AUTO
ARCJ
December
1995
Form:
OM-157
066D
Effective
With
Serial
No.
KG034070
OWNERS
MANUAL
~l
U
~
-.
Read
and
follow
these
instructions
and
all
safety
blocks
carefully.
Have
only
trained
and
qualified
persons
install,
operate,
or
service
this
unit.
Call
your
distributor
if
you
do
not
understand
the
directions.
~
Give
this
manual
to
the
operator.
1I~fl
For
help,
call
your
distributor
or:
MILLER
Electric
Mfg.
Co.,
P.O.
Box
1079,
Appleton,
WI
54912
414-734-9821
Auto
Arcfi
Model
255
DC/CV
Welding
Power
Source/Wire
Feeder
For
GMAW
And
FCAW
Welding
Uses
.023
.045
Hard
Wire
And
.030
.045
Flux
Cored
Wire
200
Amperes,
28
Volts
DC
At
60%
Duty
Cycle
Uses
Single-Phase
Input
Power
Overheating
And
Motor
Overload
Protection
Includes
Gun
And
Shielding
Gas
Valve
auto_arc
7/93
ST-157
072-A
PRINTED
IN
USA
MILLERS
TRUE
BLUEfi
LIMITED
WARRANTY
Effective
January
1,
1995
(Equipment
with
a
serial
number
preface
of
KD
or
newer)
This
limited
wsrrsnty
supersedes
eli
previous
MILLER
wsrrsnties
snd
is
esclusive
with
no
other
guarantees
or
wsrrenties
expressed
or
implied.
U
LIMITED
WARRANTY
Subject
to
the
terms
snd
conditions
below,
MILLER
Electric
Mt
g.
Co.,
Appleton,
Wisconsin,
wsrrsnts
to
its
originsl
retsil
purchaser
that
new
MILLER
equipment
sold
after
the
effective
dale
of
this
limited
warranty
is
free
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
IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY
AND
FIT
NESS.
Within
the
warranty
periods
listed
below,
MILLER
will
repair
or
replace
any
war
ranted
parts
or
components
that
fail
due
to
such
defects
in
material
or
workmanship.
MILLER
must
be
notified
in
writing
within
thirty
(30)
days
of
such
detect
or
failure,
at
which
lime
MILLER
will
provide
instructions
on
the
warranty
claim
procedures
lobe
followed.
MILLER
shall
honor
warranty
claims
on
warranted
equipment
listed
below
in
the
event
of
such
a
failure
within
the
warranty
time
periods.
All
warranty
lime
periods
start
on
the
dale
that
the
equipment
wax
delivered
to
the
original
retail
purchaser,
or
one
year
after
the
equipment
is
sent
to
a
North
American
distributor
or
eighteen
months
aher
the
equipment
ix
sent
to
an
tntemational
distributor.
1.
5
Years
Parts
3
Years
Labor
Original
main
power
rectifiers
Inverters
(input
and
output
rectifiers
only)
2.
3
Years
Parts
and
Labor
*
Transtormer/Rectifier
Power
Sources
Plasma
Arc
Culling
Power
Sources
Semi-Automatic
and
Automatic
Wire
Feeders
Inverter
Power
Supplies
Inlellitigs
Robots
3.
2 Years
Parts
and
Labor
Engine
Driven
Welding
Generators
(NOTE:
Engines
are
warranted
separately
by
the
engine
manufacturer.)
Air
Compressors
4.
1
Year
Farm
and
Labor
Motor
Driven
Guns
Process
Controllers
*
IHPS
Power
Sources
Water
Coolant
Systems
HF
Units
Grids
Spot
Welders
Load
Banks
SDX
Transformers
Running
Gear/Trailers
Plasma
Culling
Torches
(except
APT,
ZIPCUT
&
PLAZCUT
Models)
Tecumseh
Engines
DeuI.z
Engines
(outside
North
America)
Field
Options
(NOTE:
Field
options
are
covered
under
True
Bluefi
for
the
remaining
warranty
period
of
the
product
they
are
installed
in,
or
for
a
minimum
ot
one
year
whichever
is
greater.)
.1
6
Months
Batteries
6.
90
Days
Parts
and
Labor
MIG
Guna/TIG
Torches
APT,
ZIPCUT
&
PLAZCUT
Model
Plasma
Culling
Torches
Remote
Controls
Accessory
Kits
Replacement
Parts
MILLERS
True
Bluefi
Umited
Warranty
shall
not
apply
to:
1.
Items
furnished
by
MILLER,
but
manufactured
by
others,
such
as
engines
or
trade
accessories.
These
items
are
covered
by
the
manufacturers
warranty,
if
any.
2.
Consumable
components;
such
as
contact
tips,
culling
nozzles,
contactorx
.and
relays
or
pans
that
tail
due
to
normal
wear.
3.
Equipment
that
has
been
modified
by
any
party
other
than
MILLER,
or
equip
ment
that
has
been
improperly
installed,
improperly
operated
or
misused
based
upon
industry
standards,
or
equipment
which
has
not
had
reasonable
and
necessary
maintenance,
or
equipment
which
has
been
used
for
operation
outside
of
the
specifications
for
the
equipment.
