Miller KG194818 Owner's manual

Brand: Miller

Model: KG194818

Category: Welding System

Type: Owner's manual

This manual is also suitable for

AEROWAVE CE

Miller

August1996

Effective

With

Form:

Serial

No.

OM-183

KG194818

17~7

OWNERS

MANUAL

CE

Ae

rowave

ﬁ

CC

AC/DC

Welding

Power~Source

For

GTAW

And

SMAW

Welding

'

1996

MILLER

Electric

Mfg.

Co.

cover_om

4/9~



ST-800

311-B

Rated

Welding

Output

Amperes

Input

at

AC

Balanced

Rated

Load

Output;

50

Hz,

Three-Phase

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

PRINTED

IN

USA

LIMITED

WARRANTY

Subject

to

the

terms

end

conditions

below,

MILLER

Electric

Mfg.

Co.,

Appleton,

Wisconsin,

wsrrsnts

to

its

original

retail

purchaser

thst

new

MILLER

equipment

sold

sfter

the

effective

dste

of

this

limited

werranty

is

free

of

de

fects

in

materiel

end

workmsnship

at

the

time

it

is

shipped

by

MILLER.

THIS

WAR

RANTY

IS

EXPRESSLY

IN

LIEU

OF

ALL

OTHER

WARRANTIES,

EXPRESS

OR

IMPLIED,

INCLUDING

THE

WARRAN11ES

OF

MERCHANTABILITY

AND

FIT

NESS.

Within

the

wsrrsnty

periods

listed

below,

MILLER

will

repsir

or

repisce

any

wsr

ranted

pens

or

components

thst

fell

due

to

such

defects

In

msterisl

orworkrnenship.

MILLER

must

be

notified

in

writing

within

thIrty

(30)

days

of

such

defect

or

tsiiure,

at

which

time

MILLER

will

provide

Instructions

on

the

warranty

claim

procedures

to

be

followed.

MILLER

shell

honor

warranty

claims

on

warranted

equipment

iisted

below

in

the

event

of

such

a

failure

within

the

warranty

time

periods.

All

wsrranty

time

periods

start

on

the

date

that

the

equipment

wss

delivered

to

the

originsi

retsil

purchaser,

or

one

year

after

the

equipment

Is

sent

to

a

North

American

distributor

or

eighteen

months

after

the

equipment

Is

sent

to

err

internstionsi

distributor.

2.

Consumable

components;

such

as

contact

tips,

cutting

nozzles,

contactors

and

relays

or

pens

that

fail

due

to

normal

wear.

3.

Equipment

that

has

been

modified

by

any

party

other

than

MILLER,

or

equip

ment

that

has

been

improperly

installed,

improperty

operated

or

misused

based

upon

Industry

standards,

or

equipment

which

has

not

had

reasonable

and

necesssry

msintensnce,

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

CIALI1NDUSTR1AL

USERS

AND

PERSONS

TRAINED

AND

EXPERIENCED

IN

ThE

USE

AND

MAINTENANCE

OF

WELDING

EOU1PMENt

tn

the

event

of

a

warranty

claim

covered

by

this

warranty,

the

exclusIve

remedies

shell

be,

at

MILLERS

option:

(1)

repalr

or

(2)

replacement;

or;

where

authorized

In

writing

by

MILLER

in

approprista

cases,

(3)

the

reasonable

cost

of

repair

or

replace

ment

at

an

authorized

MILLER

service

station;

or

(4)

payment

of

orcredit

forthe

pur

chsse

price

(teas

reasonable

depreciation

based

upon

actual

use)

upon

retum

of

the

goods

at

customers

risk

end

expense.

MILLERS

option

of

repair

or

replacement

wilt

be

FOB.,

Factory

at

Appleton,

Wisconsin,

or

ROB.

ate

MILLER

authorized

ser

vice

facility

as

determined

by

MILLER.

Therefore

no

compensatIon

or

reimburse

ment

for

transportatIon

costs

of

any

kind

will

be

allowed.

