Miller KK289381 Owner's manual

Miller
Brand
Miller
Model
KK289381
Category
Welding System
Type
Owner's manual

This manual is also suitable for

/
/
OM-187
321G
November
1999
Processes
MIG
(GMAW)
Welding
Flux
Cored
(FCAW)
Welding
Description
.
.
AUTO
ARCJ
Arc
Welding
Power
Source
And
Wire
Feeder
Auto
Arc
190
For
Warranty
Claims
And
Technical
Support,
Contact:
Milweld
Inc.,
National
Distributor
P.O.
Box
338,
Hortonville,
WI
54944-0338
Tel
920-779-0916
Fax
920-779-0924
__
OWNERS
MANUAL
S
S
TABLE
OF
CONTENTS
The
following
term
is
used
interchangeably
throughout
this
manual:
MIG=GMAW
a
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.)
OM-187
321G
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
a
Iarc
5
1-3.
Dangers
supplØmentaires
en
relation
avec
linstallation,
le
fonctionnement
et
Ia
maintenance
7
1-4.
Principales
normes
de
sØcuritØ
8
1-5.
Information
sur
les
champs
electromagnØtiques
8
SECTION
2
-
INSTALLATION
9
2-1.
Specifications
9
2-2.
Volt-Ampere
Curves
9
2-3.
Duty
Cycle
And
Overheating
10
2-4.
Installing
Work
Clamp
10
2-5.
Installing
Gas
Supply
11
2-6.
Installing
Welding
Gun
12
2-7.
Setting
Gun
Polarity
12
2-8.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
13
2-9.
Changing
Input
Voltage
13
2-10.
Electrical
Service
Guide
14
2-11.
Selecting
A
Location
And
Connecting
Input
Power
14
2-12.
Threading
Welding
Wire
15
2-13.
Weld
Parameter
16
2-14.
Aluminum
Weld
Parameter
For
Use
With
Optional
Spoolmate
185
17
SECTION
3
-
OPERATION
t8
3-1.
Front
Panel
Controls
18
SECTION
4-
MAINTENANCE
&TROUBLESHOOTING
19
4-1.
Routine
Maintenance
19
4-2.
Circuit
Breakers
CB1
And
CB2
19
4-3.
Changing
Drive
Roll,
Inlet
Wire
Guide
19
4-4.
Cleaning
Or
Replacing
Gun
Liner
20
4-5.
Replacing
Gun
Contact
Tip
21
4-6.
Troubleshooting
21
SECTION
5
-
ELECTRICAL
DIAGRAM
22
SECTION
6
-
MIG
WELDING
(GMAW)
GUIDELINE&
23
6-1.
Typical
MIG
Process
Connections
23
6-2.
Typical
MIG
Process
Control
Settings
24
6-3.
Holding
And
Positioning
Welding
Gun
25
6-4.
Conditions
That
Affect
Weld
Bead
Shape
26
6-5.
Gun
Movement
During
Welding
27
6-6.
Poor
Weld
Bead
Characteristics
27
6-7.
Good
Weld
Bead
Characteristics
27
6-8.
Troubleshooting
-
Excessive
Spatt&
28
6-9.
Troubleshooting
-
Porosity
28
6-10.
Troubleshooting
-
Excessive
Penetration
29
6-11.
Troubleshooting
-
Lack
Of
Penetration
29
6-12.
Troubleshooting
-
Incomplete
Fusion
29
6-13.
Troubleshooting
-
Burn-Through
30
6-14.
Troubleshooting
-
Waviness
Of
Bead
30
6-15.
Troubleshooting
-
Distortion
30
6-16.
Common
MIG
Shielding
Gases
31
SECTION
7
-
PARTS
LIST
.32
WARRANTY
.
SECTION
1
-
SAFETY
PRECAUTIONS
-
READ
BEFORE
USING
som
_nd_4/98
1-1.
SymbolLisage
AA
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
A
Marks
a
special
safety
message.
l17
Means
Wote~
not
safety
related.
:j~.2;
Arc
Welding
Hazards
A
The
symbols
shown
below
are
used
throughout
this
manual
to
call
attention
to
and
identity
possible
hazards.
When
you
see
the
symbol,
watch
out,
and
followthe
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.
A
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
A
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.
Do
not
touch
live
electrical
parts.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
Do
not
use
AC
output
in
damp
areas,
if
movement
is
confined,
or
if
there
is
a
danger
of
falling.
Use
AC
output
ONLY
if
required
for
the
welding
process.
If
AC
output
is
required,
use
remote
output
control
if
present
on
unit.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
29
CFR
191
0.147
(see
Safety
Standards).