MILLER
PRODUCTS
ARE
INTENDED
FOR
PURCHASE
AND
USE
BY
COMMER
CIAL/INDUSTRIAL
USERS
AND PERSONS
TRAINED
AND
EXPERIENCED
IN
THE
USE
AND
MAINTENANCE
OF
WELDING
EQUIPMENT
In
the
event
of
a
warranty
claim
covered
by
this
warranty,
the
escfusive
remedies
ahall
be,
at
MILLERS
option:
(1
(repair;
or
(2)
replacement;
or,
where
authorized
in
writing
by
MILLER
in
appropriate
cases,
(3)
the
reasonable
cost
of
repair
or
replace
ment
at
an
authorized
MILLER
service
station;
or
(4)
payment
of
or
credit
for
the
pur
chase
price
(less
reasonable
depreciation
based
upon
actual
use)
upon
retum
of
the
goods
at
customers
risk
and
expense.
MILLERS
option
of
repair
or
replacement
will
be
FOB.,
Factory
at
Appleton,
Wisconsin,
or
FOB.
at
a
MILLER
authorized
ser
vice
facilrty
ax
determined
by
MILLER.
Therefore
no
compensation
or
reimburse
ment
for
transportation
costs
of
any
kind
will
be
allowed.
TO
THE
EXTENT
PERMITTED
BY
LAW,
THE
REMEDIES
PROVIDED
HEREIN
ARE
THE
SOLE
AND
EXCLUSIVE
REMEDIES.
IN
NO
EVENT
SHALL
MILLER
BE
LIABLE
FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL
DAMAGES
(INCLUDING
LOSS OF
PROFIT),
WHETHER
BASED
ON
CON
TRACT,
TORT
OR
ANY
0TH
ER
LEGAL
THEORY.
ANY
EXPRESS
WARRANTY
NOT
PROVIDED
HEREIN
AND
ANY
IMPLIED
WAR
RANTY,
GUARANTY
DR
REPRESENTATtON
ASTD
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
DR
COURSE
OF
DEAUNG,
IN
CLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
PARTICULAR
PURPOSE,
WITH
RESPECT
TO
ANY
AND
ALL
EQUIPMENT
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
lasts,
or
the
exclusion
of
incidental,
indirect,
special
or
consequential
damages,
so
the
above
limitation
or
exclusion
may
not
apply
to
you.
This
warranty
provides
spe
cific
legal
rights,
and
other
rights
may
be
available,
but
may
vary
Irom
state
to
state.
In
Canada,
legislation
in
some
provinces
provides
tor
certain
additional
warranties
or
remedies
other
than
as
stated
herein,
and
to
the
extent
that
Ihey
may
not
be
waived,
the
limitations
and
exclusions
set
out
above
may
not
apply.
This
Limited
Warranty
provides
specific legal
rights,
and
other
rights
may
be
available,
but
may
vary
from
province
to
province.
RECEIVING-HANDLING
Before
unpacking
equipment,
check
carton
for
any
damage
that
may
have
occurred
during
shipment.
File
any
claims
for
loss
or
damage
with
the
delivering
carrier.
Assistance
for
filing
or
settling
claims
may
be
obtained
from
distributor
and/or
equipment
manufacturers
Transportation
Department.
When
requesting
information
about
this
equipment,
always
provide
Model
Designation
and
Serial
or
Style
Number.
Use
the
following
spaces
to
record
Model
Designation
and
Serial
or
Style
Number
of
your
unit.
The
information
is
located
on
the
rating
label
or
nameplate.
Model
__________
Serial
or
Style
No.
Date
of
Purchase
miller
6/95
ARC
WELDING
SAFETY
PRECAUTIONS
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
touchin9
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.
4.
Disconnect
input
power
or
stop
engine
before
installing
or
servicing
this
equipment.
1.
2.
3.
5.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
Turn
off
all
equipment
when
not
in
use.
Do
not
use
worn,
damaged,
undersized,
or
poorly
spliced
cables.
8.
Do
not
wrap
cables
around
your
body.
9.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground.
10.
Do
not
touch
electrode
while
in
contact
with
the
work
(ground)
circuit.
11.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
12.
Wear
a
safety
harness
to
prevent
falling
if
working
above
floor
level.
13.
Keep
all
panels
and
covers
securely
in
place.
a
WARNING
ARC
WELDING
can
be
hazardous.
PROTECT
YOURSELF
AND
OTHERS
FROM
POSSIBLE
SERIOUS
INJURY
OR
DEATH.
KEEP
CHILDREN
AWAY.
PACEMAKER
WEARERS
KEEP
AWAY
UNTIL
CONSULTING
YOUR
DOCTOR.
In
welding,
as
in
most
jobs,
exposure
to
certain
hazards
occurs.
Welding
is
safe
when
precautions
are
taken.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
that
will
be
found
in
the
Safety
Standards
listed
on
the
next
page.
Read
and
follow
all
Safety
Standards.
HAVE
ALL
INSTALLATION,
OPERATION,
MAINTENANCE,
AND
REPAIR
WORK
PERFORMED
ONLY
BY
QUALIFIED
PEOPLE.
6.
7.
/,..
9~-22-
ARC
RAYS
can
burn
eyes
and
skin;
1.
Wear
a
welding
helmet
fitted
with
a
proper
shade
of
filter
(see
NOISE
can
damage
hearing.
ANSI
Z49.1
listed
in
Safety
Standards)
to
protect
your
face
and
eyes
when
welding
or
watching.
Arc
rays
from
the
welding
process
produce
intense
2.
Wear
approved
safety
glasses.
Side
shields
recommended.
heat
and
strong
ultraviolet
rays
that
can
burn
eyes
3.
