Miller KG194820 Owner's manual

Miller
Brand
Miller
Model
KG194820
Category
Welding System
Type
Owner's manual

This manual is also suitable for

Miller
September
1996
Form:
OM-183
173A
Effective
With
Serial
No.
KG1
94820
OWNERS
MANUAL
~llJ~
''~~
~
¶'
~
CE
Ae
rowave
fi
CC
ACIDC
Welding
Power
Source
For
GTAW
And
SMAW
Welding
Rated
Welding
Output
Amperes
Input
at
AC
Balanced
Rated
Load
Output;
50
Hz
KVA
KW
Amperage
Range
Max
OCV
380
V
415
V
Three-Phase:
NEMA
Class
I
(60)
300
Amperes,
32
Volts
AC/DC,
60%
Duty
Cycle
23
21
14.8
14
1375
A
90
Single-Phase:
NEMA
Class
I
(60)
200
Amperes,
28
Volts
AC/DC,
60%
Duty
Cycle
61
54
23.1
21.1
1350
A
90
cover_om
4/95
5T-800
311-B
'
1996
MILLER
Electric
Mfg.
Co.
PRINTED
IN
USA
MILLERS
TRUE
BLUEfi
LIMITED
WARRANTY
Effective
February
7,
1996
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
warranty
supersedes
all
previous
MILLER
warranties
and
is
exclusive
with
no
other
guarantees
or
warranties
exprassed
or
impliad.
I,
LIMITED
WARRANTY
Subject
to
theterma
and
conditions
below,
MILLER
Electric
Mtg.
Co.,
Appleton.
Wisconsin,
warrants
to
its
original
retail
purchaser
that
new
MILLER
equipment
sold
after
the
effective
date
ot
this
limited
warranty
is
twe
of
de
fects
in
material
and
workmanship
at
the
time
it
is
shipped
by
MILLER.
THIS
WAR
RANTY
IS
EXPRESSLY
IN
LIEU
OF
ALL
OTHER
WARRANTIES,
EXPRESS
OR
IMPUED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILJTY
AND
FIT
NESS.
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war
ranted
parts
orcomponenta
that
fail
due
to
such
defects
in
material
orworfcmanahip.
MILLER
must
be
notified
in
writing
within
thirty
(30)
days
of
auch
defect
or
failure,
at
which
time
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
to
be
followed.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
such
a
failure
within
the
warranty
time
periods.
Alt
warmnty
time
periods
start
on
the
date
that
the
equipment
was
delivered
to
the
original
retail
purchaser,
or
one
year
after
the
equipment
is
sent
to
a
North
American
distributor
or
eighteen
months
after
the
equipment
ia
sent
to
an
International
distributor.
1.
5YearaParta3YeareLabor
*
Original
main
power
rectifiers
*
Inverfem
(input
and
output
rectifiers
only)
2.
3
Years
Parts
and
Labor
*
Transformer/Rectifier
Power
Sources
Plasma
Arc
Cutting
Power
Sources
*
Semi-Automatic
and
Automatic
Wire
Feeders
Inverter
Power
Supplies
*
Intellitig
*
Robots
(1
year
labor)
3.
2
Years
Parta
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
Cootant
Systems
*
HFUnita
*
Grids
*
Spot
Welders
Load
Banks
SDX
Transformers
*
Miller
Cyclomatic
Equipment
Running
Gear/Trailers
*
Plasma
Cutting
Torches
(except
APT,
ZIPCUT
&
PLAZCUT
Models)
*
Tecumaeh
Engines
Deutz
Engines
(outside
North
America)
*
Field
Options
(NOTE:
Field
optiona
are
covered
under
True
Bluefi
for
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
for
a
minimum
of
one
year
whichever
is
greater.)
5.
6
Months
Batteries
fi~
go
Days
Parts
and
Labor
*
MIG
GunaTtiG
Torches
*
APT,
ZIPCUT
&
PLAZCUT
Modal
Plasma
Cutting
Torches
*
Remote
Controls
*
Accessory
Kite
Replacement
Parts
MILLERS
True
Bluefi
Umited
Warranty
shall
not
apply
to:
1.