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual and
national,
state,
and
local
codes.
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.
When
making
input
connections,
attach
proper
grounding
conductor
first
-
double-check
connections.
Frequently
inspect
input
power
cord
for
damage
or
bare
wiring
-
replace
cord
immediately
if
damaged
-
bare
wiring
can
kill.
Turn
off
all
equipment
when
not
in
use.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
Do
not
drape
cables
over
your
body.
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.
If
earth
grounding
of
the
workpiece
is
required,
ground
it
directly
with
a
separate
cable.
Do
not
touch
electrode
if
you
are
in
contact
with
the
work,
ground,
or
another
electrode
from
a
different
machine.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
Maintain
unit
according
to
manual.
Wear
a
safety
harness
if
working
above
floor
level.
Keep
all
panels
and
covers
securely
in
place.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
or
worktable
as
near
the
weld
as
practical.
Insulate
work
clamp
when
not
connected
to
workpiece
to
prevent
contact
with
any
metal
object.
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.
Turn
Off
inverter,
disconnect
input
power,
and
discharge
input
capacitors
according
to
instructions
in
Maintenance
Section
before
touching
any
parts.
FUMES
AND
GASES
can
be
hazardous.
Welding
produces
fumes
and
gases.
Breathing
these
fumes
and
gases
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
remove
welding
fumes
and
gases.
If
ventilation
is
poor,
use
an
approved
air-supplied
respirator.
Read
the
Material
Safety
Data
Sheets
(MSDS5)
and
the
manufacturers
instructions
for
metals,
consumables,
coatings,
cleaners,
and
degreasers.
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
breathing
air
is
safe.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
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.
.
S
S
OM-187
321
Page
1
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.
Wear
awelding
helmet
fitted
with
a
propershade
offilterto
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Z49.1
and
Z87.1
listed
in
Safety
Standards).
Wear
approved
safety
glasses
with
side
shields
under
your
helmet.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
glare;
warn
others
not
to
watch
the
arc.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(leather
and
wool)
and
foot
protection.
WELDING
can cause
fire
or
explosion.
Welding
on
closed
containers,
such
as
tanks,
drums,
or
pipes,
can
cause
them
to
blowup.
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.
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.
Be
alert
that
welding
sparks
and
hot materials
from
welding
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
Be
aware
that
welding
on
a
ceiling,
floor,
bulkhead,
or
partition
can
cause
fire
on
the
hidden
side.
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).
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.
Do
not
use
welder
to
thaw
frozen
pipes.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
contact
tip
when
not
in
use.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
welding.
FLYING
METAL
can
injure
eyes.
Welding,
chipping,
wire
brushing,
and
grinding
cause
sparks
and
flying
metal.
As
welds
cool,
they
can
throw
off
slag.
Wear
approved
safety
glasses
with
side
shields
even
under
your
welding
helmet.
BUILDUP
OF
GAS
can
Injure
or
kill
Shut
off
shielding
gas
supply
when
not
in
use.
Always
ventilate
confined
spaces
or
use
approved
air-supplied
respirator.
i:
HOT
PARTS
can
cÆusesevere
burns.
Do
not
touch
hot
parts
bare
handed.
Allow
cooling
period
before
working
on
gun
or
torch.
MAGNETIC
FIELDS
can
affect
pacemakers.
Pacemaker
wearers
keep
away.
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.
Wear
approved
ear
protection
if
noise
level
is
high.
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.
Protect
compressed
gas
cylinders
from
excessive
heat,
mechanical
shocks,
slag,
open
flames,
sparks,
and
arcs.
Install
cylinders
in
an
upright
position
by
securing
to
a
stationary
support
or
cylinder
rack
to
prevent
falling
or
tipping.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
Never
drape
a
welding
torch
over
a
gas
cylinder.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
Never
weld
on
a
pressurized
cylinder
-
explosion
will
result.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
ARC
RAYS
can
burn
eyØs:aæd
skin:
.
OM-1
87
321
Page
2
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
possible.
About
Pacemakers:
Pacemaker
wearers
consult
your
doctorfirst.
If
cleared
by
your
doctor,
then
following
the
above
procedures
is
recommended.
.
OM-187
321
Page
4
LES
RAVONS
DE
LARC
peuvent
pro
voquer
des
brlures
dans
IesyØux
el
Le
rayonnement
de
larc
du
procØde
de
soudage
gØnŁre
des
rayons
visibles
et
invisibles
intenses
(ultraviolets
et
infrarouges)
susceptibles
de
provoquer
des
brOlures
dans
les
yeux
et
sur
Ia
peau.
Des
Øtincelles
sont
projetØes
pendant
le
soudage.