Use
protective
screens
or
barriers
to
protect
others
from
flash
and
skin.
Noise
from
some
processes
can
damage
and
glare;
warn
others
not
to
watch
the
arc.
earIng.
4.
Wear
protective
clothing
made
from
durable,
flame-resistant
material
(wool
and
leather)
and
foot
protection.
5.
Use
approved
ear
plugs
or
ear
muffs
if
noise
level
is
high.
FUMES
AND
GASES
can
be
hazardous
5.
Work
in
a
confined
space
only
if it
is
well
ventilated,
or
while
4~
to
your
health.
wearing
an
air-supplied
respirator.
Shielding
gases
used
for
Welding
produces
fumes
and
gases.
Breathing
welding
can
displace
air
causing
injury
or
death.
Be
sure
the
these
fumes
and
gases
can
be
hazardous
to
your
breathing
air
is
safe.
ea
.
6.
Do
not
weld
in
locations
near
degreasing,
cleaning,
or
spraying
operations.
The
heat
and
rays
of
the
arc
can
react
with
vapors
to
1.
Keep
your
head
out
of
the
fumes.
Do
not
breathe
the
fumes.
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
(MSDS5)
and
the
weld
area,
the
area
is
well
ventilated,
and
if
necessary,
while
manufacturers
instruction
for
metals,
consumables,
coatings,
wearing
an
air-supplied
respirator.
The
coatings
and
any
metals
and
cleaners.
containing
these
elements
can
give
off
toxic
fumes
if
welded.
WELDING
can
cause
fire
or
explosion.
Sparks
and
spatter
fly
off
from
the
welding
arc.
The
flying
sparks
and
hot
metal,
weld
spatter,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Accidental
contact
of
electrode
or
welding
wire
to
metal
objects
can
cause
sparks,
overheating,
or
fire.
5.
6.
7.
8.
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
or
drums.
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
Protect
yourself
and
others
from
flying
sparks
and
hot metal,
hazards.
Do
not
weld
where
flying
sparks
can
strike
flammable
material.
9.
Do
not
use
welder
to
thaw
frozen
pipes.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
welding
arc.
10.
Remove
stick
electrode
from
holder
or
cut
off
welding
wire
at
If
this
is
not
possible,
tightly
cover
them
with
approved
covers,
contact
tip
when
not
in
use.
4.
Bealertthatweldingsparksandhotmaterialsfromweldingcan
11.
Wear
oil-free
protective
garments
such
as
leather
gloves,
through
small
cracks
and
openings
to
adjacent
areas.
heavy
shirt,
cuff
less
trousers,
high
shoes,
and
a
cap.
FLYING
SPARKS
AND
HOT
METAL
can
1.
cause
injury,
Chipping
and
grinding
cause
flying
metal.
As
welds
2.
cool,
they
can
throw
off
slag.
Wear
approved
face
shield
or
safety
goggles.
Side
shields
recommended.
Wear
proper
body
protection
to
protect
skin.
CYLINDERS
can
explode
if
damaged.
Shielding
gas
cylinders
contain
gas
under
high
pressure.
If
damaged,
a
cylinder
can
explode.
Since
gas
cylinders
are
normally
part
of
the
welding
process,
be
sure
to treat
them
carefully.
1.
Protect
compressed
gas
cylinders
from excessive
heat,
mechanical
shocks,
and
arcs.
2.
Install
and
secure
cylinders
in
an
upright
position
by
chaining
them
to
a
stationary
support
or
equipment
cylinder
rack
to
prevent
falling
or
tipping.
3.
Keep
cylinders
away
from
any
welding
or
other
electrical
circuits.
4.
Never
allow
a
welding
electrode
to
touch
any
cylinder.
5.
Use
only
correct
shielding
gas
cylinders,
regulators,
hoses,
and
fittings
designed
for
the
specific
application;
maintain
them
and
associated
parts
in
good
condition.
6.
Turn
face
away
from
valve
outlet
when
opening
cylinder
valve.
7.
Keep
protective
cap
in
place
over
valve
except
when
cylinder
is
in
use
or
connected
for
use.
8.
Read
and
follow
instructions
on
compressed
gas
cylinders,
associated
equipment,
and
CGA
publication
P-i
listed
in
Safety
Standards.
PRINCIPAL
SAFETY
STANDARDS
Safety
in
Welding
and
Cutting,
ANSI
Standard
Z49.i,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
Miami
FL
33126
Safetyand
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
Cuffing
of
Containers
That
Have
Held
Hazardous
Substances,
American
Weld
ing
Society
Standard
AWS
F4.i,
from
American
Welding
Society,
550
N.W.
LeJeune
Rd,
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
50i,
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.
Cuffing
And
Welding
Processes,
NFPA
Standard
51
B,
from
National
Fire
Protection
Association,
Batterymarch
Park,
Quincy,
MA
02269.
EMF
INFORMATION
TABLE
OF
CONTENTS
SECTION
1
SAFETY
INFORMATION
1
SECTION
2
SPECIFICATIONS
1
2-1.
Volt-Ampere
Curves
2
2-2.
Duty
Cycle
2
SECTION
3INSTALLATION
3
3-1.
Installing
Work
Clamp
3
3-2.
Installing
Gas
Supply
4
3-3.
Gun
Polarity
Connections
5
34.
Installing
Drive
Rolls
And
Welding
Gun
5
3-5.
Connecting
Input
Power
6
3-6.