Items
furnished
by
MILLER,
but
manufactured
by
others,
auch
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips,
cutting
nozzles,
contactore
and
relays
or
parts
that
fail
due
to
normal
wear.
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip
ment
that
has
been
improperiy
installed,
improperiy
operated
or
misused
baaed
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necessary
maintenance,
orequipment
which
has
been
used
for
operation
outside
of
the
apecificetiona
for
the
equipment.
MILLER
PRODUCTSARE
INTENDED
FOR
PURCHASE
AND
USE
BYCOMMER
CIAL/1NDUSTRIAL
USERS
AND
PERSONS
TRAINED
AND
EXPERIENCED
IN
THE USE
AND
MAINTENANCE
OF
WELDING
EGUIPMENt
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
exclusive
remedies
ahall
be,
at
MILLERS
option:
(1)
repair;
or
(2)
replacement;
or,
where
authorized
in
writing
by
MILLER
in
appropriate
casea,
(3)
the
reasonable
coat
of
repair
or
replace-
mental
an
authorized
MILLER
service
station;
or
(4)
payment
of
orcredit
forthe
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
return
of
the
goode
at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
will
be
P.0.5.,
Factoryat
Appleton,
Wisconain,
or
FOB.
at
a
MILLER
authorized
ser
vice
facility
as
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
coats
of
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENTSHALL
MILLER
BE
UABLE
FOR
DIRECt
INDIRECt
SPECIAL,
INCIDENTALOR
CONSEOUENTIAL
DAMAGES
(INCLUDING
LOSS
OF
PROFIT),
WHETHER
BASED
ON
CON
TRAC1
TORT
OR
ANY
OTHER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
OR
REPRESENTATION
ASTO
PERFORMANCE,
AND
ANY
REMEDY
FOR
BREACH
OF
CONTRACT
TORT
OR
ANY
OTHER
LEGAL
THEORY
WHICH,
BUT
FOR
THIS
PROVISION,
MIGHT
ARISE
BY
IMPLICATION,
OPERATION
OF
LAW,
CUSTOM
OF
TRADE
OR
COURSE
OF
DEAUNG,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EOUIPMENT
FURNISHED
BY
MILLER
IS
EXCLUDED
AND
DISCLAIMED
BY
MILLER.
Some
states
in
the
U.S.A.
do
not
allow
limitations
of
how
long
an
implied
warranty
lesta,
or
the
exclusion
of
incidental,
indirect,
apecial
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
Thia
warranty
provides
spe
cific
legal
rights,
end
other
rights
may
be
available,
but
may
vary
from
state
to
state.
In
Canada,
legislation
in
some
provinces
provides
for
certain
additional
warranties
or
remedies
other
than
as
stated
herein,
and
to
the
extent
that
they
may
not
be
waived,
the
limitations
and
exclusions
set out
above
may
not
apply.
This
Umited
Werranty
provides
specific
legal
rights,
and
other
righta
may
be
available,
but
may
vary
from
province
to
province.
WHO
DO
I
CONTACT?
For
help,
contact
your
diStributor
For
additional
information,
such
as
Technical
Manuals
(SerVice
And
Parts)
Engine
Manuals
Circuit
And
Wiring
Diagrams
Process
Handbooks
To
file
a
claim
for
loss
or
damage
during
shipment,
contact
the
deliVering
cartier
Fer
assistance
in
filing
or
settling
claims,
contact
your
distributor
and/or
equipment
manufactUrers
Transportation
Department
(j~jj1
T~T1
Miller
Electric
Mfg.
Co.
CALL:
414-735-4505
FAX:
800-637-2348
(in
USA),
or
414-735-4136
(outside
USA)
Users
Guides
Distributor
Directories
contact
your
distributor
.
1e
o~
=
.
WRITE:
Miller
Electric
Mfg.
Co.
P0.
BoX
1079
Appleton,
WI
54912
USA
Always
provide
Model
Name
and
Serial
or
Style
Number
:1
milleLwarl
3/g6
Declaration
of
Conformity
For
European
Community
(CE)
Products
N
OTE
~
This
in
formation
is
provided
for
units
with
CE
certification
(see
rating
label
on
unit.)
Manufacturers
Name:
Miller
Electric
Mfg.