Porter
un
casque
de
soudage
muni
dun
Øcran
de
filtre
appropriØ
pour
protØger
votre
visage
et
vos
yeux
pendant
le
soudage
ou
pour
regar
der
(voirANSI
Z49.
1
et
Z87.
1
ØnumØrØ
dans
les
normes
de
sØcuritØ).
Porter
des
protections
approuves
pour
es
oreilles
si
le
niveau
sondre
est
trop
ØlevØ.
Utiliser
des
Øcrans
ou
des
barriŁres
pour
protØger
des
tiers
de
lØclair
etde
lØblouissement;
demander
aux
autres
personnes
de
ne
pas
re
garder
larc.
Porter
des
vŒtements
de
protection
constituØ
dans
une
matiŁre
dura
ble,
resistant
au
feu
(cuir
ou
lame)
et
une
protection
des
pieds.
m
~I
LE
SOUDAGEIpeut
provoquØr
I
k
(_m]
incendie
ou
une
explosion.
~
Le
souda~e
effectuØ
sur
des
conteneurs
fermØs
tels
que
des
reservoirs,
tambours
ou
des
conduites
peut
provoquerleurØclatement.
Des
Øtincelles
peuventØtre
projetØes
de
larc
de
soudure.
La
projection
dØtincel
es,
des
piŁces
chaudes
et
des
Øquipements
chauds
peut
provoquer
des
incendies
et
des
brOlures.
Le
contact
accidentel
de
electrode
avec
des
objets
metalliques
peut
provoquer
des
Øtincelles,
une
explosion,
un
surchauffement
ou
un
incendie.
Avant
de
commencer
le
soudage,
verifier
et
sassurer
que
lendroit
ne
prØsente
pas
de
danger.
Se
proteger
et
dautres
personnes
de
Ia
projection
dØtincelles
et
de
metal
chaud.
Ne
pas
souder
dans
un
endroit
l
o
des
Øtincelles
peuvent
tomber
sur
des
substances
inflammables.
DØplacertoutes
les
substances
inflammables
a
une
distance
del
0,7
m
de
larcde
soudage.
En
cas
dimpossibilitØ
les
recouvrir
soigneuse
ment
avec
des
protections
homologues.
Des
Øtincelles
et
des
matØriaux
chauds
du
soudage
peuvent
facile
ment
passer
dans
dautres
zones
en
traversant
de
petites
fissures
et
des
ouvertures.
SurveillertoutdØclenchementdincendie
ettenir
unextincteurproxi
mite.
Le
soudage
effectuØ
sur
un
plafond,
plancher,
paroi
ou
separation
peut
dØclencher
un
incendie
de
Iautre
ctŁ.
Ne
pas
effectuer
le
soudage
sur
des
conteneurs
fermØs
tels
que
des
reservoirs,
tambours,
ou
conduites,
a
moms
quils
naient
ØtØ
prØpa
rØs
correctement
conformØment
a
AWS
F4.1
(voir
les
normes
de
sØcuritØ).
Brancher
le
cable
sur
Ia
piŁce
le
plus
prŁs
possible
de
Ia
zone
de
sou
dage
pour
Øviter
le
transport
du
courant
sur
une
longue
distance
par
des
chemins
inconnus
Øventuels
en
provoquant
des
risques
dØlec
trocution
et
dincendie.
Ne
pas
utiliser
le
poste
de
soudage
pour
dØgeler
des
conduites
ge
lees.
En
cas
de
non
utilisation,
enlever
Ia
baguette
dØlectrode
du
porte
electrode
ou
couper
le
fil
a
Ia
pointe
de
contact.
Porter
des
vŒtements
de
protection
dØpourvus
dhuile
tels
que
des
gants
en
cuir,
une
chemise
en
matØriau
lourd,
des
pantalons
sans
re
vers,
des
chaussures
hautes
et
un
couvre
chef.
Avant
de
souder,
retirer
toute
substance
combustible
de
vos
poches
telles
quun
allumeur
au
butane
ou
des
allumettes.
I
DES
PARTICULES
VOLANTES
~
peuvent
blesser
les
yeux.
Le
soudage,
lØcaillement,
le
passage
de
Ia
piŁce
a
Ia
brosse
en
fil
de
fer,
et
le
meulage
generent
desŁtincellesetdes
particules
mŁtalliquesvolan
tes.
Pendant
Ia
pŁriode
de
refroidissement
des
soudures,
elles
risquent
de
projeter
du
laitier.
Porter
des
lunettes
de
sØcuritØ
avec
Øcrans
lateraux
ou un
Øcran
facial.
~J
.