TO

ThE

EXTENT

PERMITrED

BY

LAW,

THE

REMEDIES

PRDV1DED

HEREIN

ARE ThE

SOLEAND

EXCLUSIVE

REMEDIES.

IN

NO

EVENTSHALLMILLER

BE

UABLE

FOR

DIRECt

INDIRECt

SPECIAL,

INCIDENTAL

OR

CONSEOUENTIAL

DAMAGES

(INCLUDING

LOSS

OF

PROFIT),

WHETHER

BASED

ON

CON

TRACt

TORT

OR

ANY

OTHER

LEGAL

ThEORY.

ANY

EXPRESS

WARRANTY

NOT

PROVIDED

HEREIN

AND

ANY

IMPLIED

WAR

RANTY,

GUARANTY

OR

REPRESENTA11ON

AS

TO

PERFORMANCE,

AND ANY

REMEDY

FOR

BREACH

OF

CONTRACT

TORT

OR

ANY

OThER

LEGAL

ThEORY

WHICH,

BUT

FOR

THIS

PROVISION,

MIGHT

ARISE

BY

IMPUCATION,

OPERATiON

OF

LAW,

CUSTOM

OF

TRADE

OR

COURSE

OF

DEALING,

IN

CLUDING

ANY

IMPLIED

WARRANTY

OF

MERCHANTABILITY

OR

FITNESS

FOR

PARTICULAR

PURPOSE,

WITh

RESPECT

TO

ANY

AND

ALL

EOU1PMENT

FURNISHED

BY

MILLER

IS

EXCLUDED

AND

DISCLAIMED

BY

MILLER.

Some

statas

in

the

U.S.A.

do

not

allow

limitations

of

how

long

en

implied

warranty

lasts,

or

the

esciusion

of

incidental,

indirect,

special

or

consequential

dsmsges,

so

the

above

limitation

or

exclusion

may

not

apply

to

you.

This

warranty

provides

spe

cific

legal

rights,

end

other

rights

may

be

available,

but

may

vary

from

state

to state.

in

Csnsds,

legislation

in

some

provinces

provides

for

certain

additional

warranties

or

remedies

other

than

as

stated

herein,

end

to

the

extent

that

they

may

not

be

waived,

the

limitations

end

exclusIons

set

out

above

may

not

apply.

This

Limited

Warranty

provides

specific

legal

rights,

end

other

rights

may

be

available,

but

may

vary

from

province

to

province.

WHO

DO

I

CONTACT?

For

help,



contact

your

distribUtor

For

additional

Information,

such

as

Tochnical

Manuals

(Service

And

Parts)

Engino

Manuals

Circuit

And

Wiring

Diagrams

To

file

a

claim

for

loss

or

damage

during

shipment,

.

contact

the

doliVering

canior

For

assistance

in

filing

or

sealing

claims,



contact

your

distributor

and/or

oquipmont

manufacturers

Transportation

Dopartmont

pc~~~



~h]

Miller

Electric

Mfg.

Co.



CALL:

414-7354505



FAX:

800-637-2348

(in

USA),

or

414-735-4136

(outside

USA)

Process

Handbooks

Users

Guides

Distributor

Directories

.

o~

=

.

WRITE:

Miller

Electric

Mfg.

Co.



contact

your

distributor

P.O.

BOX

1079

Appleton,

WI

54912

USA

Always

provide

Model

Name

and

Serial

or

Style

Number

I-.

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

wsrrenties

end

is

exclusive

with

no

other

guarantees

or

warranties

expreased

or

implied.

5.

6

Months



Batteries

6.

90

Days



Parts

and

Lsbor

-

MIG

GunsfflG

Torches

*

APt

ZIPCUT

&

PLAZCUT

Model

Piasms

Cutting

Torches

*

Remote

Controls

-

Acceasory

Kits

*

Replacement

Pans

MILLERS

True

Blueﬁ

LimIted

Warranty

shall

not

apply

to:

1.

Items

fumished

by

MILLER,

but

menufsctured

by

others,

such

as

engines

or

trsde

scceasories.

