Miller KG279559 Owner's manual

KG279559
Miller
Brand
Miller
Model
KG279559
Category
Welding System
Type
Owner's manual

This manual is also suitable for

March1997
Form:
OM-157066G
~
I
Effective
With
Serial
No.
KG279559
OWNERS
MANUAL
Wire
Welder
Rated
Welding
Output
Amperage
Range
DC
Maximum
Open-Circuit
Voltage
DC
Amperes
Input
at
Rated
Load
Output,
50
or
60
Hz,
Single-Phase
200
V
230
V
KVA
KW
200
A
@
28
Volts
DC,
60%
Duty
Cycle
250A
@28
Volts
DC.
40%
Duty
Cycle
40
250
42
46
1.1.
40
1.3*
9.5
0.31
8.3
0.18*
Wire
Type
And
Diameter
Wire
Feed
Speed
Range
Overall
Dimensions
Weight
Solid
Steel
/
Stainless
Steel
Flux
Cored
j
Aluminum
.023045
in
(0.6
1.2
mm)
.030035
in
(0.80.9
mm)
And
3/64
in
(1.2
mm)
Alu
90
1030
1PM
(2.926.2
rn/mm)
Length:
37
in
(940
mm)
Width:
19
in
(483
mm)
Height:
32
in
(889
mm)
225
lb
(102
kg)
While
idling
Auto
Arcfi
Model
255
auto_arc
6/95
ST-i
57
072-A
PRINTED
IN
USA
I
~1~
~
L
LIMITED
WARRANTY
Effective
February
7,
1996
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
warranty
supersedes
all
previous
manufacturers
warranties
arid
is
exclusive
with
no
other
guarantees
or
warranties
expressed
or
implied.
LIMITED
WARRANTY
Subject
to
the
terms
and
conditions
below,
warrants
to
its
MIG
GunsIFIG
Torches
original
retail
purchaser
that
new
equipment
sold
after
the
effective
date
of
this
urn-
APT
ZIPCUT
&
PLAZCUT
Model
Plasma
Cutting
Torches
ted
warranty
is
free
of
defects
in
material
and
workmanship
at
the
time
it
is
shipped
from
factory.
THIS
WARRANTY
IS
EXPRESSLY
IN
UEU
OF
ALL
OThER
WAR-
em
e
ro
5
RAN11ES.
EXPRESS
OR
IMPUED.
INCLUDING
THE
WARRANTiES
OF
MER-
Accessory
Kits
CHANTABIUTY
AND
FITNESS
Replacement
Parts
Within
the
warrantyperiods
listed
below,
manufacturer
will
repair
or
replace
any
war-
Limited
Warranty
shall
not
apply
to:
ranted
parts
or
components
that
fail
due
to
such
defects
in
material
or
workmanship.
Manufacturer
must
be
notified
in
writing
within
thirty
(30)
days
of
such
defect
or
fail-
1.
Items
fumishedby
manufacturer,
bul
manufactured
by
others,
such
as
engines
ure.
at
which
time
manufacturer
will
provide
instructions
on
the
warranty
claim
pro-
or
trade
accessories.
These
items
are
covered
bythe
manufacturers
warranty,
cedures
to
be
followed.
if
any.
Manufacturer
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
2.
the
evenl
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
equipmenl
is
sent
to
an
International
distributor.
t.
5
Years
Parts
3
Years
Labor
Original
main
power
rectifiers
tnverters
(input
and
output
rectifiers
oniiy)
2.
3
Years
Parts
and
Labor
Transformer/Rectifier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
Semi-Automatic
and
Automatic
Wire
Feeders
tnverter
Power
Supplies
lntellitig
Robots
(1
year
labor)
3.
2
Years
Parts
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
Air
Compressors
4.
1
YearParts
and
Labor
Motor
Driven
Guns
Process
Controllers
IHPS
Power
Sources
Water
Coolant
Systems
HF
Units
Grids
Spot
Welders
-
Load
Banks
SOX
Transformers
Running
Gear/Trailers
Plasma
Cutting
Torches
(except
APT.
ZIPCUT
&
PL,AZCUT
Modeis)
Tecumseh
Engines
Deutz
Engines
(outside
North
America)
Field
Options
(NOTE:
Field
options
are
covered
under
the
limited
warranty
for
the
re
maining
warranty
period
of
the
product
they
are
instailed
in,
or
for
a
mini
mum
of
one
year
whichever
is
greater.)
