Miller KJ196822 Owner's manual

Brand: Miller

Model: KJ196822

Category: Welding System

Type: Owner's manual

This manual is also suitable for

Optima

Optima

Processes

Description

Pulsed MIG (GMAW-P)

Synergic Control

OM-2805A 182 111A

January 2001



Visit our website at

www.MillerWelds.com

Miller Electric manufactures a full line

of welders and welding related equipment.

For information on other quality Miller

products, contact your local Miller distributor

to receive the latest full line catalog or

individual catalog sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller,

or visit us at www.MillerWelds.com on the web.

Thank you and congratulations on choosing Miller.

Now you can get the job done and get it done right. We

know you don’t have time to do it any other way.

That’s why when Niels Miller first started building arc

welders in 1929, he made sure his products offered

long-lasting value and superior quality. Like you, his

customers couldn’t afford anything less. Miller

products had to be more than the best they could be.

They had to be the best you could buy.

Today, the people that build and sell Miller products continue the

tradition. They’re just as committed to providing equipment and service

that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your

Miller products. Please take time to read the Safety precautions. They

will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick

and easy. With Miller you can count on years

of reliable service with proper maintenance.

And if for some reason the unit needs repair,

there’s a Troubleshooting section that will

help you figure out what the problem is. The

parts list will then help you to decide which

exact part you may need to fix the problem.

Warranty and service information for your

particular model are also provided.

Miller is the first welding

equipment manufacturer in

the U.S.A. to be registered to

the ISO 9001 Quality System

Standard.

Working as hard as you do

– every power source from

Miller is backed by the most

hassle-free warranty in the

business.

From Miller to You

Miller offers a Technical

Manual which provides

more detailed service and

parts information for your

unit. To obtain a Technical

Manual, contact your local

distributor. Your distributor

can also supply you with

Welding Process Manuals

such as SMAW, GTAW,

GMAW, and GMAW-P.

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols for Installation, Operation, and Maintenance 3. . . . . . . . . . . . . . . . . . . . . .

1-4. Principal Safety Standards 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Connecting To Welding Power Source 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Welding Power Source Settings 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Overview and Controls 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-4. Initial Display, Manual MIG Pulser Mode, And Straight CV Mig Mode 7. . . . . . . . . . . . . . . . . .

2-5. Setup Screens 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-6. Choosing Pulse Programs And Setting Parameters 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-7. How Manual Pulsed MIG Waveform Components Affect Arc And Burn-Off Rate 10. . . . . . . . .

SECTION 3 – PROGRAMS FOR XMT 304 CC/CV AND INVISION 304P

WELDING POWER SOURCES 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Overview Of Programs 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Programs For XMT 304 CC/CV And Invision 304P Welding Power Sources 11. . . . . . . . . . . .

SECTION 4 – PROGRAMS FOR INVISION 456 CC/CV AND INVISION 456P

WELDING POWER SOURCES 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Overview Of Programs 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Programs 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – TROUBLESHOOTING 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Error Codes 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Troubleshooting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – PARTS LIST 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

OM-2805 Page 1

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_4/98

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

Y Marks a special safety message.

. Means “Note”; not safety related.

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

Y 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.

Y Only qualified persons should install, operate, maintain, and

repair this unit.

Y 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.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.

D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work

or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.

D If AC output is required, use remote output control if present on

unit.

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

D Always verify the supply ground – check and be sure that input

power cord ground wire is properly connected to ground terminal in

disconnect box or that cord plug is connected to a properly

grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first – double-check connections.

D Frequently inspect input power cord for damage or bare wiring –

replace cord immediately if damaged – bare wiring can kill.

D Turn off all equipment when not in use.

D Do not use worn, damaged, undersized, or poorly spliced cables.

D Do not drape cables over your body.

D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.

D Keep all panels and covers securely in place.

D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists after removal of

input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section

before touching any parts.

Welding produces fumes and gases. Breathing

these fumes and gases can be hazardous to your

health.

FUMES AND GASES can be hazardous.

D Keep your head out of the fumes. Do not breathe the fumes.

D If inside, ventilate the area and/or use exhaust at the arc to remove

welding fumes and gases.

D If ventilation is poor, use an approved air-supplied respirator.