Installing
Wire
Spool
And
Adjusting
Hub
Tension....
8
3-7.
Threading
And
Feeding
Welding
Wire
8
SECTION
4-OPERATION
10
SECTION
5
MAINTENANCE
&
TROUBLESHOOTING
12
5-1.
Routine
Maintenance
12
5-2.
Overload
Protection
13
5-3.
Wire
Drive
Assembly
Maintenance
14
5-4.
Gun
Maintenance
15
5-5.
Troubleshooting
16
SECTION
6
ELECTRICAL
DIAGRAM
17
SECTION
7
PARTS
LIST
ia
Figure
7-1.
Main
Assembly
18
Figure
7-2.
MWG-21C
Gun
19
Figure
7-3.
Baffle
w/Cmpts
20
NOTE
~
Magnetic
Fields
Considerations
About
Welding
And
The
Effects
Of
Low
Frequency
Electric
And
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
produce
changes
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
among
those
also
normally
recommended
for
pacemaker
wearers.
Consult
your
doctor
for
complete
information.
modl
0.1
4/93
6
SECTION
1
SAFETY
INFORMATION
Read
all
safety
messages
throughout
this
manual.
U
Obey
all
safety
messages
to
avoid
injury.
U
Learn
the
meaning
of
WARNING
and
CAUTION.
a
WARNING
a
CAUTION
modl.1
2/93
1
Safety
Alert
Symbol
1
2
2
2
Signal
Word
~
WARNING
means
possible
death
or
serious
injury
can
happen.
!~!~!t
;1~lI~Ie~U
3
CAUTION
means
possible
minor
=9
ELECTRIC
SHOCK
can
kIII.f
MOVING
PARTS
can
Injure,
injury
or
equipment
damage
can
~\
S
Donottouchliveelectricalparts.
~fl
Keepawayfrommovingparts.
happen.
S
Disconnect
input
power
before
r
Keep
all
panels
and
covers
closed
3
Statement
Of
Hazard
And
installing
or
servicing.
..4J
when
operating.
Result
/
4
Safety
Instructions
To
Avoid
5
Hazard
5
Hazard
Symbol
(If
Available)
6
Safety
Banner
READ
SAFETY
BLOCKS
at
start
of
Section
3-1
before
proceeding.
Read
safety
blocks
for
each
sym
bol
shown.
7
NOTE
7H
NOTE
~
Turn
Off
switch
when
using
high
frequency.
Special
instructions
for
best
oper
ation
not
related
to
safety.
Figure
1-1.
Safety
Information
SECTION
2-
SPECIFICATIONS
Table
2-1.
Welding
Power
Source
Specifications
Description
Type
Of
Output
Direct
Current/Constant
Voltage
(DC/CV)
Rated
Weld
Output
200
Amperes,
28
Volts
DC,
60%
Duty
Cycle
(See
Section
2-2)
Type
Of
Input
Power
Single-Phase;
60
Hz;
At
200
Or
230
Volts
AC
Input
Amperes
At
Rated
Output
46
A
At
200
V.
40
A
At
230
V
Maximum
Input
Amperes
While
Idling
1.2
A
At
200
V,
1
A
At
230
V
KVA/KW
Used
At
Rated
Output
9.5
kVA/8.3
kW
Maximum
KVA/KW
Used
While
Idling
0.24
kVA/0.17
kW
Max.
Open-Circuit
Voltage
42
Volts
DC
Control
Circuit
Voltage
At
Gun
24
Volts
DC
Welding
Processes
Gas
Metal
Arc
(GMAW)
And
Flux
Cored
Arc
Welding
(FCAW)
Calculated
Speed Range
At
No
Load
128
To
1051
ipm
(3.2
To
266.9
mpm)
Wire
Diameter
Range
.030
To
.045
in
(0.8
To
1.1
mm)
Flux
Cored
Wire;
.023
To
.045
in
(0.6
To
1.1
mm)
Hard
Wire
Overall
Dimensions
Length:
37
in
(940
mm);
Width:
19
in
(483
mm);
Height:
30-1/4
in
(768
mm)
Weight
Net:
225
lb
(102
kg);
Ship:
271
lb
(123
kg)
Welding
Gun
Rated
Output
(Air
Cooled)
200
Amperes
At
60%
Duty
Cycle
Using
CO2
Shielding
Gas
(See
Section
2-2)
Cable
Length
15
ft
(4.6
m)
OM-157
066
Page
1
2-1.
Volt-Ampere
Curves
Figure
2-1.
Volt-Ampere
Curves
2-2.
Duty
Cycle
A~
CAUTION
Figure
2-2.
Duty
Cycle
OUTRTr1
a)
Ui
~
.~..
~
-
~~1~
------H-----
Jo
x
DurY
CYCLE
The
volt-ampere
curves
show
the
50
minimum
and
maximum
voltage
and
amperage
output
capabilities
of
the
welding
power
source.
Curves
of
other
settings
fall
be
tween
the
curves
shown.
R~~E
RAP~E
0
I I
I
I I
0
25
50
75
100
125
150
175
200
225
DC
AMPERES
ssbl
.110/91
SB-049
424-0
WELDING
LONGER
THAN
RATED
DUTY
CYCLE
can
damage
unit
or
gun
and
void
warranty.
Do
n
ot
weld
at
rated
load
longer
than
shown
below.
wfwam8.2
8/93
Definition
Duty
Cycle
is
percentage
of
10
10
minutes
that
unit
or
gun
can
weld
at
rated
load
without
over
Minutes
heating.