5.
6
Months
Batteries
6.
90
Days
Parts
and
Labor
Consumable
components;
such
as
contact
tips,
cutting
nozzles.
contactora
and
relays
or
parts
that
fail
due
to
normal
wear.
Equipment
that
has
been
modified
by
any
party
other
than
manufacturer,
or
equipment
that
has
been
improperly
inataiied.
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necessary
maintenance.
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MANUFACTURERS
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMERCIALIINOUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPE
RIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT.
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
shall
be.
at
manufacturers
option:
I
1)
repair;
or
(2)
replacement;
or.
where
authorized
in
writing
by
manufacturer
in
appropriate
cases.
i3)
the
reasonable
cost
of
repair
or
replacement
at
an
authonzed
service
station;
or
4)
payment
of
or
credit
for
the
pur
chase
pnce
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goods
at
customers
risk
and
expense.
Manufacturers
option
Of
repair
or
replace
ment
will
be
FOB..
Factory
at
Appleton.
Wisconsin,
or
FOB.
Stan
authonzed
ser
vice
facility
as
determined
by
manufacturer.
Therefore
no
compensation
or
reim
bursement
for
transportation
costs
of
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMITTED
BY
LAW.
THE
REMEDIES PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MANUFAC
TURER
BE
LIABLE
FOR
DIRECT.
INDIRECT,
SPECIAL
INCIDENTAL
OR
CON
SEQUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CONTRACT,
TORT
OR
ANY
OTHER
LEGAL
ThEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTATION
AS
TO
PERFORMANCE.
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION.
MIGHTARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEAUNG.
IN
CLUDING
ANY
IMPUED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
FURNISHED
BY
MANUFACTURER
IS
EXCLUDED
AND
DISCLAIMED
BY
MAN
UFACTURER.
Some
stales
in
the
U.S.A.
do
not
allow
limitalions
of
how
long
an
implied
warranty
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
iimilation
or
exclusion
may
not
appiy
to
you.
This
warranty
provides
spe
cific
legal
rights,
and
other
rights
maybe
available,
but
may
vary
from
slate
to
stale,
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
other
than
as
slated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
iimitations
and
exclusions
set
out
acove
may
not
apply.
This
Limited
Warranty
provides
specific
legal
rights,
and
other
rights
may
be
avaeiabte,
but
may
vary
from
province
to
province.
_I_
t_
_1
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
Or
damage
with
the
delivering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distnbutor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Modet
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit,
The
information
is
located
on
the
rating
label
or
nameplate.
Model
_________
Serial
or
Style
No.
Date
of
Purchase
brand_war
3/96
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
OM.157
0663
-
3/97
sateIy_eom~
4195
1-1.
Symbol
Usage
AA
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
I
This
group
of
symbols
means
Warning!
Watch
Oull
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
AA
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
should
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.
Lockout/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
verify
the
supply
ground
check
and
be
sure
that
input
power
cord
ground
wire
is
properly
connected
to
ground
~,,
~
.~.
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
that
can
burn
eyes
and
skin.
Noise
from
some
3.
Wear
approved
safety
glasses
with
side
shields.
~nnding,
and
welds
coo9ing
throw
9ff
~
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
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
~
I
Welding
produces
fumes
and
gases.
Breathing
watchpersonnearby.Weldingfumesandgasescandisplacealr
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
(MSDSs)
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
oft
toxic
fumes
if
welded.
A
Marks
a
special
safety
message.
CT
Means
NOTE;
not
safety
related.
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly
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
poorly
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
~q
nA~r
thA
walti
OM-157
066
Page
1
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to
treat
them
carefully.
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.
4.
Never
drape
a
welding
torch
over
a
gas
cylinder.
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
current
from
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
off
welding
wire
at
contact
tip
when
not
in
use.
11.
Wearoil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
12.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
1-3.
Additional
Installation,
Operation,
And
Maintenance
Hazards
FIRE
OR
EXPLOSION
can
result
from
placing
unit
on,
over,
or
near
combustible
surfaces.
1.
Do
not
locate
unit
on,
over,
or
near
combustible
surtaces.
2.
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.
1.
Keep
away
from
moving
parts
such
as
fans.
2.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
MAGNETIC
FIELDS
FROM
HIGH
CURRENTS
can
affect
pacemaker
operation.