Fermer
Ialimentation
du
gaz
protecteur
en
cas
de
non
utilisation.
Veiller
toujours
a bien
aØrer
es
espaces
confines
ou
se
servir
dun
respi
rateur
dadduction
dair
homologue.
DES
PIECES.
CHAUDES
peuverit
pro~
voquer
des.brlures
graves.
Ne
pas
toucher
des
parties
chaudes
a
mains
nues
PrØvoir
une
pØriode
de
refroidissement
avant
dutiliser
le
pistolet
ou
Ia
torche.
LES
CHAMPS
MAGNETIQUES
peuvent
affecter
les
stimulateurs
cardiaques.
Porteurs
de
stimulateur
cardiaque,
restez
a
distance.
Les
porteurs
dun
stimulateur
cardiaque
doivent
dabord
consulter
leur
mØdecin
avant
de
sapprocher
des
operations
de
soudage
a
arc,
de
gougeage
ou
de
soudage
par
points.
LE
BRUIT
peut
affecter
louIe.
Le
bruit
des
processus
et
des
Øquipements
peut
affecter
louIe.
Porter
des
protections
approuvØs
pour
es
oreilles
si
le
niveau
sondre
eat
trop
ØlevØ.
Si
des
BOUTEILLES
sont
endomma
gØes,
elles
pourront
exploser.
Des
bouteilles
de
gaz
protecteur
contiennent
du
gaz
sous
haute
pression.
Si
une
bouteille
eat
endomma
gee,
eIle
peutexploser.
Du
faitque
lea
bouteilles
degaz
font
normalement
partie
du
procØdŁ
de
soudage,
les
manipuler
avec
precaution.
Proteger
es
bouteilles
de
gaz
comprime
dune
chaleur
excessive,
des
chocs
mecaniques,
du
laitier,
des
flammes
ouvertes,
des
Łtin
celles
et
des
arcs.
Placer
les
bouteilles
debout
en
les
fixant
dana
un
support
station
naire
ou
dans
un
porte-bouteilles
pour
les
empŒcher
de
tomber
ou
de
se
renverser.
Tenir
es
bouteilles
eloignees
des
circuits
de
soudage
ou
autres
cir
cuits
Łlectriques.
Ne
jamais
placer
une
torche
de
soudage
sur
une
bouteille
a
gaz.
Une
electrode
de
soudage
ne
dolt
jamais
entrer
en
contact
avec
une
bouteille.
Ne
jamais
souder
une
bouteille
pressurisØe
-
risque
dexplosion.
Utiliser
seulement
des
bouteilles
de
gaz
protecteur,
rØgulateurs,
tuyaux
et
raccords
convenables
pour
cette
application
spØcifique;
lea
maintenir
ainsi
que
lea
ØlØments
associØs
en
bon
Øtat.
Ne
pas
tenir
Ia
tŒte
en
face
de
Ia
sortie
en
ouvrant
Ia
soupape
de
Ia
bouteille.
Maintenir
le
chapeau
de
protection
sur
Ia
soupape,
sauf
en
cas
dutilisation
ou
de
branchement
de
Ia
bouteille.
Ure
et
suivre
les
instructions
concernant
les
bouteilles
de
gaz
corn
prime,IesŁquipementsassociŁsetlespublications
P-i
CGAØnu
mØrØes
dana
les
normes
de
sŁcuritØ.
~l~LES
ACCUMULATIONS
DE
GZrls
quent
de
provoquer
des
blessUres
ou
..rnŒmelamott.
..
.
S
OM-187
321
Page
6
et
Ia
maintenance
Risque
DJNCENDIE
OU
DEXPLOSION.
Ne
pas
placer
lappareil
sur,
au-dessus
ou
a
proximitØ
de
surfaces
infliammables.
Ne
pas
installer
lappareil
a
proximitØ
de
produits
inflammables
Ne
pas
surcharger
linstallation
electrique
-
sassurer
que
lalimen
tation
est
correctement
dimensionnØ
et
protØgØ
avant
de
mettre
lappareil
en
service.
LA
CHUTE
DE
LAPPAREIL
peut.
blesser.
Utiliser
lanneau
de
levage
uniquement
pour
sou
lever
lappareil,
NON
PAS
les
chariot,
les
bouteil
les
de
gaz
ou
tout
autre
accessoire.
Utiliser
un
engin
dune
capacitØ
appropriØe
pour
soulever
lappareil.
En
utilisant
des
fourches
de
levage
pour
dØplacer
lunitØ,
sassurer
que
les
fourches
sont
suffisamment
longues
pourdØpasser
du
ctØ
oppose
de
lappareil.