UNIT
60%
Duty
Cycle
At
200
Amperes
g
c3
6
Minutes
Welding
4
Minutes
Resting
Chart
GUN
GUN
60%
Duty
Cycle
At
180
Amperes
Using
Mixed
Gas
sbl
.38/93
SB-150
215
6
minutes
Welding
4
minutes
Resting
OM-157
066
Page
2
3-1.
Installing
Work
Clamp
Figure
3-1.
Installing
Work
Clamp
SECTION
3-INSTALLATION
5
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
cov
er
connection
with
boot.
4
Hardware
5
WorkClamp
Route
cable
through
clamp
handle
and
secure
to
top
of
clamp
with
hardware.
Close
door.
Tools
Needed:
~ZZ~
1/2,
3/4
in
Ret.
5T-154
630-A
1
2
OM-157
066
Page
3
3-2.
Installing
Gas
Supply
CYLINDERS
can
explode
if
damaged.
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
Never
touch
cylinder
with
welding
electrode.
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
BUILDUP
OF
SHIELDING
GAS
can
harm
health
or
kill.
Shut
oft
shielding
gas
supply
when
not
in
use.
1
Cylinder
Bracket
2
S-Hook
Crimp
between
small
hole
in
brack
et
and
chain.
3
Chain
4
Snap
2
Crimp
onto
open
end
of
chain.
Obtain
gas
cylinder
and
chain
to
running
gear.
5
Cap
6
Cylinder
Valve
Remove
cap,
stand
to
side
of
valve,
and
open
valve
slightly.
Gas
flow
blows
dust
and
dirt
from
valve.
Close
valve.
7
Cylinder
8
Regulator/Flowmeter
Install
so
face
is
vertical.
9
Gas
Hose
Connection
Fitting
has
5/8-18
right-hand
threads.
Obtain
and
install
gas
hose.
10
Flow
Adjust
Typical
flow
rate
is
20
cfh
(cubic
feet
per
hour).
Check
wire
man
ufacturers
recommended
flow
rate.
Make
sure
flow
adjust
is
closed
when
opening
cylinder
to
avoid
damage
to
the
flowmeter.
11
CO2
Adapter
12
0-Ring
Install
adapter
with
0-ring
between
regulator/flowmeter
and
CO2
cylinder.
Tools
Needed:
~
5/8,1-1/8in
ssb3.r
5/94
ST-154
623
/
ST.158
697-A
a
WARNING
wam4.1
9/91
Figure
3-2.
Typical
Regulator/Flowmeter
Installation
OM-157
066
Page
4
3-3.
Gun
Polarity
Connections
4A
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
Swami
.1
2/93
Loosen
securing
knob.
Insert
gun
end
through
opening
until
it
bot
toms
against
drive
assembly.
Tighten
knob.
Insert
into
receptacle,
and
tighten
threaded
collar.
Close
pressure
assembly.
Close
Shown
As
Shipped
Set For
Electrode
Positive
(DCEP)
For
Solid
Steel
Or
Aluminum
Wires
(GMAW
Process).
Wire
Drive
Assembly
Lead
To
Positive
()
Output
Terminal
5
Work
Clamp
Lead
To
Negative
()
Output
Terminal
GUN
POLARIfl
CHANGEOVER
CONNECTIONS
Reverse
Lead
Connections
For
Electrode
Negative
(DCEN)
For
Flux
Cored
Wires
(FCAW
Process).
Drive
Assembly
Becomes
Negative
S-144
~
1
Polarity
Changeover
Label
2
Wire
Drive
Assembly
3
Positive
(+)
Output
Terminal
4
Negative
()
Output
Terminal
Always
read
and
follow
wire
man
ufacturers
recommended
polarity.
5
Circuit
Breaker
CB1
(see
Section
5-2).
Tools
Needed:
~
3/4,11/l6in
Ref.
ST-153
874-B
Figure
3-3.
Gun
Polarity
Connections
3-4.
Installing
Drive
Rolls
And
Welding
Gun
5
1
Pressure
Adjustment
2
Pressure
Assembly
3
Drive
Roll
4
Securing
Screw
Install
correct
drive
roll
for
wire
size
and
type
using
supplied
screws.
5
Wire
Drive
Assembly
6
Gun
Securing
Knob
7
Gun
End
8
Gun
Trigger
Plug
Figure
3-4.
Gun
Connections
door.
Tools
Needed:
ST-
154
621
/
Ref.
ST-154
624-A
OM-157
066
Page
5
3-5.
Connecting
Input
Power
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Off
welding
power
source,
and
disconnect
input
power
before
inspecting
or
installing.
Have
only
qualified
persons
install
unit.
Installation
must
meet
National
Electrical
Code
and
all
other
codes.
A.
Positioning
Jumper
Links
Jumper
links
allow
operation
on
different
input
voltages
and
are
factory
set
for
the
highest
input
voltage.
Check
input
voltage
available
at
site.
1
Input
Voltage
Label
Look
at
jumper
links
and
compare
link
position
with
applicable
label.
2
Screw
3
Access
Door
~
3/8
in
ssb5.1
2/92/
Ret.
5T-154
626-B
/
Ref.
5T-154
628-B
Figure
3-5.
Input
Voltage
Jumper
Links
Location
swam3,1
2/93
200
VOLTS
230
VOLTS
S-153
980
2
To
change
link
position,
remove
screw
and
pivot
door
up.