Co.
Manufacturers
Address:
1635
W.
Spencer
Street
Appleton,
WI
54914
USA
Declares
that
the
product
Pe
rowave
fi
conforms
to
the
following
Directives
and
Standards:
Directives
Machine,y
Directives:
89/392/EEC,
91/368/EEC,
93/C
133/04,
93/68/EEC
Electromagnetic
Capabillty
Directives:
89/336,
92/31/EEC
Standards
Electromagnetic
compatibility
(EMC)
Product
standard
for
arc
welding
equipment:
EN50199:
August
1995
European
Contact:
Mr.
Luigi
Vacchini,
Managing
Director
MILLER
Europe
S.P.A.
Via
Privata
lseo
20098
San
Giuliano
Milanese,
Italy
Telephone:
39(02)98290-1
Fax:
39
(02)98281
-552
decconi
10/95
SECTION
1
-
SAFETY
PRECAUTIONS
FOR
ARC
WELDING
sat
oty_somi
4/95
1-1.
Symbol
Usage
4A
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
A
Marks
a
special
safety
message.
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
~
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
I
actions
to
avoid
the
hazards.
1-2.
Arc
Welding
Hazards
A~
WARNING
The
symbols
shown
below
are
used
throughout
this
manual
to
call
attention
to
and
identify
possible
hazards.
When
you
see
the
symbol,
watch
out,
and
follow
the
related
instructions
to
avoid
the
hazard.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
found
in
the
Safety
Standards
listed
in
Section
1-4.
Read
and
follow
all
Safety
Standards.
Only
qualified
persons
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
nower
~nrd
nrnund
wire
i~
~~
~~
to
around
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
powercord
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
near
the
weld
-
-
-
-
-
- -
--
-
M,
%JIJCI
ly
SnJI
II
IOSnCSS
-
-
-
-
-
-
VYflfl
~MI~~C
Sn
11511
flt~IJ~51S~
-
-
-
ARC
RAYS
can
burn
eyes
and
skin;
ARC
RAYS
NOISE
can
damage
hearing;
FLYING
~
SLAG
OR
SPARKS
can
injure
eyes.
2.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
to
protect
your
face
and
eyes
when
welding
or
watching
(see
ANSI
Arc
rays
from
the
welding
process
produce
intense
Z49.1
and
Z87.1
listed
in
Safety
Standards).
--
visible
and
invisible
(ultraviolet
and
infrared)
rays
3.
Wear
approved
safety
glasses
with
side
shields.
-
that
can
burn
eyes
and
skin.
Noise
from
some
processes
can
damage
hearing.
Chipping,
4.
Use
protective
screens
or
barriers
to
protect
others
from
flash
grinding,
and
welds
cooling
throw
off
pieces
of
metal
or
slag.
and
glare;
warn
others
not
to
watch
the
arc.
NOISE
5.
Wear
protective
clothing
made
from
durable,
flame-resistant
1.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
material
(wool
and
leather)
and
foot
protection.
hazardous
to
your
health.
wearing
an
air-supplied
respirator.
Always
have
a
trained
r~
FUMES
AND
GASES
can
be
5.
Work
in
a
confined
space
only
if
it
is
well
ventilated,
or
while
Welding
produces
fumes
and
gases.
Breathing
watchperson
nearby.
Welding
fumes
and
gases
can
displace
air
these
fumes
and
gases
can
be
hazardous
to
your
and
lower
the
oxygen
level
causing
injury
or
death.
Be
sure
the
health.
breathing
air
is
safe.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
form
highly
toxic
and
irritating
gases.
2.
If
inside,
ventilate
the
area
and/or
use
exhaust
at
the
arc
to
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
deaners,
and
degreasers.
containing
these
elements
can
give
off
toxic
fumes
if
welded.
OM-183
173
Page
1
OVERUSE
can
cause
OVERHEATED
EQUIPMENT.
Allow
cooling
period.
Reduce
current
or
reduce
duty
cycle
before
starting
to
weld
again.
Follow
rated
duty
cycle.
Put
on
grounded
wrist
strap
BEFORE
L.
boards
or
parts.
Use
proper
static-proof
bags
and
boxes
to
store,
move,
or
ship
PC
boards.