D Read the Material Safety Data Sheets (MSDSs) and the

manufacturer’s instructions for metals, consumables, coatings,

cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch-

person nearby. Welding fumes and gases can displace air and

lower the oxygen level causing injury or death. Be sure the breath-

ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form

highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld

area, the area is well ventilated, and if necessary, while wearing an

air-supplied respirator. The coatings and any metals containing

these elements can give off toxic fumes if welded.

OM-2805 Page 2

Arc rays from the welding process produce intense

visible and invisible (ultraviolet and infrared) rays

that can burn eyes and skin. Sparks fly off from the

weld.

ARC RAYS can burn eyes and skin.

D Wear a welding helmet fitted with a proper shade of filter to protect

your face and eyes when welding or watching (see ANSI Z49.1

and Z87.1 listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash and

glare; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant mate-

rial (leather and wool) and foot protection.

Welding on closed containers, such as tanks,

drums, or pipes, can cause them to blow up. Sparks

can fly off from the welding arc. The flying sparks, hot

workpiece, and hot equipment can cause fires and

burns. Accidental contact of electrode to metal objects can cause

sparks, explosion, overheating, or fire. Check and be sure the area is

safe before doing any welding.

WELDING can cause fire or explosion.

D Protect yourself and others from flying sparks and hot metal.

D Do not weld where flying sparks can strike flammable material.

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.

D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D 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).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly

unknown paths and causing electric shock and fire hazards.

D Do not use welder to thaw frozen pipes.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

FLYING METAL can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,

they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off shielding gas supply when not in use.

D Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.

D Allow cooling period before working on gun or

torch.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away.

D Wearers should consult their doctor before

going near arc welding, gouging, or spot

welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can

damage hearing.

D Wear approved ear protection if noise level is

high.

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.

CYLINDERS can explode if damaged.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.

D Never drape a welding torch over a gas cylinder.

D Never allow a welding electrode to touch any cylinder.

D Never weld on a pressurized cylinder – explosion will result.

D Use only correct shielding gas cylinders, regulators, hoses, and fit-

tings designed for the specific application; maintain them and

associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and CGA publication P-1 listed in Safety

Standards.

OM-2805 Page 3

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring – be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of

unit.

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.

D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

D Keep away from moving parts.

D Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading

welding wire.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.

D Keep all doors, panels, covers, and guards

closed and securely in place.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and

communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa-

tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.

D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to

minimize the possibility of interference.

ARC WELDING can cause interference.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as

computers and computer-driven equipment

such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D 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.

1-4. Principal Safety Standards

Safety in Welding and Cutting, ANSI Standard Z49.1, from American

Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126

Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-

dent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cut-

ting 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 Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,

from Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from

Canadian Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3.

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 51B, from National

Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

OM-2805 Page 4

1-5. EMF Information

Considerations About Welding And The Effects Of Low Frequency

Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro-

magnetic fields. There has been and still is some concern about such

fields. However, after examining more than 500 studies spanning 17

years of research, a special blue ribbon committee of the National

Research Council concluded that: “The body of evidence, in the

committee’s judgment, has not demonstrated that exposure to power-

frequency electric and magnetic fields is a human-health hazard.”

However, studies are still going forth and evidence continues to be

examined. Until the final conclusions of the research are reached, you

may wish to minimize your exposure to electromagnetic fields when

welding or cutting.

To reduce magnetic fields in the workplace, use the following

procedures:

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

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

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

4. Keep welding power source and cables as far away from opera-

tor as practical.

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

ble.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,

then following the above procedures is recommended.

OM-2805 Page 5

SECTION 2 – INSTALLATION

2-1. Connecting To Welding Power Source

ST-801 316-A / Ref. ST-801 192 / ST-801 718

1 XMT 304 CC/CV Or Invision

304P Welding Power Source

2 Invision 456P Or Phoenix 456

CC/CV Welding Power

Source

3 Remote 14 Cord On Control

Unit

4 14-Pin Extension Cord

(Customer-Supplied)

Use one of these MILLER exten-

sion cords:

043 690 – 25 ft (7.6 m)

043 691 – 50 ft (15.2 m)

. Make sure total cord length

does not exceed 200 ft (61 m).

5 Wire Feeder

Connect control as shown if you

want control to be close to feeder.

If you want control to be close to

welding power source, connect

control to welding power source,

and connect extension cord be-

tween control cord and feeder.

