Miller KF771637 Owner's manual

Brand: Miller

Model: KF771637

Category: Welding System

Type: Owner's manual

This manual is also suitable for

Visit our website at

www.MillerWelds.com

Processes

Description

TIG (GTAW) Welding

Arc Welding Power Source

OM-206 141 754E

July 1999

Stick (SMAW) Welding

152 Model

175 Model

Maxstar 152 And 175

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 orindividual 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 the

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.

The following terms are

used interchangeably

throughout this manual:

TIG = GTAW

Stick = SMAW

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 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION 5. . . . . . . . . . . . . . . . . . . . .

1-1. Signification des symboles 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Dangers relatifs au soudage à l’arc 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement

et la maintenance 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. Principales normes de sécurité 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Information sur les champs électromagnétiques 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – SPECIFICATIONS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Volt-Ampere Curves 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Duty Cycle And Overheating 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Selecting A Location 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Selecting And Preparing Weld Output Cables 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Weld Cable Size 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Connecting To Weld Output Receptacles 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Remote 14 Receptacle Information And Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Remote 14 Socket Information 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Connecting Input Power To 152 Models 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Electrical Service Guide For 152 Ampere Models 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Connecting Input Power To 175 Models 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Electrical Service Guide For 175 Ampere Models 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – OPERATION 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Output (Contactor) Switch 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Amperage Controls 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Weld Process Switch 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Lift-Arc Switch 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Power Switch And Pilot Light 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – MAINTENANCE & TROUBLESHOOTING 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

5-2. Measuring Input Capacitor Voltage 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Troubleshooting 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – ELECTRICAL DIAGRAMS 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – SELECTING AND PREPARING TUNGSTEN ELECTRODE 24. . . . . . . . . . . . . . . . . . . . .

7-1. Selecting Tungsten Electrode 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Preparing Tungsten For AC Or DC Electrode Positive (DCEP) Welding 25. . . . . . . . . . . . . . . .

7-3. Preparing Tungsten For DC Electrode Negative (DCEN) Welding 25. . . . . . . . . . . . . . . . . . . . .

SECTION 8 – GUIDELINES FOR TIG WELDING (GTAW) 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Positioining The Torch 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Torch Movement During Welding 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Positioning Torch Tungsten For Various Weld Joints 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 – PARTS LIST 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

WARNING

This product, when used

for welding or cutting,

produces fumes or

gases which contain

chemicals known to the

State of California to

cause birth defects and,

in some cases, cancer.

(California Health &

Safety Code Section

25249.5 et seq.)

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OM-206 Page 1

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

som _nd_5/97

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 – do not use work clamp or work 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-206 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-206 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-206 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.

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OM-206 Page 8

1-4. Principales normes de sécurité

Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-

ding Society, 550 N.W. Lejeune Rd, Miami FL 33126

Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent

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

20402.

Recommended Safe Practice for the Preparation for Welding and Cut-

ting of Containers That Have Held Hazardous Substances, norme AWS

F4.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL

33126

National Electrical Code, NFPA Standard 70, de la National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA 02269.

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

de la Compressed Gas Association, 1235 Jefferson Davis Highway,

Suite 501, Arlington, VA 22202.

Règles de sécurité en soudage, coupage et procédés connexes, norme

CSA W117.2, de l’Association canadienne de normalisation, vente de

normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3.

Safe Practices For Occupation And Educational Eye And Face Protec-

tion, norme ANSI Z87.1, de l’American National Standards Institute,

1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme NFPA 51B, de la National Fire

Protection Association, Batterymarch Park, Quincy, MA 02269.

1-5. Information sur les champs électromagnétiques

Données sur le soudage électrique et sur les effets, pour l’organisme,

des champs magnétiques basse fréquence

Le courant de soudage, pendant son passage dans les câbles de sou-

dage, causera des champs électromagnétiques. Il y a eu et il y a encore

un certain souci à propos de tels champs. Cependant, après avoir ex-

aminé plus de 500 études qui ont été faites pendant une période de

recherche de 17 ans, un comité spécial ruban bleu du National Re-

search Council a conclu: “L’accumulation de preuves, suivant le

jugement du comité, n’a pas démontré que l’exposition aux champs

magnétiques et champs électriques à haute fréquence représente un

risque à la santé humaine”. Toutefois, des études sont toujours en cours

et les preuves continuent à être examinées. En attendant que les con-

clusions finales de la recherche soient établies, il vous serait

souhaitable de réduire votre exposition aux champs électromagnéti-

ques pendant le soudage ou le coupage.

Afin de réduire les champs électromagnétiques dans l’environnement

de travail, respecter les consignes suivantes :

1 Garder les câbles ensembles en les torsadant ou en les

attachant avec du ruban adhésif.