.LEMPLOI
EXCESSIF
petit
SIJRCHAUFFER
LEQUIPEMENT.
PrØvoir
une
pØriode
de
refroidissement,
respec
ter
le
cycle
opØratoire
nominal.
RØduire
le
courantou
le
cycle
opØratoire
avantde
recommancer
le
soudage.
Ne
pas
obstruer
les
passages
dair
du
poste.
LES
CHARGESELECTROSTATIQUES
peuveflt
endommager
les
circuits
im
primes.
Etablir
Ia
connexion
avec
Ia
barrette
de
terre
avant
de
manipuler
des
caries
ou
des
piŁces.
Utiliser
des
pochettes
et
des
boltes
antistatiques
pour
stocker,
dØplacer
ou
expŁdier
des
caries
de
circuits
imprimes.
DES
ORGANES
MOBILES
peuvent
provoquer
des.b!essures.
Ne
pas
sapprocher
des
organes
mobiles.
Ne
pas
sapprocher
des
points
de
coincement
tels
que
des
rouleaux
de
commande.
LES
FILS
DE.SOUDAGE
peuvent
pro
voquer
des
blessures.
Ne
pas
appuyer
sur
Ia
gachette
avant
den
avoir
recu
linstruction.
Ne
pas
diriger
le
pistolet
vers
soi,
dautres
per
sonnes
ou
toute
piŁce
mØcanique
en
engageant
le
fil
de
soudage.
DES
ORGANES
MOBILES
peuvent
provoquer.des
blessures.
Rester
a
lŁcart
des
organes
mobiles
comme
le
ventilateur.
Maintenir
fermØs
et
fixement
en
place
les
portes,
panneaux,
recouvrements
et
dispositifs
de
protection.
LE
RAYONNEMENT
HAUTE
FRE-.
QUENCE
(H.E)
risque
de
provoquer
des
interferences.
Le
rayonnement
hautefrequence
peut
provoquer
des
interferences
avec
les
Øquipements
de
ra
dio-navigation
etde
communication,
les
services
de
sØcuritØ
et
les
ordinateurs.
Demander
seulement
a
des
personnes
qualifiØes
familiarisØes
avec
des
Øquipements
Ølectroniques
de
faire
fonctionner
installa
tion.
Lutilisateur
est
tenu
de
faire
corriger
rapidement
par
un
Ølectricien
qualifiØ
les
interferences
resultant
de
linstallation.
Si
le
FCC
signale
des
interferences,
arrŒter
immØdiatement
Iappa
reil.
Etfectuer
rØguliŁrement
le
contrle
et
lentretien
de
installation.
Maintenir
soigneusement
fermŁs
les
portes
et
es
panneaux
des
sources
de
haute
frequence,
maintenirles
Øclateurs
a
une
distance
correcte
et
utiliser
une
terre
et
et
un
blindage
pour
rØduire
les
inter
fŁrences
Łventuelles.
LE
SOUDAGE
A
LARC
risque
de~
provoquer
des
interferences.
LØnergie
ŁlectromagnØtique
risque
de
provoquer
des
interferences
pour
lŁquipement
Ølectronique
sensible
tel
que
les
ordinateurs
et
lŁquipement
commandØ
par
ordinateur
tel
que.
les
robots.
Veiller
ace
que
tout
lØquipement
de
Ia
zone
de
soudage
soit
com~
patible
ØlectromagnØtiquement.
Pour
rØduire
Ia
possibilitØ
dinterfØrence,
maintenir
les
cables
de
soudage
aussi
courts
que
possible,
les
grouper,
et
les
poser
aussi
bas
que
possible
(ex.
par
terre).
Veiller
a
souder
a
une
distance
de
100
metres
de
tout
Łquipement
electronique
sensible.
Veiller
a
ce
que
ce
poste
de
soudage
soit
pose
et
mis
a
Ia
terre
conformØment
a
ce
mode
demploi.
En
cas
dinterfØrences
aprŁs
avoir
pris
es
mesures
prØcØdentes,
il
incombe
a
lutilisateur
de
prendre
des
mesures
supplØmentaires
telles
que
le
dØplacement
du
poste,
lutilisation
de
cables
blindØs,
lutilisation
de
filtres
de
ligne
ou
Ia
pose
de
protecteurs
dans
Ia
zone
de
travail.
LES
CHAMPS
MAGNETIQUES
peuvent
affecter
les
stimulateurs
cardiaques.
Porteurs
de
stimulateur
cardiaque,
restez
a
dis
tance.