4
Input
Voltage
Jumper
Links
Location
Move
links
to
match
input
voltage.
For
example,
use
200
volts
posi
tion
when
200
volts
input
power
is
available.
Close
door
and
secure
with
screw.
Close
side
door.
Tools
Needed:
OM-157
066
Page
6
B.
Connecting
Input
Power
Figure
3-6.
Input
Power
Connections
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
Table
3-1.
Conductor
rating
must
comply
with
national,
state,
and
local
electrical
codes.
Install
and
connect
grounding
conductor
and
input
conductors
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
Table
3-1.
Install
into
deenergized
line
disconnect
device
(fused
dis
connect
switch
shown).
6
Input
Power
Plug
Turn
off
unit
Power
switch,
and
connect
plug
to
wall
receptacle.
ssb2.2
12/94
Ret.
5T-154
619-B
I
Ret.
ST-149
405-B
Table
3-1.
Electrical
Service
Requirements*
Input
Voltage
200
230
Input
Amperes
At
Rated
Output
46
40
Recommended
Standard
Fuse
Or
Circuit
Breaker
Rating
In
Amperes
70
60
Mm
Input
Conductor
Size
In
AWGIKcmiI
8
8
Max
Input
Conductor
Length
In
Feet
(Meters)
89(27)
117
(36)
Mm
Grounding
Conductor
Size
In
AWGIKcmiI
8
10
5
3
Tools
Needed:
These
values
are
calculated
from
the
1993
edition
of
the
National
Electrical
Code
(NEC).
S-0092-H
OM-157
066
Page
7
3-6.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
Figure
3-7.
Installing
Wire
Spool
And
Adjusting
Hub
Tension
3-7.
Threading
And
Feeding
Welding
Wire
a
WARNING
CYLINDERS
can
explode
if
damaged.
Keep
cylinders
away
from
welding
and
other
electrical
circuits.
Never
touch
cylinder
with
welding
electrode.
Always
secure
cylinder
to
running
gear,
wall,
or
other
stationary
support.
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
The
welding
wire,
drive
rolls,
drive
assembly,
and
all
metal
parts
touching
the
welding
wire
are
electrically
live
when
welding
or
feeding
wire
using
gun
trigger.
WELDING
WIRE
can
cause
puncture
wounds.
Do
not
press
gun
trigger
until
instructed
to
do
so.
Do
not
point
gun
toward
any
part
of
the
body,
other
people,
or
any
metal
when
threading
welding
wire.
HOT SURFACES
can
burn
skin.
Allow
gun
to
cool
before
touching.
swarn5.1
10/91
/swarn2.1
9/91
Turn
Off
unit.
1
Wire
Spool
2
Gun
Contact
lip
If
necessary,
cut
welding
wire
off
at
contact
tip,
and
retract
wire
onto
spool
and
secure.
3
Retaining
Ring
4
Compression
Spring
Remove
ring
and
pull
off
spool.
Compression
spring
is
used
with
8
in
(200
mm)
spools.
5
Hub
6
Hub
Pin
Slide
spool
onto
hub
so
wire
feeds
off
bottom.
Turn
spool
until
hub
pin
fits
hole
in
back
of
spool.
Reinstall
retaining
ring.
7
Hub
Tension
Nut
Grasp
spool
in
one
hand
and
turn
while
using
a
wrench
to
adjust
hub
tension
nut.
When
a
slight
force
is
needed
to
turn
spool,
tension
is
set.
Thread
welding
wire
(see
Section
3-7).
Close
door.
Tools
Needed:
Z~
15/16
in
Ref.
ST-154
626-B
/
Ref.
ST-072
573-B
OM-157
066
Page
8
1
Wire
Spool
2
Welding
Wire
3
Inlet
Wire
Guide
4
Pressure
Adjustment
Knob
5
Pressure
Assembly
6
Drive
Roll
7
Outlet
Wire
Guide
8
Gun
Conduit
Cable
Lay
gun
cable
out
straight.
Close
and
tighten
pressure
assembly,
and
let
go
of
wire.
Remove
gun
nozzle
and
contact
tip.
/
Press
gun
trigger
until
wire
comes
out
of
gun.
Reinstall
contact
tip
and
nozzle.
-~
Feed
wire
to
check
drive
roll
pressure.
Tighten
knob
enough
to
prevent
slipping.
6
Cut
off
wire.
Close
and
latch
door.
Figure
3-8.
Threading
And
Feeding
Welding
Wire
ST-800
739-A
/
ST.154
251
/
S-0627-A
Hold
wire
tightly
to
keep
it
from
unraveling.
Open
pressure
assembly.
Pull
and
hold
wire;
cut
off
end.
Push
wire
thru
guides
into
gun;
continue
to
hold
wire.
-~
=~
ION
POWER
=
OOF~
Set
switch.
OM-157
066
Page
9
SECTION
4-
OPERATION
a
WARNING
ELECTRIC
SHOCK
can
kill.
Always
wear
dry
insulating
gloves.
Insulate
yourself
from
work
and
ground.
Do
not
touch
live
electrical
parts.
Keep
all
panels
and
covers
securely
in
place
FUMES
AND
GASES
can
be
hazardous
to
your
health.
Keep
your
head
out
of
the
fumes.
Ventilate
area,
or
use
breathing
device.
Read
Material
Safety
Data
Sheets
(MSDS5)
and
manufacturers
instructions
for
material
used.
WELDING
can
cause
fire
or
explosion.