2 Mettre tous les câbles du côté opposé de l’opérateur.

3 Ne pas courber pas et ne pas entourer pas les câbles autour de

votre corps.

4 Garder le poste de soudage et les câbles le plus loin possible de

vous.

5 Relier la pince de masse le plus près possible de la zone de

soudure.

Consignes relatives aux stimulateurs cardiaques :

Les personnes qui portent un stimulateur cardiaque doivent avant tout

consulter leur docteur. Si vous êtes déclaré apte par votre docteur, il est

alors recommandé de respecter les consignes ci–dessus.

OM-206 Page 9

SECTION 2 – SPECIFICATIONS

Unless otherwise noted, the 175 model is shown throughout this manual.

NOTE

2-1. Specifications

Model

Rated Welding

Output

Amperage

Range

Maximum

Open-Circuit

Voltage DC

Amperes Input at

Rated Load Output

KVA KW Weight

Overall

Dimensions

152

120 A @

25 Volts DC,

100% Duty Cycle

1–150

230 Volts AC; 50/60 Hz;

Single-Phase

27.1 (0.5)*

6.2

0.12*

3.7

0.01*

31 lb

(14 kg)

Length: 16-1/2 in

(419 mm)

Width: 9-1/2 in

(241 mm)

Height: 8 in

(203 mm)

175

140 A @

25.6 Volts DC,

100% Duty Cycle

1–175

460 Volts AC; 50/60 Hz;

Three-Phase

7.4 (1.0)*

5.9

0.4*

3.9

0.17*

39 lb

(18 kg)

Length: 16-1/2 in

(419 mm)

Width: 9-1/2 in

(241 mm)

Height: 10 in

(254 mm)

* While idling

ssb1.1 10/91 – SB-151 604 / SB-143 476-B

The volt-ampere curves show the

minimum and maximum voltage

and amperage output capabilities of

the welding power source. Curves

of other settings fall between the

curves shown.

A. 152 Model B. 175 Model

2-2. Volt-Ampere Curves

OM-206 Page 10

2-3. Duty Cycle And Overheating

rduty1 5/95 – SB-121 591-B / SB-144 507-B / ST-157 356-B

Duty Cycle is percentage of 10 min-

utes that unit can weld at rated load

without overheating.

Y Exceeding duty cycle can

damage unit and void

warranty.

minutes

When overheated, thermostat

opens, output stops, and cooling

fan keeps running.

Let fan run for

15 minutes.

Start welding.

Overheating

A. 152 Model B. 175 Model

Continuous Welding

100% Duty Cycle At 120 Amperes For 152

Models; 140 Amperes For 175 Models

OM-206 Page 11

SECTION 3 – INSTALLATION

1 10 in (254 mm) Open Space

On Right Side And Rear Of

Unit For Good Airflow

2 Lifting Handle

Use handle to move unit.

3 Rating Label

Locate unit near correct input

power supply.

Right

Rear

3-1. Selecting A Location

Ref. SA-145 666-C

1 Weld Output Cable

Determine total cable length in weld

circuit and maximum welding am-

peres. Use Section 3-3 to select

proper cable size.

Use shortest cables possible.

Do not use damaged cables.

2 Terminal Lug

Use lugs of proper amperage ca-

pacity and hole size for connecting

to work clamp, electrode holder, or

wire feeder.

3 Insulated Electrode Holder

Install according to manufacturer’s

instructions.

4 Work Clamp

Install onto work cable.

5 Dinse-Type Connector

Install onto weld cable.

10 ft (3 m)

Total Cable

Length In Weld

Circuit = 20 ft (6 m)

10 ft (3 m)

For Example,

sb6.2* 5/94 – S-0656

Tools Needed:

3-2. Selecting And Preparing Weld Output Cables

3-3. Weld Cable Size*

Total Cable (Copper) Length In Weld Circuit Not Exceeding

100 ft (30 m) Or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Welding

Amperes

10 To 60%

Duty Cycle

60 Thru 100%

Duty Cycle

10 Thru 100% Duty Cycle

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

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

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

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

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

OM-206 Page 12

1 Positive (+) Weld Output

Receptacle

2 Negative (–) Weld Output

Receptacle

3 Connector

For Electrode Positive (DCEP),

connect work cable connector to

negative (–) receptacle and elec-

trode holder cable connector to

positive (+) receptacle.

For Electrode Negative (DCEN),

reverse cable connections.

Align keyway, insert connector, and

turn clockwise.

Ref. SC-140 373 / Ref. ST-152 126

3-4. Connecting To Weld Output Receptacles

sb7.1 5/94 – ST-801 174 / Ref. S-0004-A / S-0750 / Ref. ST-141 127-B

1 Remote 14 Receptacle RC7

(See Section 3-6)

2 Keyway

3 Plug

4 Threaded Collar

To connect to receptacle, align

keyway, insert plug, and tighten

threaded collar.