Les
porteurs
dun
stimulateur
cardiaque
doivent
dabord
consulter
leur
mØdecin
avant
de
sappro
cher
des
operations
de
soudage
a
larc,
de
gou
geage
ou
de
soudage
par
points.
1-3.
Dangers
supplØmentaires
en
relation
avec
Iinstallatioh,
le
fonctionnement
OM-187
321
Page
7
Safetyin
Welding
and
Cutting,
normeANSi
Z49.1,
delAmericanWel
ding
Society,
550
N.W.
Lejeune
Ad,
Miami
FL
33126
Safetyand
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,
Mia
mi
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
de
a
National
Fire
Pro
tection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
de
Ia
Compressed
Gas
Association,
1235
Jefferson
Davis
High
way,
Suite
501,
Arlington,
VA
22202.
Regles
de
sØcuritØ
en
soudage,
coupage
et
procØdØs
connexes,
nor-
me
CSA
Wi
17.2,
de
Association
canadienne
de
normalisation,
vente
de
normes,
178
Rexdale
Boulevard,
Rexdale
(Ontario)
Canada
M9W
1R3.
Safe
Practices
ForOccupationAndEducational
EyeAnd
Face
Protec
tion,
norme
ANSI
Z87.1,
de
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
and
Welding
Processes,
norme
NFPA
SiB,
de
a
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
1-5.
Information
sUr
les
champs
ØlectromgnØtiques
DonnØes
sur
le
soudage
electrique
et
sur
les
effets,
pour
lorganisme,
des
champs
magnetiques
basse
frØquence
Le
courant
de
soudage,
pendant
son
passage
dans
es
cables
de
sou
dage,
causera
des
champs
ØlectromagnØtiques.
II
y
a
eu
et
ii
y
a
encore
un
certain
souci
a
propos
de
tels
champs.
Cependant,
aprŁs
avoir
examine
plus
de
500
etudes
qui
ont
ØtØ
faites
pendant
une
pØ
node
de
recherche
de
17
ans,
un
comitØ
special
ruban
bleu
du
National
Research
Council
aconclu:
Laccumulation
de
preuves,
sui
vant
le
jugement
du
comitØ,
na
pas
dØmontrØ
que
lexposition
aux
champs
magnØtiques
et
champs
electriques
a
haute
frequence
reprØ
sente
un
risque
a
Ia
sante
humaine.
Toutefois,
des
etudes
sont
toujours
en
cours
et
les
preuves
continuent
a
Œtre
examinØes.
En
at
tendant
que
les
conclusions
finales
de
Ia
recherche
soient
Øtablies,
II
vous
serait
souhaitable
de
rØduire
votre
exposition
aux
champs
Ølec
tromagnØtiques
pendant
le
soudage
ou
le
coupage.
Afin
de
rØduire
les
champs
Ølectromagnetiques
dans
lenvironnement
de
travail,
respecter
les
consignes
suivantes
1
Garder
les
cables
ensembles
en
les
torsadant
ou en
les
attachant
avec
du
ruban
adhØsif.
2
Mettre
tous
les
cables
du
ctØ
oppose
de
IopØrateur.
3
Ne
pas
courber
pas
et
ne
pas
entourer
pas
les
cables
autour
de
votre
corps.
4
Garder
le
poste
de
soudage
et
les
cables
le
plus
loin
possible
de
vous.
5
Relier
Ia
pince
de
masse
le
plus
prŁs
possible
de
Ia
zone
de
soudure.
Consignes
relatives
aux
stimulateurs
cardiaques
Les
personnes
qui
portent
un
stimulateur
cardiaque
doivent
avant
tout
consulter
leur
docteur.
Si
vous
Œtes
dØclarØ
apte
par
votre
docteur,
il
est
alors
recommandØ
de
respecter
les
consignes
ci-dessus.
1-4
Pnncipaies
normes
de
securitØ
S
OM-187
321
Page
8
SECTION
2-
INSTALLATION
2-1.
Specifications
Rated
Welding
Output
Amperage
Range
Maximum
Open-Circuit
Voltage
DC
Amperes
Input
at
Rated
Load
Output,
60
Hz,
Single-Phase
Weight
Overall
Dimensions
200V
230V
KVA
KW
Length:
36
in
(915
mm)
150
A
@23
Volts
DC,
60%
Duty
Cycle
30
-
185
33
30
(1.6)*
26
(1.4)*
6
(0.27)*
5
(0.13)~
165
lb
(75
kg)
Width:
18
in
(457
mm)
Height:
27
in
(686
mm)
Wire
Type
And
Diameter
Calculated
Wire
Speed
Range
At
No
Load
Max
Wire
Feed
Speed
While
Welding
Solid
Steel
/
Flux
Cored
I
Aluminum
Stainless
Steel
I
.023
-
.035
in
I
.030
-
.045
in
I
.030
-
.035
in
(0.6
-
0.9
mm)
(0.8
-
1.2
mm)
(0.8
-
0.9
mm)
138
-
795
1PM
(3.5
-
20.3
rn/mm)
650
1PM
(16.5
rn/mm)
*While
idling
2-2.