Pacemaker
wearers
keep
away.
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.
1.
Do
not
press
gun
trigger
until
instructed
to
do
so.
2.
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
HIGH-FREQUENCY
RADIATION
can
interfere
with
radio
navigation,
safety
services,
computers,
and
communications
equipment.
Have
only
qualified
persons
familiar
with
electronic
equipment
perform
this
installation.
The
user
is
responsible
for
having
a
qualified
electrician
promptly
correct
any
interference
problem
resulting
from
the
installation.
If
notified
by
the
FCC
about
interference,
stop
using
the
equipment
at
once.
Have
the
installation
regularly
checked
and
maintained.
Keep
high-frequency
source
doors
and
panels
tightly
shut,
keep
spark
gaps
at
correct
setting,
and
use
grounding
and
shielding
to
minimize
the
possibility
of
interference.
1.
2.
3.
WELDING
WIRE
can
cause
puncture
wounds.
OM-157
066
Page
2
OVERUSE
can
cause
OVERHEATED
I,-,
SIGNIFICANT
DC
VOLTAGE
exists
after
EQUIPMENT.
1.
Allow
cooling
penod.
2.
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
touching
any
parts.
1-4.
Principal
Safety
Standards
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
1.
Shutoff
shielding
gas
supply
when
not
in
use.
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.1,
from
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
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
1
R3.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances.
American
Welding
Society
Standard
AWS
F4.i,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd.
Miami,
FL
33126
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protection,
ANSI
Standard
Z87.1,
from
Ameflcan
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51B,
from
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
MA
02269.
1-5.
EMF
Information
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
To
reduce
magnetic
fields
in
the
workplace,
use
the
following
Electric
And
Magnetic
Fields
procedures:
The
following
is
a
quotation
from
the
General
Conclusions
Section
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
1.
Keep
cables
close
together
by
twisting
or
taping
them.
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
Background
Paper,
OTA-BP.E-53
(Washington,
DC:
U.S.
2.
Arrange
cables
to
one
side
and
away
from
the
operator.
Government
Printing
Office,
May
1989):
~.
.
.
there
is
now
a
very
large
volume
of
scientific
findings
based
on
experiments
at
the
3.
Do
not
coil
or
drape
cables
around
the
body.
cellular
level
and
from
studies
with
animals
and
people
which
clearly
4.
Keep
welding
power
source
and
cables
as
far
away
as
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
practical.
produce
changes
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
possible.
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
questions
of
possible
About
Pacemakers:
riskortoofferclearscience-basedadviceonstrategiestominimize
The
above
procedures
are
also
recommended
for
pacemaker
or
avoid
potential
risks.
wearers.
Consult
your
doctor
for
complete
information.
OM-157
066
Page
3
2-3.
Installing
Welding
Gun
1
Drive
Assembly
2
Gun
Securing
Knob
3
Gun
End
Loosen
securing
knob.
Insert
gun
end
through
opening
until
it
bot
toms
against
drive
assembly.
Tighten
nut.
4
Gun
Trigger
Plug
Insert
plug
into
receptacle,
and
tighten
threaded
collar.
Close
door.
Ref.
ST-SOt
677
2-4.
Installing
Drive
Roll
And
Wire
Inlet
Guide
I
Securing
Screw
2
Inlet
Wire
Guide
Loosen
screw.
Slide
tip
as
close
to
drive
rolls
as
possible
without
touching.
Tighten
screw.
3
Anti-Wear
Guide
Install
guide
as
shown.
4
Drive
Roll
Install
correct
drive
roll
for
wire
size
and
type.
5
Drive
Roll
Securing
Nut
Turn
nut
one
click
to
secure
drive
roll.
Tools
Needed:
5/64
in
7/l6in
ST150227-C
OM-157
066
Page
5
2-5.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
Tools
Needed:
~:_
i~
3/4,11/l6in
1
Polarity
Changeover
Label
(Located
Near
Drive
Assembly)
Always
read
and
follow
manufac.
tures
recommended
polarity.
2-6.
Setting
Gun
Polarity
Shown
As
Shipped
Set
For
Electrode
Positive
(DCEP)
For
Solid
Steel
Or
Aluminum
Wires
(GMAW
Process).