SIGNIFICANT
DC
VOLTAGE
exists
after
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.
-
STATIC
ELECTRICITY
can
damage
parts
on
circuit
boards.
1-4.
Principal
Safety
Standards
.1
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
1.
Shut
off
shielding
gas
supply
when
not
in
use.
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.i,
from
American
Welding
Society,
550
N.W.
Le.Jeune
Ad,
Miami
FL
33126
Safety
and
Health
Standards,
OSHA
29
CFR
1910,
from
Superintendent
of
Documents,
U.S.
Government
Printing
Office,
Washington,
D.C.
20402.
Recommended
Safe
Practices
for
the
Preparation
for
Welding
and
Cutting
of
Containers
That
Have
Held
Hazardous
Substances,
American
Welding
Society
Standard
AWS
F4.i,
from
American
Welding
Society,
550
N.W.
LeJeune
Ad,
Miami,
FL
33126
National
Electrical
Code,
NFPA
Standard
70,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
Safe
Handling
of
Compressed
Gases
in
Cylinders,
CGA
Pamphlet
P-i,
from
Compressed
Gas
Association,
1235
Jefferson
Davis
Highway,
Suite
501,
Arlington,
VA
22202.
Code
for
Safety
in
Welding
and
Cutting,
CSA
Standard
Wi
17.2,
from
Canadian
Standards
Association,
Standards
Sales,
178
Rexdale
Boulevard,
Rexdale,
Ontario,
Canada
M9W
1
R3.
Safe
Practices
For
Occupation
And
Educational
Eye
And
Face
Protection,
ANSI
Standard
Z87.1,
from
American
National
Standards
Institute,
1430
Broadway,
New
York,
NY
10018.
Cutting
And
Welding
Processes,
NFPA
Standard
51B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
1-5.
EMF
Information
Considerations
About
Welding
And The
Effects
Of
Low
Frequency
Electric
And
Magnetic
Fields
The
following
is
a
quotation
from
the
General
Conclusions
Section
of
the
U.S.
Congress,
Office
of
Technology
Assessment,
Biological
Effects
of
Power
Frequency
Electric
&
Magnetic
Fields
Background
Paper~
OTA-BP-E-53
(Washington,
DC:
U.S.
Government
Printing
Office,
May
1989):
.
.
.
there
is
now
a
very
large
volume
of
scientific
findings
based
on
experiments
at
the
cellular
level
and
from
studies
with
animals
and
people
which
clearly
establish
that
low
frequency
magnetic
fields
can
interact
with,
and
producechanges
in,
biological
systems.
While
most
of
this
work
is
of
very
high
quality,
the
results
are
complex.
Current
scientific
understanding
does
not
yet
allow
us
to
interpret
the
evidence
in
a
single
coherent
framework.
Even
more
frustrating,
it
does
not
yet
allow
us
to
draw
definite
conclusions
about
questions
of
possible
risk
or
to
offer
clear
science-based
advice
on
strategies
to
minimize
or
avoid
potential
risks.
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
the
body.
4.
Keep
welding
power
source
and
cables
as
far
away
as
practical.
5.
Connect
work
clamp
to
workpiece
as
close
to
the
weld
as
possible.
About
Pacemakers:
The
above
procedures
are
also
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
OM-183
173
Page
3
Warning!
Watch
Out!
There
are
,~___
possible
hazards
as
shown
by
the
symbols.
1
Electnc
shock
from
welding
electrode
or
wiring
can
kill.
1.1
Wear
dry
insulating
gloves.
Do
not
touch
electrode
with
bare
hand.
Do
not
wear
wet
or
damaged
gloves.
1.2
Protect
yourself
from
electric
shock
by
insulating
yourself
from
work
and
ground.
Disconnect
input
plug
or
power
before
working
on
machine.
Breathing
welding
fumes
can
be
hazardous
to
your
health.
2.1
Keep
your
head
out
of
the
2.2
Use
forced
ventilation
or
local
exhaust
to
remove
the
fumes.
2.3
Use
ventilating
fan
to
remove
fumes.
3
Welding
sparks
can
cause
explosion
or
fire.
3.1
Keep
flammables
away
from
welding.