Volt-Ampere
Curves
Volt-ampere
curves
show
mini
mum
and
maximum
voltage
and
amperage
output
capabilities
of
unit.
Curves
of
other
settings
fall
between
curves
shown.
35
Cl)
!
o
30
>
LLI
CD
25
<
~
0
>
20
a
<
0
~1
15
10
0
50
100
150
200
LOAD
,
AMPS
va_curvel
4/95
-
SB-180
824
OM-187
321
Page
9
2-3.
Duty
Cycle
And
Overheating
-~
~-
2-4.
Installing
Work
Clamp
S
S
RATED
OUTPUT-1
200
Duty
Cycle
is
percentage
of
10
minutes
that
unit
can
weld
at
rated
load
without
overheating.
-__
~%
iiiiiiiii~S
111111
~
Cl)
w
w
a
____
~150
-J
w
___
____
100
30
40
50
60
%
DUTY
CYCLE
60%
Duty
Cycle
At
150
Amperes
6
Minutes
Welding
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.
10
80
90100
4
Minutes
Resting
AorV
Minutes
4
5
2
1
Work
Cable
2
Boot
Slide
boot
onto
work
cable.
Route
cable
out
front
panel
opening
from
inside.
3
Negative
(-)
Output
Terminal
Connect
cable
to
terminal
and
cover
connection
with
boot.
4
Hardware
5
Work
Clamp
Route
cable
through
clamp
handle
and
secure
as
shown.
Close
door.
ST-801
566
3
Tools
Needed:
1/2,3/4
in
OM-187
321
Page
10
2-5.
Installing
Gas
Supply
1
Cap
2
Cylinder
Valve
Remove
cap,
stand
to
side
of
valve,
and
open
valve
slightly.
Gas
flow
blows
dust
and
dirt
from
valve.
Close
valve.
3
Cylinder
4
Regulator/Flowmeter
Install
so
face
is
vertical.
5
Regulator/Flowmeter
Gas
Hose
Connection
6
Welding
Power
Source
Gas
Hose
Connection
Connect
customer
supplied
gas
hose
between
regulator/flowme
ter
gas
hose
connection,
and
fitting
on
rear
of
welding
power
source.
7
Flow
Adjust
Typical
flow
rate
is
20
cfh
(cubic
feet
per
hour).
Check
wire
man
ufacturers
recommended
flow
rate.
8
CO2
Adapter
(Customer
Supplied)
9
0-Ring
(Customer
Supplied)
Install
adapter
with
0-ring
be
tween
regulator/flowmeter
and
CO2
cylinder.
2
4
3
r
Argon
Gas
Obtain
gas
cylinder
and
chain
to
running
gear,
wall,
or
other
sta
tionary
support
so
cylinder
cannot
fall
and
break
off
valve.
Ret
ST-148
265-B
I
ST-802
028
Tools
Needed:
~~:-
-r
1-1/8,5/8in
CO2
Gas
OM-187321
Page
11
2-6.
Installing
Welding
Gun
2-7.
Setting
Gun
Polarity
.
2
3
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-801
936
1
Polarity
Changeover
Label
(Located
Near
Drive
Assembly)
Wire
Drive
Assembly
Lead
To
Positive
()
Output
Terminal
Always
read
and
follow
manufac
tures
recommended
polarity.
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
~
449-0
Tools
Needed:
~
3/4,11/l6in
OM-187
321
Page
12
2-8.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
2-9.
Changing
Input
Voltage
Use
compression
spring
with
8
in
(200
mm)
spools.
Tools
Needed:
15/i6in
When
a
slight
force
is
needed
to
turn
spool,
tension
is
set.
ST-072573-B
A
Turn
Off
unit,
and
discon
nect
input
power.
Unit
was
shipped
from
factory
set
for
230
volts.
1
Transformer
Ti
2
Rear
Of
Power
Switch
Si
3
Lead
Marked
230
Volt
And
Fan
Motor Lead
Disconnect
230
volt
lead
and
fan
motor
lead
from
rear
of
Si.
Leave
fan
motor
lead
connected
to
230
volt
lead.
4
Lead
Marked
200
Volt
i
Remove
cable
tie,
and
slide
short
piece
of
sleeving
off
200
volt
lead,
and
slide
sleeving
over
end
of
230
volt
and
fan
motor
leads.
