece;
only
a
low
sensing
voltage
is
present
be
tween
electrode
and
workpiece.
The
solid-state
output
contactor
does
not
energize
until
after
elec
trode
is
touching
workpiece.
This
allows
electrode
to
touch work-
piece
without
overheating,
sticking,
or
getting
contaminated.
Ref.
S-156 279
Do
NOT
Strike
Like
A
Matchl
2
9buch
1
TIG
Electrode
2
Workpiece
ItT
Procedure
requires:
~I
(3.
control
Start
sequence:
Touch
tungsten
electrode
to
workpiece
at
weld
start
point.
Momentarily
depress
output
switch.
Slowly
lift
electrode.
An
arc
will
form
when
electrode
is
lifted.
To
stop
welding,
momentarily
depress
output
switch
and
out
put
will
shut
oft.
Note:
if
output
switch
is
momen
tarily
depressed
and
tungsten
is
not
touching
workpiece:
Do
not
touch
tungsten
to
work.
Outputwill
shut
off
in
3
seconds.
Start
sequence
over.
Ref
.
S-i
56 279
Do
NOT
Strike
Like
A
Match!
OM-180
670
Page
16
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Miller KG177169 Owner's manual

KG177169
Miller
Brand
Miller
Model
KG177169
Category
Welding System
Type
Owner's manual
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