Do
not
weld
near
flammable
material.
Watch
for
fire;
keep
extinguisher
nearby.
Do
not
locate
unit
over
combustible
surfaces.
Do
not
weld
on
closed
containers.
Allow
work
and
equipment
to
cool
before
handling
ARCING
can
damage
switch.
Do
not
change
Voltage
switch
position
while
welding.
Arcing
inside
switch
can
damage
contacts,
causing
switch
to
fail.
P
~
~
ARC
RAYS
can
burn
eyes
and
skin;
NOISE
can
damage
hearing.
Wear
welding
helmet
with
correct
shade
of
filter.
S
Wear
correct
eye,
ear,
and
body
protection.
,..~
~
~
MOVING
PARTS
can
cause
injury.
Keep
away
from
pinch
points
such
as
drive
rolls.
Keep
all
doors,
panels,
covers,
and
guards
closed
and
securely
in
place.
-
~
MAGNETIC
FIELDS
FROM
HIGH
CUR
RENTS
can
affect
pacemaker
operation.
Pacemaker
wearers
keep
away.
Wearers
should
consult
their
doctor
before
going
near
arc
welding,
gouging,
or
spot
welding
opera
tions.
WELDING
CURRENT
can
damage
elec
tronic
parts
in
vehicles.
Disconnect
both
battery
cables
before
welding
on
a
vehicle.
Place
work
clamp
as
close
to
the
weld
as
possible.
See
Safety
Precautions
at
beginning
of
manual
for
ba
sic
welding
safety
information.
swam6.2
8/92
Wear
the
following
while
welding:
2
3
/
1
Dry,
Insulating
Gloves
2
Safety
Glasses
With
Side
Shields
3
Welding
Helmet
With
Correct
Shade
Of
Filter
(See
ANSI
Z49.1)
sb3.1
1/94
Figure
4-1.
Safety
Equipment
1
Wire
Mode
Switch
For
better
control
of
wire
speed
use
Low
position
when
wire
speed
is
between
90
and 670
ipm.
Use
Full
position
when
wire
speed
is
be
tween
150
ipm
and
1030
ipm.
2
Voltage
Range
Selector
Place
switch
in
desired
position.
See
inside
rear
cover
for
settings.
Ret.
ST-153
874-B
/
S-171
601
Figure
4-2.
Center
Baffle
Controls
OM-157
066
Page
10
Tools
Needed:
Ref.
5T-154
622-B
/
5T-171
639/
Ref.
ST-154
251
Figure
4-3.
Front
Panel
Controls
1
Wire
Speed
Control
Use
control
to
set
wire
teed
speed.
2
Voltage
Control
Use
control
and
Voltage
Range
Selector
(see
Figure
4-2)
to
set
arc
voltage.
Step
6
ot
Low
range
and
Step
1
ot
High
range
overlap.
4
Power
Switch
Use
switch
to
turn
unit
On
and
Ott.
The
pilot
light
comes
on
when
unit
is
turned
on.
Use
wire
brush
or
sandpaper
to
clean
metal
at
weld
joint
area.
Connect
work
clamp
to
clean,
paint-tree
location
on
workpiece,
as
close
as
possible
to
weld
area.
OM-157
066
Page
11
SECTION
5-
MAINTENANCE
&
TROUBLESHOOTING
a
WARNING
ELECTRIC
SHOCK
can
kill.
Do
not
touch
live
electrical
parts.
Turn
Ofl
welding
power
source,
and
disconnect
input
power
before
inspecting,
maintaining,
or
servicing.
HOT
PARTS
can
cause
severe
burns.
Allow
cooling
period
before
maintaining
or
servicing.
4f
M
OVING
PARTS
can
cause
injury.
Keep
away
from
moving
parts.
Keep
away
from
pinch
points
such
as
drive
rolls.
0
Maintenance
and
troubleshooting
to
be
performed
only
by
qualified
persons.
swarnS
2
2/93
5-1.
Routine
Maintenance
Turn
Off
all
power
before
maintaining.
Each
Spool
Of
Wire
Blow
Out
See
Gun
Section
I
Casing
5.4
~
Clean
Nozzle
________
And
Check
Contact
lip
-~
6
Months
Blow
Out
Or
Vacuum
Inside
During
Heavy
Service,
Clean
Monthly
-~
3
Months
W~N~
Replace
Unreadable
Labels
7
Clean
_
~
lighten
3-1
Terminals
~Replace
~9
Parts
14-Pin
Cord
Gas
Hose
Gun
Cable
Clean
Drive
Rolls
3-4
Figure
5-1.
Maintenance
Schedule
OM-157
066
Page
12
5-2.
Overload
Protection
a
WARNING
A.
Circuit
Breaker
CB1
B.
Fuses
Fl
And
F2
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
Turn
Off
unit
and
disconnect
input
power.
1
Fuse
Fl
(See
Parts
List
For
Rating)
Fl
protects
the
115
volts
ac
wind
ing
of
transformer
Ti.
If
Fl
opens,
all
weld
output
stops
and
pilot
light
PL1
goes
out.
2
Fuse
F2
(See
Parts
List
For
Rating)
F2
protects
the
24
volts
ac
winding
of
transformer
Ti.
If
F2
opens,
all
weld
output
stops.
Ret.
ST-800
928-B
1
Circuit
Breaker
CB1
If
CB1
opens,
wire
feed
stops.