Wire
Drive
Assembly
Lead
To
Positive
(+)
Output
Terminal
Work
Clamp
Lead
To
Negative
()
Output
Terminal
GUN
POLARITY
CHANGEOVER
CONNECTIONS
Reverse
Lead
Connections
For
Electrode
Negative
(DCEN)
For
Flux
Cored
Wires
(FCAW
Process).
Drive
Assembly
Becomes
Negative
~
~
p_lI
.
2-7.
Positioning
Jumper
Links
2-8.
Electrical
Service
Guide
Input
Voltage
200
230
Input
Amperes
At
Rated
Output
46
40
Max
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes
70
60
Mm
Input
Conductor
Size
In
AWGIKcm1I
8
8
Max
Recommended
Input
Conductor
Length
In
Feet
(Meters)
89
(27)
117
(36)
Mm
Grounding
Conductor
Size
In
AWG/Kcmil
8
8
Reference:
1996
National
Electrical
Code
(NEC).
s.oos~
2~
3~i1V0~T5
230
VOLTS
S-153
980
Check
input
voltage
available
at
site.
1
Jumper
Links
Access
Door
Open
door.
2
Jumper
Link
Label
3
Input
Voltage
Jumper
Link
Move
jumper
link
to
match
input
voltage.
Close
and
secure
access
door.
Ret.
ST-800
922B
Tools
Needed:
c::::::::3z=:==cl
3/8
in
OM-157
066
Page
7
2-9.
Selecting
A
Location
And
Connecting
Input
Power
1
Rating
Label
Supply
correct
input
power.
2
Plug
3
Receptacle
(Not
Supplied)
Connect
plug
to
receptacle.
4
Line
Disconnect
De~-~
See
Section
2-8.
A
Special
installation
may
be
required
where
gasoline
or
volatile
liquids
are
present
see
NEC
Article
511
or
CEC
Section
20.
A
Do
not
move
or
operate
unit
where
it
could
tip.
A
Always
connect
grounding
conductor
first.
OM.157
066
Pages
2-10.
Threading
Welding
Wire
1
Wire
Spool
2
Welding
Wire
3
Inlet
Wire
Guide
4
Pressure
Adjustment
Knob
5 Drive
Roll
6
Outlet
Wire
Guide
7
Gun
Conduit
Cable
Lay
gun
cable
out
straight.
Close
and
tighten
pressure
assembly,
and
let
go
of
wire.
Remove
gun
nozzle
and
contact
tip.
Press
gun
trigger
until
wire
comes
out
of
gun.
Reinstall
contact
tip
and
nozzle.
II
II
Feed
wire
to
check
drive
roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
Cut
oft
wire.
Close
and
latch
door.
Tools
Needed:
Open
pressure
assembly.
Pull
and
hold
wire:
cut
off
end.
Push
wire
thru
guides
into
gun:
continue
to
hold
wire.
Ret.
ST.801
677/
S0627-A
OM-157
066
Page
9
SECTION
3-
OPERATION
3-1.
Front
Panel
Controls
3-2.
Center
Baffle
Controls
1
Wire
Mode
Switch
For
better
control
of
wire
speed
use
the
Low
position
when
wire
speed
is
between
90
and
670
1pm.
Use
the
Full
position
when
wire
speed
is
between
150
ipm
and
1030
1pm.
2
Voltage
Range
Selector
Place
switch
in
desired
position.
Ret.
ST-800919/S-171
601
OM-157
066
Page
10
3-3.
Duty
Cycle
And
Overheating
DUTY
CYCLE
Duty
Cycle
is
percentage
of
10
minutes
that
unit
can
weld
at
rated
load
without
overheating.
If
unit
overheats,
thermostat(s)
opens,
output
stops,
and
cooling
fan
runs.
Wait
fifteen
minutes
for
unit
to
cool.
Reduce
amperage
or
voltage,
or
duty
cycle
before
welding.
A
Exceeding
duty
cycle
can
damage
unit
and
void
warranty.
Overheating
60%
Duty
Cycle
At
200
Amperes
6 Minutes
Welding
dutyl
4/95S8-150215
Cl)
Ui
a
a
-j
LU
20
30
40
50
00
7000
00100
4
Minutes
Resting
-~
-~
Minutes
~Aor
V
OR
Reduce
Duty
Cycle
-+~
OM-157
066
Page
11
SECTION
4-
MAINTENANCE
&
TROUBLESHOOTING
4-1.
Routine
Maintenance
4-2.