These

items

are

covered

by

the

manufacturers

warranty,

if

any.

.J

ii

(7)

S

Yesm

Parts

-3

Years

Lsbor

*

Original

main

power

rectifiers

-

Invertere

(Input

and

Output

rectifiers

only)

2.

3YesrePertssndLsbor

.



~

-

Trsnsfomier/Rectlfier

Power

Sources

*

Plasma

Arc

Cutting

Power

Sources

*

Semi-Automatic

end

Automatic

Wire

Feeders

*

Inverter

Power

Supplies

intettlig

-

Robots

(1

yesr

labor)

3.

2

Years



Pens

and

Labor

-

Engine

Driven

Welding

Generators

(NOTE:

Engines

are

warranted

separately

by

the

engine

msnufscturer.)

-

Air

Compreasors

4.

1

Year

Pans

and

Labor

-

Motor

Driven

Guns

*

Process

Controllers

*

IHPS

Power

Sources

Water

coolant

Systems

HF

Units

Grids

-

Spot

Welders



Load

Banks

*

SDX

Transformers

Miller

Cyciomatic

Equipment

-

Running

Gear/Trailers

*

Plasma

Cutting

Torches

(except

APt

Z1PcuT

&

PLAZCuT

Models)

*

Tecumseh

Engines



Deutz

Engines

(outside

North

America)

*

Field

Options

(NOTE:

Field

options

era

covered

under

True

Blueﬁ

for

the

remaining

warranty

period

of

the

product

they

are

Installed

in,

or

fore

minimum

of

one

year

whichever

is

greater.)

miller

wan

3/96

Declaration

of

Conformity

For

European

Community

(CE)

Products

NOTE

~

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

Ae

rowave

ﬁ

con

forms

to

the

following

Directives

and

Standards:

Directives

Machinery

Directives:

89/392/EEC,

91/368/EEC,

93/C

133/04,

93/68/EEC

Electromagnetic

Capabillty

Directives:

89/336,

92131/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

Iseo

20098

San

Giuliano

Milanese,

Italy

Telephone:

39(02)98290-1

Fax:

39(02)98281-552

dec_coni

10/95

TABLE

OF

CONTENTS

SECTION

1

-

SAFETY

PRECAUTIONS

FOR

ARC

WELDING

1

1-1.

Symbol

Usage

1

1-2.

Arc

Welding

Hazards

1

1-3.

Additional

Installation,

Operation,

And

Maintenance

Hazards

2

1-4.

Principal

Safety

Standards

3

1-5.

EMF

Information

3

SECTION

2-

DEFINITIONS

4

2-1.

Warning

Label

Definitions

4

2-2.

Rating

Label

For

CE

Products

5

2-3.

Symbols

And

Definitions

6

SECTION

3-INSTALLATION

7

3-1.

Dimensions

And

Weights

7

3-2.

Selecting

A

Location

7

3-3.

115

VAC

Receptacle,

Circuit

Breaker,

And

Shielding

Gas

Connections

8

3-4.

Weld

Output

Terminals

And

Selecting

Cable

Sizes

8

3-5.

Remote

14

Receptacle

Information

9

3-6.

Electrical

Service

Guide

9

3-7.

Placing

Jumper

Links

10

3-8.

Connecting

Input

Power

11

SECTION

4OPERATION

12

4-1.

Controls

12

4-2.

Polarity

Switch

And

Pilot

Lights

12

4-3.

Mode

Switch

13

4-4.

Amperage/Preset

Meter

And

Voltmeter

13

4-5.

Output

Switch

And

Pilot

Light

13

4-6.

Amperage

Adjustment

Controls

14

4-7.

Examples

Of

Combination

Remote

Amperage

Control

15

4-8.

AC

Balance

Control

16

4-9.

AC

Frequency

Controls

16

4-10.

Postflow

Time

Control

17

4-11.

Start

Switch

17

4-12.

Power

Switch

17

4-13.

Optional

Controls

18

4-14.

GTAW

Trigger

Hold

Switch

(Optional)

18

4-15.