Check
gun
liner
for
blockage
or
kinks,
and
check
for
jammed
wire,
binding
drive
gear,
or
misaligned
drive
rolls.
Allow
a
cooling
period
before
resetting
CB1.
Ret.
ST-153
874-B
Figure
5-2.
Circuit
Breaker
CB1
C.
Overheating
Figure
5-3.
Fuse
Location
Figure
5-4.
Overheating
OM-157
066
Page
13
5-3.
Wire
Drive
Assembly
Maintenance
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
Figure
5-5.
Wire
Drive
Assembly
Maintenance
Turn
Off
unit
and
disconnect
input
power.
Ret.
ST-154
626-B
/
SA-145
763
/
ST-i
54633
1
Wire
Spool
2
Gun
Contact
lip
Cut
welding
wire
off
at
contact
tip.
Retract
wire
onto
spool
and
se
cure.
3
Drive
Roll
Alignment
Bolt
Turn
in
or
out
until
groove
lines
up
with
wire
guide.
4
Drive
Roll
5
Wire
Inlet
Guide
Remove
guide
by
pressing
on
barbed
area
or
cutting
off
one
end
near
housing
and
pulling
it
out
of
hole.
Push
new
guide
into
hole
from
rear
until
it
snaps
in
place.
6
Pressure
Roll
Arm
7
Cotter
Pin
8
Pin
9
Screw
10
Bearing
Remove
bearing
as
shown.
Install
new
bearing
and
secure
with
screw.
Reinstall
arm
onto
pin
and
secure
with
cotter
pin.
Thread
welding
wire
(see
Section
3-7).
Close
door.
Tools
Needed:
OM-157
066
Page
14
5-4.
Gun
Maintenance
a
WARNING
FLYING
METAL
CHIPS
AND
DIRT
can
cause
injury
and
damage
equipment.
S
Point
gun
away
from
people
and
in
a
safe
direction
when
blowing
out
with
compressed
air.
I
READ
SAFETY
BLOCKS
at
start
of
Section
5
before
proceeding.
swarnlo.1
10/91
Turn
Off
unit
and
disconnect
input
power.
1
Wire
Spool
Cut
welding
wire
off
at
contact
tip.
Retract
wire
onto
spool
and
se
cure.
2
Gun
Securing
Knob
Loosen
knob
and
remove
gun
and
trigger
plug.
Reassemble
gun.
To
Reassemble
Gun:
Install
contact
tip.
Insert
new
liner.
Install
collet
onto
liner
and
tighten
into
gun/feeder
connector
using
wrench.
Cut
liner
off
near
collet
so
that
liner
end
is
as
close
to
drive
rolls
as
pos
sible
without
touching.
Install
nozzle.
Reinstall
gun
(see
Section
3.4).
Thread
welding
wire
(see
Section
3-7).
Close
door.
Gun/Feeder
Connector
Ret.
ST-154
624-A/
ST-801
149
Figure
5-6.
Gun
Maintenance
Head
Tube
/
//
II
/
f
Remove
nozzle,
contact
tip,
and
liner
collet.
out
gun
casin
/
Remove
liner.
Tools
Needed:
~
3/8in
OM-157
066
Page
15
5-5.
Troubleshooting
a
WARNING
READ
Sectio
SAFETY
n
5
befor
BLOCKS
at
start
of
e
proceeding.
Welding
Trouble
No
weld
output;
wire
does
not
feed.
Remedy
Secure
power
cord
plug
in
receptacle.
Reset
circuit
breaker
CB1.
Replace
fuse
Fl
and/or
F2.
Replace
building
line
fuse
or
reset
circuit
breaker
if
open
Secure
gun
trigger
plug
in
receptacle
or
repair
leads,
or
replace
trigger
switch.
No
weld
output;
wire
does
not
feed;
fan
i
-.
motor
continues
to
run
and
pilot
light
is
off.
Section
-a
3-5
-a
5-2
-~
3-5
-~
3-4
No
weld
output;
wire
feeds.
Thermostat
open
(overheating).
Allow
tan
to
run;
the
thermostat
will
close
when
the
unit
has
cooled.
Low
weld
output.
5-2
-
Replace
contact
tip.
Connect
work
clamp
to
get
good
metal
to
metal
contact.
Wire
Drive/Gun
Trouble
Electrode
wire
feeding
stops
during
i
-.
welding.
I
1
-~
Figure
4-3
]-..,
5-4
-
Connect
unit
to
proper
input
voltage
or
check
for
low
line
volt~~j
-
~
I
-~
5-4
-~
3-6
-~
3-7
Straighten
gun
cable
and/or
replace
damaged
parts.
Adjust
hub
tension.
Adjust
drive
roll
pressure.
Replace
contact
tip
if
blocked.
Clean
or
replace
wire
inlet
guide
or
liner
if
dirty
or
plugged.
Replace
drive
roll
or
pressure
bearing
if
worn
or
slipping.
Secure
gun
trigger
plug
in
receptacle
or
repair
leads,
or
replace
trigger
switch.
Check
and
replace
Fl
and/or
F2.
Check
and
clear
any
restrictions
at
drive
assembly
and
liner.
Have
nearest
Factory
Authorized
Service
Station
check
drive
motor.
5-4
-a
5-3,
5-4
5-3
3-4
-a
-~
5-2
-a
5-3,
5-4
-a
OM-157
066
Page
16
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Miller AUTO ARC 255 Owner's manual
- Category
- Welding System
- Type
- Owner's manual
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