Circuit
Breaker
CB1
OM-157
066
Page
12
4-3.
Fuses
Fl
And
F2
OM-157
066
Page
13
4-4.
Aligning
Drive
Rolls
And
Wire
Guide
A
Turn
Off
unit.
Horizontal
Alignment
View
is
from
top
of
drive
rolls
look
ing
down
with
pressure
assembly
open.
1
AlIen
Wrench
2
Drive
Roll
Securing
Nut
3
Drive
Roll
4
Wire
Guide
5
Welding
Wire
6
Drive
Gear
Insert
wrench,
and
turn
screw
in
or
out
until
dnve
roll
groove
lines
up
with
wire
guide.
Vertical
Alignment
7
Housing
Bolts
8
Weld
Cable
Terminal
Loosen
bolts
and
terminal
nut(s).
9
Wire
Guide
10
Drive
Roll
11
Pressure
Roll
Slide
housing
up
or
down
until
groove
in
drive
roll
and
pressure
roll
line
up
with
wire
guide.
Tighten
hardware.
Close
pressure
roll
assembly.
Horizontal
Alignment
Correct
4.
5
Incorrect
6
I
Vertical
Alignment
7
Tools
Needed:
5/1!
~
3/16
in
Ref.
ST-BOO
412-A
OM-157
066
Page
14
4-5.
Troubleshooting
Remedy
Straighten
gun
cable
anwor
replace
damaged
parts
(see
Gun
Owners
Manual).
Adjust
drive
roll
pressure
(see
Section
2-10).
Readjust
hub
tension
(see
Section
2-5).
Replace
contact
tip
if
blocked
(see
Gun
Owners
Manual).
Clean
or
replace
wire
inlet
guide
or
liner
if
dirty
or
plugged
(see
Gun
Owners
Manual).
Replace
drive
rotls
if
worn
or
slipping
(see
Section
2-4).
Secure
gun
trigger
plug
in
receptacle
or
repair
leads,
or
replace
trigger
switch
(see
Section
2-3).
Check
and
replace
Fl
and/or
F2
(see
Section
4-3).
Check
and
clear
any
restrictions
at
drive
assembly
and
liner
(see
Gun
Owners
Manual).
Have
nearest
Factory
Authorized
Service
Agent
check
drive
motor.
!1~1~4*j
Welding
Trouble
Remedy
No
weld
output;
wire
does
not
feed.
Secure
power
cord
plug
in
receptacle
(see
Section
2-9).
Reset
circuit
breaker
CB1
(see
Section
4-2).
Replace
fuse Fl
and/or
F2
(see
Section
4-3).
Replace
building
line
fuse
or
reset
circuit
breaker
if
open
(see
Section
2-9).
Secure
gun
trigger
plug
in
receptacle
or
repair
leads,
or
replace
trigger
switch
(see
Section
2-3).
ThermostatTPl
open
(overheating).
Allow
fan
to
run;
the
thermostat
will
close
when
the
unit
has
cooled
(see
Section
3-3).
No
weld
output:
wire
feeds.
Connect
work
clamp
to
get
good
metal
to
metal
contact.
Replace
contact
tip
(see
Gun
Owners
Manual).
Low
weld
output.
Connect
unit
to
proper
input
voltage
or
check
for
low
line
voltage
(see
Section
2-9).
Wire
Drive/Gun
Trouble
Electrode
wire
feeding
stops
during
welding.
OM-157
066
Page
15
SECTION
5-
ELECTRICAL
DIAGRAM
~
For
Primar/
Circuit
Diagram
Pomon,
refer
to
Circuit
Diagram
located
inside
the
wrapper
of
the
we/ding
power
source.
S8-173
544-C
pI.~
51A
54
I
2
PCI
PC3-~
>>___~?<i
FI~G2
2
~3-n
>
~
3
Ji~
~
>>
~
*1
c3-3~>
rc3-2>>--
7
~
Fc3-~>
PC3-13))--
r~t
Figure
5-1.
CIrcuit
Diagram
For
Welding
Power
Source
OM-157
066
Page
16
SECTION
6-PARTS
LIST
NOTE:
All
items
indented
by
a
dot(s)
are
included
with
the
item
listed
directly
above.
item
Part
No.
No.