Dont
weld
near
flammables.
3.2
Welding
sparks
can
cause
fires.
Have
a
fire
extinguisher
nearby
and
have
a
watch
person
ready
to
use
it.
3.3
Do
not
weld
on
drums
or
any
closed
containers.
4
Arc
rays
can
bum
eyes
and
injure
skin.
4.1
Wear
hat
and
safety
glasses.
Use
ear
protection
and
button
shirt collar.
Use
welding
helmet
with
correct
shade
of
filter.
Wear
complete
body
protection.
Become
trained
and
read
the
instructions
before
working
on
the
machine
or
welding.
Do
not
remove
or
paint
over
(cover)
the
label.
SECTION
2-
DEFINITIONS
2-1.
Warning
Label
Definitions
OM-183
173
Page
4
2-2.
Rating
Label
For
CE
Products
EN
60974-1
U0
=
90V
lA/i
OV
375A/25V
40% 60%
100%
375A
300A
235A
19.4V
1
A/20V
375A/35V
40% 60%
100%
375A
300A
235A
29.4V
U0
=
90V
U1
380V
umax
23A
1ietf
14.6A
3
50Hz
U2
415V
umax
21A
1ien
13.4A
Q
=
4.0
Kvar
1
A/i
OV
350A/24V
20%
60%
100%
350A
200A
155A
U0
=
90V
16.2V
1
A/20V
350A/34V
20%
60%
100%
350A
200A
1
55A
26.2V
U0
=
90V
U1
380V
umax
61A
1leff
27A
1~
50Hz
U2
415V
umax
54A
he~
24A
OM-183
173
Page
5
2-3.
Symbols
And
Definitions
a4~~
Amperes
0
PanelLocal
Q$
Gas
Tungsten
Arc
Welding
(GTAW)
~t:
.
..
Shielded
Metal
Arc
Welding
(SMAW)
V
Volts
f
Frequency
V
Itfi
Over
Voltage
....
t
Spot
Timer
c?~
Output
Circuit
Breaker
Remote
Touch
Start
(GTAW)
.=
Protective
Earth
(Ground)
P\,
Alternating
Current
High
Frequency
-
Start
Input
t2
Postflow
Timer
ti
Preflow
Timer
Q
Kvar
El
F
High
Frequency
S
Seconds
Gas
Input
Gas
Output
f~
Gas
(Supply)
On
Q
Off
Thickness
Gauge
Direct
Current
11~~
Balance
Control
.h~
~
Maximum
Cleaning
-~
Maximum
Penetration
+
A
~
..
Electrode
Positive
/\

Electrode
Negative
Work
.~~44
Electrode
3\,
Three-Phase
j1~j~
Pulse
Frequency
%
Pulse
Percent
On
Time
JlJl~
Pulse
Background
Amperage
liz
He~
~Jt~,
Start
Time
~~\
Start
Amperage
Final
Slope
O,Z0
Percent
U
o
Rated
No
Load
Voltage
(Average)
U1
Pnmar~,
Voltage
~J2
Conventional
Load
Voltage
IJ
~
Line
Connection
I.~
PnmaryCurrent
12
Rated
Welding
Current
X
DutyCycle
3D-J~jj~
Three-Phase
CombinedAC/DC
Power
Source
I
P
Degree
Of
Protection
1
eff
Maximum
Eftective
Supply
Current
1
max
Rated
Maximum
Supply
Current
Spark
Gap
()
Increase/Decrease
Of
Quantity
At
Final
Sequence
Two-Step
Trigger
Operation
(GTAW)
t.~j~j
Four-Step
Trigger
Operation
(GTAW)
~~~f\
Initial
Sequence
Final
Amperage
J$~j_
Final
Time
f~\
Initial
Slope
Press
And
Hold
L~
Trigger
Hold
(GTAW)
Itfi
High
Temperature
1
~
Single-Phase
OM-183
173
Page
6
SECTION
3-INSTALLATION
3-1.
Dimensions
And
Weights
A
35-1/2
in
(910
mm)
B
24in(615mm)
C
22-3/4
in
(583
mm)
*With
lifting
eye
down
Weight
c~
Dimensions
B
dim_i
3/96
-
ST-800
402
/
ST-i
17
264-C
3-2.