Spot

Time

Controls

(Optional)

19

4-16.

Preflow

Time

Controls

(Optional)

19

4-17.

Initial

Sequence

Controls

(Optional)

19

4-18.

Pulser

Controls

(Optional)

20

4-19.

Final

Sequence

Controls

(Optional)

20

4-20.

Pulsed

Weld

Waveforms

21

4-21.

Duty

Cycle

And

Overheating

22

SECTION

5-

MAINTENANCE

&

TROUBLESHOOTING

22

5-1.

Routine

Maintenance

22

5-2.

Overload

Protection

And

Adjusting

Spark

Gap

23

5-3.

Troubleshooting

24

SECTION

6-

ELECTRICAL

DIAGRAM

26

SECTION

7

HIGH

FREQUENCY

(HF)

28

7-1.

Welding

Processes

Using

HF

28

7-2.

Sources

Of

HF

Radiation

From

Incorrect

Installation

28

7-3.

Correct

Installation

29

SECTION

8

PARTS

LIST

30

OM-183

1738196

1-1.

Symbol

Usage

~H~id

1-2.

Arc

Welding

Hazards

a

WARNING

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

191

0.147

(see

Safety

Standards).

5.

Properly

install

and

ground

this

equipment

according

to

its

Owners

Manual and

national,

state,

and

local

codes.

6.

Always

verify

the

supply

ground



check

and

be

sure

that

input

power

cord

ground

wire

is

properly

connected

to

ground

ARC

RAYS

can

burn

eyes

and

skin;

NOISE

can

damage

hearing;

FLYING

SLAG

OR

SPARKS

can

injure

eyes.

Arc

rays

from

the

welding

process

produce

intense

visible

and

invisible

(ultraviolet

and

infrared)

rays

that

can

bum

eyes

and

skin.

Noise

from

some

processes

can

damage

hearing.

Chipping,

_______

grinding,

and

welds

cooling

throw

off

pieces

of

metal

or

slag.

I

ear

plugs

or

ear

muffs

if

noise

level

is

high

FUMES

AND

GASES

can

be

hazardous

to

your

health.

Welding

produces

fumes

and

gases.

Breathing

these

fumes

and

gases

can

be

hazardous

to

your

health.

1.

Keep

your

head

out

of

the

fumes.

Do

not

breathe

the

fumes.

2.

If

inside,

ventilate

the

area

and/or

use

exhaust

at

the

arc

to

remove

welding

fumes

and

gases.

3.

If

ventilation

is

poor,

use

an

approved

air-supplied

respirator.

4.

Read

the

Material

Safety

Data

Sheets

(MSDSs)

and

the

manufacturers

instruction

for

metals,

consumables,

coatings,

cleaners,

and

degreasers.

terminal

in

disconnect

box

or

that

cord

plug

is

connected

to

a

properly

grounded

receptacle

outlet.

7.

When

making

input

connections,

attach

proper

grounding

conductor

first



double-check

connections.

8.

Frequently

inspect

input

power

cord

for

damage

or

bare

wiring



replace

cord

immediately

if

damaged



bare

wiring

can

kill.

9.

Turn

off

all

equipment

when

not

in

use.

10.

Do

not

use

worn,

damaged,

undersized,

or

poorly

spliced

cables.

11.

Do

not

drape

cables

over

your

body.

12.

If

earth

grounding

of

the

workpiece

is

required,

ground

it

directly

with

a

separate

cable



do

not

use

work

clamp

or

work

cable.

13.

Do

not

touch

electrode

if

you

are

in

contact

with

the

work,

ground,

or

another

electrode

from

a

different

machine.

14.

Use

only

well-maintained

equipment.

Repair

or

replace

damaged

parts

at

once.

Maintain

unit

according

to

manual.

15.

Wear

a

safety

harness

if

working

above

floor

level.

16.

Keep

all

panels

and

covers

securely

in

place.

17.

Clamp

work

cable

with

good

metal-to-metal

contact

to

workpiece

or

worktable

as

near

the

weld

as

practical.

