KG177169

Miller KG177169, XMT 304 CC AND C, XMT 304 CC AND CC/CV CE (400 V) Owner's manual

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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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