Selecting
A
Location
351
lb
(159
kg)
OM-183
173
Page
7
3-3.
115
VAC
Receptacle,
Circuit
Breaker,
And
Shielding
Gas
Connections
3-4.
Weld
Output
Terminals
And
Selecting
Cable
Sizes
A
ARC
WELDING
can
cause
Electromagnetic
Interference.
To
reduce
possible
interference,
keep
weld
cables
as
short
as
possible,
close
together,
and
down
low,
such
as
on
the
floor.
Locate
welding
operation
100
meters
from
any
sensitive
electronic
equipment.
Be
sure
this
welding
machine
is
installed
and
grounded
according
to
this
manual.
If
interference
still
occurs,
the
user
must
take
extra
measures
such
as
moving
the
welding
machine,
using
shielded
cables,
using
line
filters,
or
shielding
the
work
area.
~i~~Ei
Weld
Output
Terminals
Welding
Amperes
Total
Cable
(Copper)
Length
In
Weld
Circuit
Not
Exceeding
100
ft
(30
m)
Or
Less
150ft
(45
m)
200ft
1
(60
m)
250ft
I
_(70_m)_
300ft
(90
m)
350ft
(105_m)j
400ft
(120
m)
1060%
Duty
Cycle
60100%
Duty
Cycle
10
100%
Duty
Cycle
100
r~
150
200
250
300
350
400
Ref.
ST-800
312-A
500
4
4
4
3
2
1
1/0 1/0
3
3
3
2
2
1
1
1/0
1/0
2/0
2/0
3/0
3/0
4/0
3/0
4/0
2
1
1/0
2/0
3/0 4/0
2-2/0 2-2/0
1
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
1/0
2/0
3/0
4/0
2-2/0
2-3/0
2-3/0
2-4/0
1/0
2/0
3/0
4/0
2-210 2-3/0 2-4/0
2-4/0
2/0
3/0
4/0
2-2/0 2-3/0
2-4/0 3-3/0
3-3/0
Weld
cable
size
(AWG)
is
based
on
either
a
4
volts
or
less
drop
or
a
current
density
of
at
least
300
circular
mils
per
ampere.
S.0007-D
1
ll5Vl5AACReceptacle
RC2
2
Circuit
Breaker
CB1
Receptacle
is
protected
from
over
load
byCBl.
Press
button
to
reset
breaker.
3
Gas
Fittings
2
Fittings
have
5/8-18
right-hand
threads.
4
Cylinder
Valve
Open
valve
slightly
so
gas
flow
blows
dirt
from
valve.
Close
valve.
5
Regulator/Flowmeter
6
Flow
Adjust
I
3
Typical
flow
rate
is
15
cfh
(cubic
feet
per
hour).
Tools
Needed:
~
5/8,1-1/Bin
Ref.
ST-800
312-A/Ref.
ST-i
58 697-A
OM-183
173
Page
8
3-5.
Remote
14
Receptacle
Information
3-6.
Electrical
Service
Guide
A
24
volts
ac.
f~
~
OWPUT
(CONTPC1OR)
B
Contact
closure
to
A
completes
24
volts
ac
contactor
control
circuit.
Three-Phase
Input
Voltage
380
415
Input
Amperes
At
Rated
Output
23
21
Max
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes
35
30
Mm
Input
Conductor
Size
In
AWG/Kcmil
12
12
Max
Recommended
Input
Conductor
Length
In
Feet
(Meters)
132(40)
158(48)
Mm
Grounding
Conductor
Size
In
AWGIKcmiI
12
12
Reference:
1996
National
Electrical
Code
(NEC).
S-0092J
Single-Phase
Input
Voltage
380
415
Input
Amperes
At
Rated
Output
61
54
Max
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes
90
80
Mm
Input
Conductor
Size
In
AWGIKcmil
8
8
Max
Recommended
Input
Conductor
Length
In
Feet
(Meters)
127(39)
151
(46)
Mm
Grounding
Conductor
Size
In
AWGIKcmII
8
8
Reference:
1996
National
Electrical
Code
(NEC).