Set applicable welding power

source controls as explained in

Section 2-2.

2-2. Welding Power Source Settings

Welding Power Source

Model

Mode Switch Setting Voltage/Amperage Control

Switch Setting

Inductance/Dig or

Inductance Control Setting

XMT 304 CC/CV Pulsed MIG Remote This control is not functional with

welding power source in Pulsed

MIG mode. Adjust as normal

when welding power source is

used in MIG mode.

Invision 304P No Mode switch - setting auto-

matically done by control unit.

No V/A Control switch - setting

automatically done by control unit.

Same as above

Phoenix 456 CC/CV Pulsed MIG Remote Same as above

Invision 456P No Mode switch - setting auto-

matically done by control unit.

No V/A Control switch - setting

automatically done by control unit.

Same as above

OM-2805 Page 6

Select third line, and turn

knob to set arc length to 36.

>Prg 3 035Al 5356 Ar

Adapt ive

50 Arc Length

2-3. Overview and Controls

ST-801 315-A

Overview

The control unit provides three

modes of operation:

Straight CV Mig – control functions

as a remote voltage control.

Manual MIG Pulser – control func-

tions as a discrete pulsed MIG CC

control.

Synergic Pulser – programs that

use factory-entered values are

used to control process.

Setup screens (see Section 2-5) al-

low the type of welding power

source in use to be defined, pro-

grams or modes to be made inac-

cessible (locked out) to the opera-

tor, and the language used in the

displays (English, French, etc.) to

be defined.

Controls

1 Display

2 Parameter Select Push Button

Press button to move > on display.

The parameter indicated by > is

selected.

3 Parameter Adjust Knob

Turn knob to change selected pa-

rameter. Knob turns in either

direction.

When top line of display is selected,

turning knob accesses pre-written

pulse programs, Straight CV MIG

mode, or Manual MIG Pulser mode.

See example at left.

Prg 3 035Al 5356 Ar

>Non Adapt ive

50 Arc Length

Prg 3 035Al 5356 Ar

Non Adapt ive

> 50 Arc Length

Example

Select top line by pressing

push button until > is on top

line, and turn knob until

Program 3 appears.

Press push button to select

second line, and turn knob so

Non Adaptive appears.

To select Program 3, set to Non Adaptive, and set Arc Length to 36, proceed as follows:

OM-2805 Page 7

2-4. Initial Display, Manual MIG Pulser Mode, And Straight CV Mig Mode

1 Software Number

2 Defined Welding Power

Source Type

When power is applied, initial dis-

play with software number and

welding power source type appears

momentarily, and then last program

to be viewed before control was

shut down appears.

If welding power source type does

not match welding power source in

use, change according to Section

2-5.

3 Manual MIG Pulser Mode

The control unit functions as a dis-

crete pulsed MIG CC control in this

mode.

Select top line of display, and turn

knob until Manual MIG Pulser is dis-

played.

Select Amps Peak line, and use

knob to set peak amperage from

100–400 amps, but always at least

1 amp more than background am-

perage.

Select Amps Background line, and

use knob to set background amper-

age (min: 10 amps; max: 300 amps,

but always at least 1 amp less than

peak setting).

Select PPS Frequency line, and

use knob to set pulse frequency (20

- 300 pulses per second, but max

setting may be less depending on

Pulse Width setting).

Select ms Pulse Width line, and use

knob to set pulse width (1 - 5 ms, but

max setting may be less depending

on Frequency setting).

Select Amps Start line, and use

knob to set starting amperage (10 -

530 amperes). This amperage val-

ue is used at the start of the weld or

when an arc is restarted.

4 Straight CV Mig Mode

The control unit functions as a re-

mote voltage control in this mode.

The welding power source Induc-

tance/Dig control is active in this

mode (see Section 2-2).

Select top line of display, and turn

knob until Straight CV MIG is dis-

played. Select Volts line, and use

knob to set arc voltage from min to

max of welding power source

voltage.

190662 XMT / IN 304

MILLER Elect r i c

M f g. C o.

>St ra i gh t CV MIG

10.0 Vo l t s

>Manual MIG Pulser

34.6 Amps Peak

7.8 Amps BackGround

127 PPS Frequency

7.8 Amps BackGround

127 PPS Frequency

1.73 ms Pulse Width

530 Amps Star t

Display scrolls to

show lines 5 and 6.