Fold
sleeving
over
and
secure
in
place.
Connect
200
volt
lead
to
Si
where
230
volt
lead
was
removed.
Reinstall
wrapper.
4
Tools
Needed:
3/8,7/i6in
ST.801
580-A
OM-187
321
Page
13
2-10.
Electrical
Service
Guide
Input
Voltage
200
230
Input
Amperes
At
Rated
Output
30
26
Max
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes
45
40
Mm
Input
Conductor
Size
In
AWG/KcmiI
10
10
Max
Recommended
Input
Conductor
Length
In
Feet
(Meters)
97
(29)
128
(39)
Mm
Grounding
Conductor
Size
In
AWG/Kcmil
10
10
Reference:
1996
National
Electrical
Code
(NEC).
S-0092-J
.
2-11.
Selecting
A
Location
And
Connecting
Input
Power
OM-187
321
Page
14
2-12.
Threading
Welding
Wire
rir*~L~Hd
*4
~H
~6in~
(150
mm)
Pull
and
hold
wire;
cut
off
end.
Tools
Needed:
Remove
gun
nozzle
and
contact
tip.
Push
wire
thru
guides
into
gun;
continue
to
hold
wire.
ON
POWER
-e
Qon
Turn
On.
/
Cut
off
wire.
Close
and
latch
door.
Press
gun
trigger
until
wire
comes
out
of
gun.
1111
II
Feed
wire
to
check
drive
roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
Cut
off
wire.
Close
and
latch
door.
Open
pressure
assembly.
Close
and
tighten
pressure
assembly,
and
let
go
of
wire.
-4
Reinstall
contact
tip
and
nozzle.
Ref.
ST-aol
938/Ref.
ST-149
326-A
OM-187
321
Page
15
2-13.
Weld
Parameter
*Do
not
change
Voltage
switch
position
while
welding
Wire
Speed
value
in
Table
is
a
starting
value
only,
and
Wire
Speed
control
sethng
can
be
fine
tuned
during
welding.
S-181
020-A
.
Wire
Type,
Shielding
Gas,
And
Flow
Rate
Wire
Diameter
(inch)
Operator
Controls
Material
Thickness
3/8in
(9.5
mm)
1/4in
(6.4
mm)
3/l6in
(4.8
mm)
1/8in
(3.2
mm)
12
ga
14
ga
16
ga
18
ga
20
ga
22
ga
E7OS-6
Co2
20
cfh+
.023
Voltage
Tap
-
-
6
5
4
3
3
2
1
1
-
-
Wire
Speed
- -
100 90
70
65 60
40
25
20
-
-
.030
Voltage
Tap
-
-
4
4
3
2
2
2
1
-
-
- -
Wire
Speed
-
-
70
60
50
45
40
30
25
-
-
-
-
.035
Voltage
Tap
6
4 4
3
3
2 2
1
- -
-
-
Wire
Speed
80
65
40
35
30
25
30
10
-
-
-
-
E7OS-6
75%
Argon
25%
CO2
20
cfh+
.023
Voltage
Tap
- -
3
4
3
3
2
2
1
1
1
WireSpeed
--
80
90
70
60
70
40
45
25 12
.030
Voltage
Tap
6
4 4
3
3
2
2
1
1
- -
Wire
Speed
90
58
70
55 50
48
45
30
5
- -
.035
Voltage
Tap
6
4
4
3
3
2
2
1
1
-
-
Wire
Speed
80
48
60
50 35
27
30
11
3
-
-
E71
T-GS
Flux
Core
.030
Voltage
Tap
5
4
4
3
2 2
1
1
-
-
-
-
Wire
Speed
80
65
65
50
30
30
10
5
-
-
- -
.035
Voltage
Tap
5
4
3
2
2
2
1 1
- -
-
-
Wire
Speed
50
50 40
30
25
20
10
0
- -
-
-
ER
308
Stainless
Steel
Tn-Mix
20
cfh+
.023
VoltageTap
5 4
4
4
3 3
3
2
2
2
Wire
Speed
95 85
80
60
50
50
50
30
20
20
.030
Voltage
Tap
5 5
4
3
3
2
2
2
1
-
-
Wire
Speed
70 70
70
50 45
50
45
40
0
-
-
.035
Voltage
Tap
6
5
5
4
3 2
2
2
- -
- -
Wire
Speed
65
40
40
30 30
25
20
10
- -
-
-
OM-187
321
Page
16
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Miller KK289381 Owner's manual

Miller
Brand
Miller
Model
KK289381
Category
Welding System
Type
Owner's manual
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