ARC

RAYS

2.

Wear

a

welding

helmet

fitted

with

a

proper

shade

of

filter

to

protect

yourface

and

eyes

when

welding

or

watching

(see

ANSI

Z49.1

and

Z87.1

listed

in

Safety

Standards).

3.

Wear

approved

safety

glasses

with

side

shields.

4.

Use

protective

screens

or

barriers

to

protect

others

from

flash

and

glare;

warn

others

not

to

watch

the

arc.

5.

Wear

protective

clothing

made

from

durable,

flame-resistant

material

(wool

and

leather)

and

foot

protection.

5.

Work

in

a

confined

space

only

if

it

is

well

ventilated,

or

while

wearing

an

air-supplied

respirator.

Always

have

a

trained

watchperson

nearby.

Welding

fumes

and

gases

can

displace

air

and

lower

the

oxygen

level

causing

injury

or

death.

Be

sure

the

breathing

air

is

safe.

6.

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.

7.

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.

SECTION

1

-

SAFETY

PRECAUTIONS

FOR

ARC

WELDING

8afety_soml

4/95

4A

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.

~

Means

NOTE;

not

safety

related.

This

group

of

symbols

means

Warning!

Watch

Out!

possible

ELECTRIC

SHOCK,

MOVING

PARTS,

and

HOT

PARTS

hazards.

Consult

symbols

and

related

instructions

below

for

necessary

actions

to

avoid

the

hazards.

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.

NOISE

OM-183

173

Page

1

CYLINDERS

can

explode

if

damaged.

Shielding

gas

cylinders

contain

gas

under

high

pressure.

If

damaged,

a

cylinder

can

explode.

Since

gas

cylinders

are

normally

part

of

the

welding

process,

be

sure

to

treat

them

carefully.

1.

Protect

compressed

gas

cylinders

from

excessive

heat,

mechanical

shocks,

slag,

open

flames,

sparks,

and

arcs.

2.

Install

cylinders

in

an

upright

position

by

securing

to

a

stationary

support

or

cylinder

rack

to

prevent

falling

or

tipping.

3.

Keep

cylinders

away

from

any

welding

or

other

electrical

circuits.

4.

Never

drape

a

welding

torch

over

a

gas

cylinder.

5.

Never

allow

a

welding

electrode

to

touch

arty

cylinder.

6.

Never

weld

on a

pressurized

cylinder



explosion

will

result.

7.

Use

only

correct

shielding

gas

cylinders,

regulators,

hoses,

and

fittings

designed

for

the

specific

application;

maintain

them

and

associated

parts

in

good

condition.

8.

Turn

face

away

from

valve

outlet

when

opening

cylinder

valve.

9.

Keep

protective

cap

in

place

over

valve

except

when

cylinder

is

in

use

or

connected

for

use.

10.

Read

and

follow

instructions

on

compressed

gas

cylinders,

associated

equipment,

and

CGA

publication

P-i

listed

in

Safety

Standards.

WELDING

can

cause

fire

or

explosion.

Welding

on

closed

containers,

such

as

tanks,

drums,

or

pipes,

can

cause

them

to

blow

up.

Sparks

can

fly

off

from

the

welding

arc.

The

flying

sparks,

hot

workpiece,

and

hot

equipment

can

cause

fires

and

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.

4.

Be

alert

that

welding

sparks

and

hot

materials

from

welding

can

easily

go

through

small

cracks

and

openings

to

adjacent

areas.

5.

Watch

for

fire,

and

keep

a

fire

extinguisher

nearby.

6.

Be

aware

that

welding

on

a

ceiling,

floor,

bulkhead,

or

partition

can

cause

fire

on

the

hidden

side.

7.

Do

not

weld

on

closed

containers

such

as

tanks,

drums,

or

pipes,

unless

they

are

properly

prepared

according

to

AWS

F4.1

(see

Safety

Standards).

8.