Rear Panel

3-5. Remote 14 Receptacle Information And Connections

OM-206 Page 13

3-6. Remote 14 Socket Information

A +15 volts dc.

B Contact closure to A completes +15 volts dc contactor control circuit.

C Output command reference; 0 to +10 volts dc depending on setting of

Amperage Adjustment control R4.

D Remote control circuit common.

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

K Chassis common

Socket InformationSocket*

REMOTE 14

OUTPUT

(CONTACTOR)

AMPERAGE/

A/V

VOLTAGE

*The remaining sockets are not used.

Have only qualified persons make

this installation.

1 Line Disconnect Device Of

Proper Rating

2 230 Volts AC Wall Receptacle

3 Input Conductors

4 Grounding Conductor

Select size and length using Sec-

tion 3-8. Conductor rating must

comply with national, state, and

local electrical codes.

Install and connect input conduc-

tors and grounding conductor in

conduit or equivalent between wall

receptacle and deenergized line

disconnect device.

Connect grounding conductor first,

then line input conductors.

Be sure grounding conductor goes

to an earth ground.

5 Overcurrent Protection

Select type and size using Section

3-8. Install into deenergized line

disconnect device (fused discon-

nect switch shown).

6 Input Power Plug

Turn Off unit Power switch, and

connect plug to receptacle.

ssb2.2* 1/94 – ST-156 250-A

3-7. Connecting Input Power To 152 Models

3-8. Electrical Service Guide For 152 Ampere Models

Input Voltage

230

Input Amperes At Rated Output

27.1

Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes

Min Input Conductor Size In AWG/Kcmil

Max Recommended Input Conductor Length In Feet (Meters)

167 (51)

Min Grounding Conductor Size In AWG/Kcmil

Reference: 1993 National Electrical Code (NEC). S-0092J

OM-206 Page 14

Have only qualified persons make

this installation.

1 Line Disconnect Device Of

Proper Rating

2 Input Conductors

3 Grounding Conductor

Select size and length using Sec-

tion 3-10. Conductor rating must

comply with national, state, and

local electrical codes. Strip 3/8 in

(10 mm) insulation off conductors.

4 Strain Relief Connector

Remove wrapper and insert con-

ductors.

5 Input Terminal Block

6 Line Terminals

7 Welding Power Source

Ground Terminal

Connect grounding conductor to

ground terminal first. Then connect

input conductors to line terminals.

Tighten strain relief connector.

8 Disconnect Device Ground

Terminal

Install and connect grounding

conductor and input conductors in

conduit or equivalent to deener-

gized line disconnect device.

Connect grounding conductor first,

then line input conductors. Be sure

grounding conductor goes to an

earth ground.

Reinstall wrapper.

9 Overcurrent Protection

Select type and size using Section

3-10. Install into deenergized line

disconnect device (fused

disconnect switch shown).

ssb2.4* 1/94 – ST-145 667-B / SA-145 666-C

Tools Needed:

5/16 in

3-9. Connecting Input Power To 175 Models

3-10. Electrical Service Guide For 175 Ampere Models

Input Voltage

460

Input Amperes At Rated Output

7.4

Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes

Min Input Conductor Size In AWG/Kcmil

Max Recommended Input Conductor Length In Feet (Meters)

443 (135)

Min Grounding Conductor Size In AWG/Kcmil

Reference: 1993 National Electrical Code (NEC). S-0092J

OM-206 Page 15

SECTION 4 – OPERATION

ST-152 127-A

1 Amperage Adjustment Control

2 Amperage Control Switch

3 Output (Contactor) Switch

4 Lift-Arc Switch

5 Weld Process Switch

6 Power Switch

7 Pilot Light

345 6

4-1. Controls

1 Output (Contactor) Switch

Use switch to select way of control-

ling output.

For front panel control, place switch

in On position.

For remote control, place switch in

Remote 14 position (see Section

3-5).

Weld output receptacles

are energized when switch

is On and Power is On.

Ref. SC-157 579-A

4-2. Output (Contactor) Switch

OM-206 Page 16

ST-159 059 / S-0769

1 Amperage Adjustment Control

Use control to select weld amper-

age. Amperage may be adjusted

while welding.

2 Amperage Control Switch

Use switch to select way of control-

ling amperage adjustment.

For front panel control, place switch

in Panel position.

For remote control, place switch in

Remote 14 position (see Section

3-5).

See Example below.

3 Remote Foot Control

4 Remote Hand Dial

5 Fingertip Control

Set Switches Adjust Remote ControlSet Control

EXAMPLE Of Combination Remote Amperage Control

Control Setting

(80 A)

Unit

Minimum

4-3. Amperage Controls

1 Weld Process Switch

Use switch to select type of weld

output current. Use GTAW position

for Gas Tungsten Arc Welding. Use

SMAW position for Shielded Metal

Arc Welding.