1
148597
2
146168
083
526
3
F1g6-2
4
171658
5
602250
6
070799
7
171213
8
148808
150783
049
399
116
996
605
227
146
524
149
332
152
742
048
420
037
957
037956
605886
605884
171
600
Description
Coupler
Rod
Enclosure
Panel
Housing
Rcpt
&
Sockets
Baffle
w/Cmpts
Transformer
Washer,
flat
Wheel
Stabilizer
Rear
Panel
w/Cmpts
Fan
Motor
Fan
Blade
Speed
Nut
Gas
Valve
Nylon
Nut,
.750
Hose
Hose
Clamp
Rectifier
Capacitor
Diode,
RP
Diode,
SP
Washer.
.750
Half
Nut.
.750-16
Thermostat,
NC
item
Part
No.
No
Description
026 947
152
862
009
970
143810
169654
044
426
9
602387
10
146165
11
089899
12
146167
13
134464
14
+170513
15
047721
16
146161
17
135390
18
121
614
19
091
685
605
741
20
602213
21
008999
22
601
871
23
027
645
Item
Part
No.
No
035
897
097
924
048 282
128755
153
197
148
956
175060
155
418
171
639
174842
144
127
057357
143974
183581
600318
130
750
173374
Description
Potentiometer
Knob
Receptacle
w/Sockets
Switch,
DPST
Selector
Switch
Switch
Handle
Front
Panel
Front
Control
Panel
Control
Plate
Nameplate
Cover,
module
opening
Bushing,
1.l25mtg
Handle
See
Gun
Owners
Manual
Gas
Hose
Weld
Cable
Ground
Clamp
Regulator/Flowmeter
Figure
6-1.
Main
Assembly
ST-800
930-B
.
Stand-Off
.
Grommet
Rectifier
Bracket
Rear
Panel
Tank
Bracket
Support
Cable
Clamp
Cylinder
Chain
Side
Panel,
LH
Latch
Side
Panel
Warning
Label
Wrapper
Cord
Set
Base
Axle
Retaining
Ring
Resistor
Clip
Lock
Washer
Caster
Jam
Nut
Front
Panel
w/Cmpts
Light
24
+When
ordenng
a
component
originally
displaying
a
precautionary
label,
the
label
should
also
be
ordered.
Be
sure
to
provide
Model
and
Serial
Number
when
ordering
replacement
parts.
OM.157
066
Page
17
NOTE:
All
items
indented
by
a
dot(s)
are
included
with
the
item
listed
directly
above.
22
Item
Part
No.
No.
Description
1
174861
2
148956
3
021
469
4
144933
5
058427
6
085
980
7
605941
8
057
543
9
057971
10
010191
11
058628
12
057745
13
058428
Hub.spool
14
177307
Support
Reel
OM-157
066
Page
18
I
Item
Part
J
No.
No.
Description
15
174812
Baffle
16
083147
Grommet
17
082 902
Strip,
mtg
center
18
092
186
Strip,
mtg
LH
&
RH
19
156517
Capacitor
20
114
780
Contactor
114786
Link
21
134
201
PC
Card
Stand-Off
22
173002
Motor
Speed
Control
Card
23
012
658
Fuse,
mintr
gi
slo-blo
2A
125V
23
073
426
Fuse,
mintr
gI
slo-blo
5A
125V
165
896
Connector
&
Sockets
135
558
Connector
&
Sockets
I
Item
Part
J
No.
No.
Description
165
745
Connector
&
Sockets
24
083
431
Circuit
Breaker
25
011
609
Toggle
Switch,
SPDT
26
171
610
Selector
Switch
27 153
322
Terminal
Assembly,
pri
2V
038618
Link
28
010199
Tubing
29
039
047
Output
Terminal,
red
30
039
046
Output
Terminal,
black
31
071
971
Cover
OPTIONAL
Recommended
Spare
Parts
Be
sure
to
provide
Model
and
Serial
Number
when
ordering
replacement
parts.
Figure
6-2.
Baffle
w/Components
(Fig
6-1
Item
3)
ST-BOO
931-B
Drive
Assembly,
(Fig
6-3)
Switch
Handle
Danger
Label
Access
Door
Retaining
Ring
Nut
Flat
Washer
Spring,
.845
OD
Keyed
Washer
Fiber
Washer
Brake
Washer
Spring,
2.430
OD
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Miller KG279559 Owner's manual

KG279559
Miller
Brand
Miller
Model
KG279559
Category
Welding System
Type
Owner's manual
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