Connect

work

cable

to

the

work

as

close

to

the

welding

area

as

practical

to

prevent

welding

current

from

traveling

long,

possibly

unknown

paths

and

causing

electric

shock

and

fire

hazards.

9.

Do

not

use

welder

to

thaw

frozen

pipes.

10.

Remove

stick

electrode

from

holder

or

cut

oft

welding

wire

at

contact

tip

when

not

in

use.

11.

Wear

oil-free

protective

garments

such

as

leather

gloves,

heavy

shirt,

cuffless

trousers,

high

shoes,

and

a

cap.

12.

Remove

any

combustibles,

such

as

a

butane

lighter

or

matches,

from

your

person

before

doing

any

welding.

1-3.

Additional

Installation,

Operation,

And

Maintenance

Hazards

FIRE

OR

EXPLOSION

can

result

from

placing

unit

on,

over,

or

near

combustible

surfaces.

1.

Do

not

locate

unit

on,

over,

or

near

combustible

surfaces.

Do

not

install

unit

near

flammables.

FALLING

EQUIPMENT

can

cause

serious

personal

injury

and

equipment

damage.

1.

Use

lifting

eye

to

lift

unit

only,

NOT

running

gear,

gas

cylinders,

or

any

other

accessories.

Use

equipment

of

adequate

capacity

to

lift

unit.

If

using

lift

forks

to

move

unit,

be

sure

forks

are

long

enough

to

extend

beyond

opposite

side

of

unit.

HOT

PARTS

can

cause

severe

burns.

1.

Do

not

touch

hot

parts

bare

handed.

2.

Allow

cooling

period

before

working

on

gun

or

torch.

MOVING

PARTS

can

cause

injury.

1.

Keep

away

from

moving

parts

such

as

fans.

2.

Keep

all

doors,

panels,

covers,

and

guards

closed

and

securely

in

place.

MAGNETIC

FIELDS

FROM

HIGH

CURRENTS

can

affect

pacemaker

operation.

Pacemaker

wearers

keep

away.

Wearers

should

consult

their

doctor

before

going

near

arc

welding,

gouging,

or

spot

welding

operations.

MOVING

PARTS

can

cause

injury.

1.

Keep

away

from

moving

parts.

2.

Keep

away

from

pinch

points

such

as

drive

rolls.

FLYING

PIECES

OF

METAL

or

DIRT

can

injure

eyes.

1.

Wear

safety

glasses

with

side

shields

or

face

shield.

WELDING

WIRE

can

cause

puncture

wounds.

2.

Do

not

point

gun

toward

any

part

of

the

body,

other

people,

or

any

metal

when

threading

welding

wire.

HIGH-FREQUENCY

RADIATION

can

interfere

with

radio

navigation,

safety

services,

computers,

and

communications

equipment.

Have

only

qualified

persons

familiar

with

electronic

equipment

perform

this

installation.

The

user

is

responsible

for

having

a

qualified

electrician

promptly

correct

any

interference

problem

resulting

from

the

installation.

If

notified

by

the

FCC

about

interference,

stop

using

the

equipment

at

once.

Have

the

installation

regularly

checked

and

maintained.

Keep

high-frequency

source

doors

and

panels

tightly

shut,

keep

spark

gaps

at

correct

setting,

and

use

grounding

and

shielding

to

minimize

the

possibility

of

interference.

1.

2.

3.

~Ił~

-jt

1.

Do

not

press

gun

trigger

until

instructed

to

do

so.

OM-183

173

Page

2

OVERUSE

can

cause

OVERHEATED

EQUIPMENT.

1.

Allow

cooling

period.

2.

Reduce

current

or

reduce

duty

cycle

before

starting

to

weld

again.

Follow

rated

duty

cycle.

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.

Put

on

grounded

wrist

strap

BEFORE

handling

boards

or

parts.

Use

proper

static-proof

bags

and

boxes

to

store,

move,

or

ship

PC

boards.

1-4.

Principal

Safety

Standards

w

BUILDUP

OF

SHIELDING

GAS

can

harm

health

or

kill.

1.

Shut

oft

shielding

gas

supply

when

not

in

use.