Switch position determines the op-

eration of the Lift-Arc switch (see

Section 4-5).

4-4. Weld Process Switch

OM-206 Page 17

Lift-Arc switch must be in Off position when using a High-Frequency unit with this

welding power source, or when using the SMAW welding process.

NOTE

1 Lift-Arc Switch

Use switch to select Lift-Arc On or

Off.

With Lift-Arc On, start an arc in

GTAW welding as follows:

2 GTAW Electrode

3 Workpiece

Touch tungsten electrode to work-

piece at weld start point, hold elec-

trode to workpiece for 1-2 sec-

onds, 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 between

electrode and workpiece. The solid-

state output contactor does not en-

ergize until after tungsten electrode

is touching workpiece. This allows

electrode to touch workpiece with-

out overheating, sticking, or getting

contaminated.

1 – 2

Seconds

“Touch”

Do NOT Strike Like A Match!

Ref. S-156 279

4-5. Lift-Arc Switch

1 Power Switch

Use switch to turn unit and pilot light

On and Off.

2 Pilot Light

4-6. Power Switch And Pilot Light

OM-206 Page 18

SECTION 5 – MAINTENANCE & TROUBLESHOOTING

Turn Off all power before maintaining.

3 Months

Blow Out

Vacuum

Inside

Replace

Unreadable

Labels

6 Months

Tape Or

Replace

Cracked

Cables

ST-145 666-C

Clean

And

Tighten Weld

Connections

3 Months

14-Pin Cord

Gas

Hose

Torch Cable

Replace

Cracked

Parts

See

Section

3-2

– –

3-4

– –

During Heavy Service,

Clean Monthly

5-1. Routine Maintenance

OM-206 Page 19

ST-153 136-B

Turn Off welding power source and

disconnect input power.

Remove wrapper.

1 Input Capacitor C1 (Both

Models)

2 Input Capacitor C2 (175

Models Only)

3 Voltmeter

Check input capacitor(s).

Measure the dc voltage across the

positive (+) and negative (–)

terminals until voltage drops to near

0 (zero) volts.

Proceed with job inside unit.

Reinstall wrapper when finished.

Tools Needed:

5/16 in

Significant DC voltage can remain on capacitors after unit

is Off. Always check capacitors as shown to be sure they

have discharged before working on unit.

5-2. Measuring Input Capacitor Voltage

OM-206 Page 20

5-3. Troubleshooting

Trouble Remedy

No weld output; unit completely inop-

erative.

Be sure Power switch is On (see Section 4-6).

Secure power cord plug in receptacle (152 model) (see Section 3-7).

Be sure line disconnect switch is On (see Section 3-9).

Check line fuse(s) and replace if necessary. Reset circuit breakers (see Sections 3-7 or 3-9).

Check for proper input power connections (see Sections 3-7 or 3-9).

No weld output; fan motor FM running

and pilot light on.

Check position of Output (Contactor) switch (see Section 4-2).

Thermostats TP1 and/or TP2 open (overheating). Allow fan to run; thermostat(s) closes when unit

has cooled (see Section 2-3).

Low weld output with no control. Check position of Amperage Control switch (see Section 4-3).

Have Factory Authorized Service Station/Service Distributor check control board PC1.

Limited output and low open-circuit

voltage.

Check incoming power for correct voltage. Replace line fuse if open or reset circuit breaker (see Sec-

tions 3-7 or 3-9).

Check for proper input and output connections (see Sections 3-2, 3-4, and 3-7 or 3-9).

Erratic or improper weld output. Tighten all welding cable connections (see Sections 3-2 and 3-4).

Check for proper size and type of cable (see Section 3-2).

Check for proper input and output connections (see Sections 3-2, 3-4, and 3-7 or 3-9).

Replace electrode (see Section 7).

Arc not forming when using Lift-Arc. Check electrode and workpiece, clean as needed to allow good contact.

Fan motor FM does not run. Check and clear blocked fan blade; be sure blade is secure on shaft.

Have Factory Authorized Service Station/Service Distributor check fan motor FM.

Wandering arc; poor control of arc di-

rection.

Reduce gas flow rate.

Select proper size tungsten (see Section 7-1).

Properly prepare tungsten (see Sections 7-2 and 7-3).

Tungsten electrode oxidizing and not

remaining bright after conclusion of

weld.

Shield weld zone from drafts.

Increase postflow time.

Check and tighten all gas fittings.

Water in torch. Refer to torch Owner’s Manual for part(s) requiring replacement, and repair torch as

necessary.

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Model: KF771637

Category: Welding System

Type: Owner's manual

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