S-0092J
ri
Socket*
Information
L
C
Command
reference;
0
to
+10
volts
dc
output
to
remote
control.
D
A
AMPERAGE
Remote
control
circuit
common.
E
*The
remaining
sockets
are
not
used.
Ref.
ST-800
312-A
0
to
+10
volts
dc
input
command
signal
from
remote
control.
K
Circuit
Common.
OM-183
173
Page
9
3-7.
Placing
Jumper
Links
I
OM-183
173
Page
10
3-8.
Connecting
Input
Power
OM-183
173
Page
11
4-1.
Controls
SECTION
4-
OPERATION
4-2.
Polarity
Switch
And
Pilot
Lights
Mode
Switch
(See
Section
4-3)
Amperage
Switch
(See
Section
4-6)
Output
Switch
And
Light
(See
Section
4-5)
Start
Switch
(See
Section
4-11)
Polarity
Switch
And
Lights
(See
Section
4-2)
Amperage/Preset
Meter
(See
Section
4-4)
Voltmeter
(See
Section
4-4)
Amperage
Adjustment
Controls
(See
Section
4-6)
AC
Frequency
Controls
(See
Section
4-9)
High
Temperature
Shutdown
Light
Over
Voltage
Shutdown
Light
See
Section
5-2)
Postflow
Time
Control
(See
Section
4-10)
AC
Balance
Controls
(See
Section
4-8)
Power
On/Off
Switch
(See
Section
4-12)
A
Do
not
use
AC
output
in
damp
areas,
if
movement
is
confined,
or
if
there
is
a
dan
ger
of
falling.
Use
AC
output
ONLY
if
required
for
the
welding
process,
and
then
use
a
remote
output
control.
1
Polarity
Switch
Use
switch
to
select
weld
output.
2
Electrode
Positive
Pilot
Light
3
Electrode
Negative
Pilot
Light
Both
lights
go
on
when
switch
is
in
AC
position.
2
23
\
4
\
5
\
3
6
\n
\ \\
4
78
II
9
I
~0
5
10
11
II
I
EU\i~V\L7iL
I
/
6
I
Pt
7
II
~oII
ii
8
~-
12
9
10
11
13
12
13
14
14
A
Wear
approved
ear
muffs
or
ear
plugs
if
noise
exposure
exceeds
OSHA
limits.
5T-800
312-A
+1-
Ref.
ST-i
69
496-A
OM-183
173
Page
12
4-3.
Mode
Switch
4-4.
Amperage/Preset
Meter
And
Voltmeter
4-5.
Output
Switch
And
Pilot
Light
A
Weld
output
terminals
are
energized
when
switch
is
On
and
power
is
On.
Do
not
touch
torch
or
electrode
and
work
clamp
at
the
same
time.
1
Output
Switch
2
Pilot
Light
Use
switch
to
select
way
of
control
ling
unit
output.
For
weld
output,
place
switch
in
On
position.
For
remote
output
control,
place
switch
in
Remote
14
position
(see
Section
3-5).
Pilot
light
stays
on
continuously
in
On
position,
but
only
when
contac
tor
is
energized
in
Remote
14
position.
1
Mode
Switch
Use
switch
to
select
SMAW
or
either
GTAW
welding
process.
Selecting
either
GTAW
position
en
ables
the
Start
switch
and
gas
valve;
both
are
disabled
when
the
Q
..~
SMAW
position
is
selected.
GTAW
Trigger
Hold
functions
as
follows:
Press
torch
switch
to
start
arc.
Switch
can
be
released
and
arc
re
mains
on.
Press
switch
to
stop
arc.
~~~~1
1
Amperage/Preset
Meter
Use
meter
to
preset
amperage,
ac
frequency,
and
ac
balance.
Meter
displays
average
weld
amperage
output
of
unit
to
nearest
ampere
when
welding.
2
Voltmeter
Voltmeter
displays
average
volt
age
(to
the
nearest
0.1
V)
at
the
weld
output
terminals.
A
V
O~2
I
I,~I~
OM-183
173
Page
13
4-6.
Amperage
Adjustment
Controls
1
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.