Safety

in

Welding

and

Cutting,

ANSI

Standard

Z49.

1,

from

Safe

Hand/mg

of

Compressed

Gases

in

cylinders,

CGA

Pamphlet

American

Welding

Society,

550

N.W.

LeJeune

Rd,

Miami

FL

33126

P-i

from

Compressed

Gas

Association,

1235

Jefferson

Davis

Safety

and

Health

Standards,

OSHA

29

CFR

1910,

from

Superintendent

of

Documents,

U.S.

Government

Printing

Office,

Washington,

D.C.

20402.

Highway,

Suite

501,

Ariington,

VA

22202.

Code

for

Safety

in

We/ding

and

Cutting,

CSA

Standard

W117.2,

from

Canadian

Standards

Association,

Standards

Sales,

178

Rexdale

Boulevard,

Rexdale,

Ontario,

Canada

M9W

1

R3.

Recommended

Safe

Practices

for

the

Preparation

for

We/ding

and

Cutting

of

Containers

.~iat

Have

Held

Hazardous

Substances,

American

Welding

Socoty

Standard

AWS

F4.1,

from

American

Welding

Society,

550

l\

V.

LeJeune

Rd,

Miami,

FL

33126

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

51

B,

from

National

Electrical

Coc

NFPA

Standard

70,

from

National

Fire

National

Fire

Protection

Association,

Batterymarch

Park,

Quincy,

Protection

Association,

~tterymarch

Park,

Quincy,

MA

02269.

MA

02269.

1-5.

EMF

Info

~ation

Considerations

AboL

elding

And

The

Effects

Of

Low

Frequency

To

reduce

magnetic

fields

in

the

workplace,

use

the

following

Electric

And

Magnet

~lds

procedures:

The

following

is

a

q~

~

from

the

General

Conclusions

Section

of

the

U.S.

Congress.

ce

of

Technology

Assessment,

Biological

1.

Keep

cables

close

together

by

twisting

or

taping

them.

Effects

of

Power

.uency

Electric

&

Magnetic

Fields



Background

Paper,

1TA-BP-E-53

(Washington,

DC:

U.S.

2.

Arrange

cables

to

one

side

and

away

from

the

operator.

Government

Printing

C~ce,

May

1989):

.

. .

there

is

now

a

very

3.

Do

not

coil

or

drape

cables

around

the

body.

large

volume

of

scientific

findings

based

on

experiments

at

the

cellularlevel

and

from

studies

with

animals

and

people

which

clearly

4.

Keep

welding

power

source

and

cables

as

far

away

as

establish

that

low

frequency

magnetic

fields

can

interact

with,

and

practical.

produce

changes

in,

biological

systems.

While

most

of

this

work

is

of

very

high

quality,

the

results

are

complex.

Current

scientific

5.

Connect

work

clamp

to

workpiece

as

close

to

the

weld

as

understanding

does

not

yet

allow

us

to

interpret

the

evidence

in

a

possible.

single

coherent

framework.

Even

more

frustrating,

it

does

not

yet

allow

us

to

draw

definite

conclusions

about

questions

of

possible

About

Pacemakers:

.

riskortoofferclearscience-basedadviceonstrategiestominimize

The

above

procedures

are

also

recommended

for

pacemaker

or

avoid

potential

risks.

wearers.

Consult

your

doctor

for

complete

information.

OM-183

173

Page

3

SECTION

2-

DEFINITIONS

1

Electric

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.

1.3

Disconnect

input

plug

or

power

before

working

on

machine.

2

Breathing

welding

fumes

can

be

hazardous

to

your

health.

2.1

Keep

your

head

out

of

the

fumes.

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.

5

Become

trained

and

read

the

instructions

before

working

on

the

machine

or

welding.

6

Do

not

remove

or

paint

over

(cover)

the

label.

2-1.

Warning

Label

Definitions

Waming!

Watch

Out!

There

are

symbols.

possible

hazards

as

shown

by

the

OM-183

173

Page

4

2-2.