With > on top line, turn

knob until Manual Mig

Pulser appears.

With > on top line, turn

knob until Straight CV

MIG appears.

OM-2805 Page 8

2-5. Setup Screens

To access Setup screens: turn

welding power source Off, press

and hold Select push button, turn

unit On, and hold push button down

until initial screen leaves.

To exit Setup screens, turn welding

power source Off and then On

again. Parameters that are dis-

played when the Setup screens are

exited are active.

1 Welding Power Source

Screen

Select third line of display, and turn

knob until desired welding power

source type is displayed.

2 Accessible Programs Screen

Select second line of display, and

turn knob until Accessible Pro-

grams is displayed. Select third line

of display and turn knob to access

each program and the Straight CV

MIG mode and the Manual MIG

Pulser mode as desired. Select the

fourth line and turn knob to define

each option On (accessible) or Off

(not accessible).

Programs and modes that are de-

fined Off are not shown when the

operator scrolls through the dis-

plays in normal operation.

3 Language Screen

Select second line of display, and

turn knob until Language is dis-

played. Select third line of display

and turn knob until desired lan-

guage is shown. The choices are

English, French, Italian, and

Spanish.

Setup

Power Source

>XMT / IN 304

Setup

Language

>Eng l i sh

Setup XMT / IN 304

Accessible Programs

Manual Mig Pulser

>Of f

OM-2805 Page 9

2-6. Choosing Pulse Programs And Setting Parameters

>Prg 7 045St Ar 5CO2

Adapt ive

50 Arc Length

Setting Arc Length:

Each pulsed weld program contains a different range of

arc length values. Numbers (0 – 100) are for reference

only.

Adjustment normally needed if wire feed speed or type of

weld joint is changed.

Set arc length that best applies to your application.

Choosing Adaptive Or Non Adaptive:

Adaptive: Pulse frequency is automatically regulated

to maintain a constant arc length, regardless of

changes in wire stickout.

Non Adaptive: Constant pulse frequency is main-

tained, regardless of the arc length.

Choose mode which best applies to your

application.

Choosing Pulse Program:

Pulse programs are pre-written and cannot be

changed by the user. The unit provides programs 1

thru 14 for the XMT 304 CC/CV and Invision 304P,

and programs 1 thru 15 for Invision 456P and Phoe-

nix 45 CC/CV. See Sections 3 and 4 for program

parameters.

Choose program depending on the type and size of

wire, and type of shielding gas used. For example,

the program shown below is for .045 steel wire using

95Ar – 5CO

gas.

OM-2805 Page 10

2-7. How Manual Pulsed MIG Waveform Components Affect Arc And Burn-Off Rate

OM-2805 Page 11

SECTION 3 – PROGRAMS FOR XMT 304 CC/CV AND

INVISION 304P WELDING POWER SOURCES

Section 3-1 provides basic information on each of the fourteen programs in the

unit’s memory for the XMT 304 CC/CV and Invision 304P welding power sources.

See Section 3-2 for more detailed information on each of the programs.

NOTE

Synergic Information: The manufacturer makes no warranties, express or implied,

that welds made using the synergic parameters of this equipment will meet the

requirements of the application.

The synergic parameters contained in this equipment are intended only to be a

general guideline. The choice and use of any synergic setting must be tested as to

its suitability for the application.

NOTE

3-1. Overview Of Programs

Program # Wire Type Wire Size Shielding Gas IPM: Min IPM: Max

1 Nickel .035 in 75Ar/25He 80 780

2 5356AL .047 in Argon 165 730

3 5356AL .035 in Argon 200 875

4 4043AL .047 in Argon 110 730

5 4043AL .035 in Argon 160 875

6 Steel .045 in 98Ar/2CO

80 550

7 Steel .045 in 95Ar/5CO

80 550

8 Steel .035 in 98Ar/2CO

100 780

9 Steel .035 in 95Ar/5CO

100 780

10 Stainless .045 in 98Ar/2CO

90 620

11 Stainless .045 in 95Ar/5CO

100 600

12 Stainless .035 in 98Ar/2CO

100 780

13 Stainless .035 in 95Ar/5CO

100 780

14 Copper/Silicon Bronze .035 in Argon 120 780

3-2. Programs For XMT 304 CC/CV And Invision 304P Welding Power Sources

Program 1 –– .035 Nickel –– 75 Argon / 25 Helium (For XMT 304 And Invision 304P)

IPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps

80 0 221 14 40 1.90 458

141 10 268 36 60 2.10 505

212 20 294 58 84 2.40 529

283 30 327 73 96 2.50 529

354 40 337 89 114 2.65 529

425 50 346 105 124 2.72 529

496 60 368 111 139 2.84 529

567 70 382 122 149 2.90 529

638 80 395 138 170 3.00 529

709 90 400 152 182 3.16 529

780 100 400 169 167 3.55 529

OM-2805 Page 12

Program 2 –– .047 Aluminum 5356 –– Argon (For XMT 304 And Invision 304P)

IPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps

165 0 294 42 59 1.40 529

222 10 304 61 69 1.50 529

279 20 320 81 75 1.65 529

336 30 335 89 96 1.80 529

393 40 348 100 107 2.00 529

450 50 362 120 116 2.20 529

507 60 374 134 129 2.30 529

564 70 384 155 140 2.45 529

621 80 393 167 156 2.60 529

678 90 400 189 166 2.70 529

730 100 400 230 222 2.93 529

Program 3 –– .035 Aluminum 5356 –– Argon (For XMT 304 And Invision 304P)

IPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps

200 0 272 31 51 1.30 484

268 10 272 43 71 1.30 510

336 20 277 54 90 1.35 529

404 30 288 67 99 1.41 529

472 40 298 78 104 1.53 529

540 50 313 86 106 1.66 529

608 60 323 103 111 1.75 529

676 70 330 117 121 1.85 529

744 80 354 134 139 2.00 529

812 90 374 149 150 2.20 529

875 100 389 144 150 2.26 529

Program 4 –– .047 Aluminum 4043 –– Argon (For XMT 304 And Invision 304P)

IPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps

110 0 268 31 50 1.35 529

172 10 298 56 75 1.45 529

234 20 309 86 82 1.59 529

296 30 329 109 97 1.75 529

358 40 348 134 126 1.90 529

420 50 356 152 135 2.14 529

482 60 373 163 148 2.31 529

544 70 387 174 171 2.50 529

606 80 400 199 195 2.74 529

668 90 400 257 212 3.11 529

730 100 400 257 227 3.70 529

OM-2805 Page 13

Program 5 –– .035 Aluminum 4043 –– Argon (For XMT 304 And Invision 304P)

IPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps

160 0 236 31 50 1.20 470

231 10 252 45 76 1.25 501

302 20 277 58 98 1.30 529

373 30 288 78 109 1.40 529

444 40 302 101 114 1.56 529

515 50 329 125 125 1.74 529

586 60 346 134 130 1.90 529

657 70 362 144 145 2.14 529

728 80 373 152 153 2.23 529

799 90 395 166 183 2.54 529

875 100 400 181 210 2.80 529

Program 6 –– .045 ER70S–3 Mild Steel –– 98 Argon / 2 Co2 (For XMT 304 And Invision 304P)

IPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps

80 0 323 48 57 2.20 498

127 10 345 65 89 2.30 529

174 20 370 90 105 2.45 529

221 30 390 92 138 2.60 529

268 40 390 108 155 2.70 529

315 50 400 119 175 2.80 529

362 60 400 144 185 2.90 529

409 70 400 155 200 2.96 529

456 80 400 181 215 3.05 529

503 90 400 221 230 3.12 529

550 100 400 277 250 3.27 529

Program 7 –– .045 ER70S–3 Mild Steel –– 95 Argon / 5 Co2 (For XMT 304 And Invision 304P)

IPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps

80 0 323 48 55 2.20 498

127 10 338 56 92 2.25 529

174 20 370 78 110 2.30 529

221 30 385 97 130 2.45 529

268 40 390 108 155 2.60 529

315 50 400 119 175 2.65 529

362 60 400 133 180 2.75 529

409 70 400 149 200 2.76 529

456 80 400 174 215 2.80 529

503 90 400 216 230 2.85 529

550 100 400 277 250 2.93 529

OM-2805 Page 14

Program 8 –– .035 ER70S–3 Mild Steel –– 98 Argon / 2 Co2 (For XMT 304 And Invision 304P)

IPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps

100 0 293 42 51 1.60 451

168 10 309 56 91 1.66 491

236 20 332 72 110 1.80 501

304 30 359 81 120 1.99 529

372 40 370 86 150 2.15 529

440 50 390 92 170 2.25 529

508 60 400 108 180 2.35 529

576 70 400 112 195 2.45 529

644 80 400 123 200 2.60 529

712 90 400 133 220 2.70 529

780 100 400 144 240 2.85 529

Program 9 –– .035 ER70S–3 Mild Steel –– 95 Argon / 5 Co2 (For XMT 304 And Invision 304P)

IPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps

100 0 282 43 46 1.50 451

168 10 298 51 95 1.55 491

236 20 332 62 110 1.66 501

304 30 346 78 127 1.73 529

372 40 349 81 160 1.76 529

440 50 359 84 190 1.85 529

508 60 370 87 210 1.90 529

576 70 379 89 220 1.97 529

644 80 389 94 230 2.00 529

712 90 395 95 260 2.05 529

780 100 400 97 280 2.10 529

Program 10 –– .045 309L Stainless Steel –– 98 Argon / 2 Co2 (For XMT 304 And Invision 304P)

IPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps

90 0 288 31 90 1.80 442

143 10 318 54 105 2.00 475

196 20 351 75 125 2.00 505

249 30 359 97 143 2.20 529

302 40 379 100 160 2.40 529

355 50 390 109 175 2.50 529

408 60 400 117 185 2.50 529

461 70 400 133 200 2.65 529

514 80 400 149 220 2.70 529

567 90 400 167 240 2.85 529

620 100 400 175 260 2.80 529

OM-2805 Page 15

Program 11 –– .045 309L Stainless Steel –– 95 Argon / 5 Co2 (For XMT 304 And Invision 304P)

IPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps

100 0 302 39 90 1.80 454

150 10 318 54 105 2.00 487

200 20 351 75 125 2.00 510

250 30 359 97 143 2.20 529

300 40 379 100 160 2.40 529

350 50 390 109 175 2.50 529

400 60 400 117 185 2.50 529

450 70 400 133 200 2.65 529

500 80 400 149 220 2.70 529

550 90 400 164 240 2.80 529

600 100 400 175 260 2.80 529

Program 12 –– .035 309L Stainless Steel –– 98 Argon / 2 Co2 (For XMT 304 And Invision 304P)

IPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps

100 0 257 26 55 1.63 400

168 10 266 42 80 1.75 430

236 20 282 67 90 1.85 451

304 30 298 81 105 1.95 472

372 40 313 86 121 1.98 494

440 50 327 92 135 2.00 510

508 60 348 108 147 2.12 529

576 70 362 112 171 2.20 529

644 80 379 117 180 2.25 529

712 90 400 120 182 2.30 529

780 100 400 123 190 2.43 529

Program 13 –– .035 309L Stainless Steel –– 95 Argon / 5 Co2 (For XMT 304 And Invision 304P)

IPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps

100 0 257 26 58 1.60 400

168 10 266 45 83 1.75 430

236 20 282 72 92 1.85 461

304 30 298 87 107 1.99 491

372 40 316 92 125 2.05 512

440 50 329 98 135 2.15 529

508 60 349 106 140 2.25 529

576 70 362 112 170 2.30 529

644 80 373 119 180 2.35 529

712 90 389 123 183 2.35 529

780 100 400 123 190 2.43 529

OM-2805 Page 16

Program 14 –– .035 Copper/Silicon Bronze –– Argon (For XMT 304 And Invision 304P)

IPM Trim Peak Amp Background Amp Freq. Pulse Width Starting Amps

120 0 238 21 61 1.20 503

186 10 272 43 71 1.30 529

252 20 282 61 95 1.43 529

318 30 301 78 110 1.51 529

384 40 324 95 129 1.50 529

450 50 341 106 136 1.70 529

516 60 363 114 138 1.82 529

582 70 378 128 143 1.88 529

648 80 387 134 148 1.96 529

714 90 400 144 160 2.10 529

780 100 400 144 194 2.16 529

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Miller KJ196822 Owner's manual

Brand: Miller

Model: KJ196822

Category: Welding System

Type: Owner's manual

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