2
Electrode
Positive
Amperage
Adjustment
Control
And
Pushbutton
Set
Polarity
switch
to
AC,
press
pushbutton
and
use
control
and
Amperage/Preset
meter
to
adjust
weld
amperage
for
positive
half
of
ac
square
wave.
When
Polarity
switch
is
in
Elec
trode
Positive
position,
push
button
does
not
need
to
be
pressed
to
adjust
control.
3
Electrode
Negative
Amperage
Adjustment
Control
And
Pushbutton
Set
Polarity
switch
to
AC,
press
pushbutton
and
use
control
and
Amperage/Preset
meter
to
adjust
weld
amperage
for
negative
half
of
ac
square
wave.
When
Polarity
switch
is
in
Elec
trode
Negative
position,
pushbut
ton
does
not
need
to
be
pressed
to
adjust
control.
The
controls
require
3
tums
to
go
from
minimum
to
maximum,
and
may
be
adjusted
while
welding.
Set
Electrode
Positive
Amperage
Level
)
Set
Electrode
Negative
Amperage
Level
Output
+150
A
Electrode
Positve
______
250
A
Electrode
Negative
Ref.
ST-169
496-A/
Ref.
s-0865
0
1A14
A
3
~
If
Polarity
switch
is
set
incorrectly,
the
Amperage/Preset
meter
goes
blank
when
the
pushbutton
is
pressed.
Example:
Setting
Amperage
For
AC
Output:
ft
150
AMPERAGE/PRESET
~offl
AMPERAGE/PRESET
AI~
OM-183
173
Page
14
1
Fingertip
Control
2
Remote
Foot
Control
3
Remote
Hand
Control
See
examples
below.
Min=1A
AC
C
Max=150
A
EP/250
A EN
3
Min=1
AAC
Percentage
Of
Range
=
50%
Max
=
75
A
EP(50%
of
ito
150)1
125
A EN
(50%
of
1
to
250)
Set
Desired
Maximum
Amperages
Adjust
Remote
Control
Ref.
ST-169496-A/S-0621-C/S-0774/ST-159059
4-7.
Examples
Of
Combination
Remote
Amperage
Control
0
o
I
,~
~L
0
0
LO
S
~~14
?~
0
+1-
A
Set
Switches
Di
50
AMPERAGEIPRESET
Set
Output
1
A~
0250
ifi
AMPERAGE/PRESET
Ak
OM-183
173
Page
15
4-8.
AC
Balance
Control
Balance
control
Waveform
Examples
Balanced
~
50
~
50%
Electrode
$~LFL
Positive
50%
Electrode
Negative
2
More
Penetration
~
0.0
Positive
10%
Electrode
 
90%
Electrode
Negative
2
More
Cleaning
~
30.0
70%
Electrode
Positive
~RE~
30%Electrode
Negative
4-9.
AC
Frequency
Controls
1
AC
Balance
Control
And
~
If
Polarity
switch
is
not
in
AC,
the
Amperage/Preset
Pushbutton
meter
goes
blank
when
the
pushbutton
is
pressed.
Set
Polarity
switch
to
AC.
Use
pushbutton,
control,
and
Amper
age/Preset
meter
to
change
the
ac
output
square
wave.
The
control
requires
3
tums
to
go
from
mini
mum
to
maximum.
Set
balance
towards
30.0
to
obtain
more
cleaning
action
of
the
work-
piece,
or
towards
90.0
to
obtain
deeper
penetration
of
the
work-
piece.
50.0
(balanced),
provides
equal
penetration
and
cleaning
action.
Ref.
ST-i
69496-A
/
5-0865
~
If
Polarity
switch
is
not
in
AC,
the
Amperage/Preset
meter
goes
blank
when
the
pushbutton
is
pressed.
1
AC
Frequency
Control
And
Pushbutton
Set
Polarity
switch
to
AC.
Press
pushbutton
and
use
control
and
Amperage/Preset
meter
to
set
ac
frequency.
Range
is
40
to
400
hertz.
The
control
requires
3
tums
to
go
from
minimum
to
maximum.
For
most
applications,
increasing
frequency
improves
arc
stability.
rL~rLru
OM-183
173
Page
16
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Miller KG194820 Owner's manual

Miller
Brand
Miller
Model
KG194820
Category
Welding System
Type
Owner's manual
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