Rating

Label

For

CE

Products

EN

60974-1

Ui

380V

I

umax

32A

j

1len

4A

U2

415V

I

imax

29A

I

left

3.7A

0

=

4.0

Kvar

OM-183

173

Page

5

2-3.

Symbols

And

Defirntions

A

Amperes

0

PanelLocal

Q~$

Gas

Tungsten

Arc

Welding

(GTAW)

/~



Shielded

Metal

Arc

Welding

(SMAW)

~%f

Volts

f

Frequency

V

Itﬁ

Over

Voltage

~~

t

Spot

Timer

Output

o o

Circuit

Breaker

,AJ

Remote

Touch

Start

(GTAW)



Protective

Earth

(Ground)

Alternating

Current

~\

High

Frequency

-

Start

Input

t2

Postflow

Timer

ti

Preflow

Timer

Q

Kvar

F~~

i:

High

Frequency

S

Seconds

Gas

Input

(~j~j~i

Gas

Output

Gas

(Supply)

On

~p

Off

Thickness

Gauge

Direct

Current

F:;iL::j

Balance

Control

9

~%

Maximum

Cleaning

-v-

Maximum

Penetration

+

A

.I,

.~..

~

Electrode

Positive

/\



Electrode

Negative

...4~.....

Work

.4~\

~

Electrode

3~\,

Three-Phase

J1J1L

Pulse

Frequency

Pulse

Percent

On

Time

J1J]~

Pulse

Background

Amperage

~j\

Start

Time

~I\

Start

Amperage

j~_~

Final

Slope

O/~

Percent

U

0

Rated

No

Load

Voltage

(Average)

U

1

Pnmar~,

Voltage

U2

Conventional

Load

Voltage

IJ

~

Line

Connection

I~

PrimaryCurrent

12

Rated

Welding

Current

X

DutyCycle

~-GD-f~~

Three-Phase

CombinedAC/DC

Power

Source

I

P

Degree

Of

Protection

left

Maximum

Effective

Supply

Current

1

max

Rated

Maximum

Supply

Current

h1!T~

~

Spark

Gap

()

Increase/Decrease

Of

Quantity

At

Final

Sequence

t

Two-Step

Trigger

Operation

(GTAW)

J~j

Four-Step

Trigger

Operation

(GTAW)

Initial

Sequence

Final

Amperage

/\~

Final

Time

~J\

Initial

Slope

Press

And

Hold

Li

Trigger

Hold

(GTAW)

j~ﬁ

High

Temperature

OM-183

173

Page

6

SECTION

3INSTALLATION

Height*

35-1/2

in

(910

mm)

Width

24

in

(615

mm)

Depth

22-3/4

in

(583

mm)

*With

lifting

eye

down

Weight

3-1.

Dimensions

And

Weights

c~

Dimensions

B

dim_i

3/96

-

ST-800

402/ST-il

7

264-C

3-2.

Seecting

A

Location

351

lb

(159

kg)

OM-183

173

Page

7

3-3.

115

VAC

Receptacle,

Circuit

Breaker,

And

Shielding

Gas

Connections

1

115

V

15

A

AC

Receptacle

RC2

2

Circuit

Breaker

CB1

Receptacle

is

protected

from

over

load

by

CB1.

Press

button

to

reset

breaker.

3

Gas

Fittings

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

Typical

flow

rate

is

15

cfh

(cubic

feet

per

hour).

~

A

ARC

WELDING

can

cause

Electromagnetic

Interference.

~f

To

reduce

possible

interference,

keep

weld

cables

as

short

as

possible,

close

together,

and

down

low,

such

as

on

the

t~r!J

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.

Weld

Output

Terminals

Welding

Amperes

Total

Cable

(Copper)

Length

In

Weld

Circuit

Not

Exceeding

100

ft

(30

m)

Or

Less

150ft

I

(45

m)

200ft

(60

m)

250ft

(70

m)

300ft

350ft

(90_m~j(105_m)

400ft

(120

m)

1060%

Duty

Cycle

60100%

Duty

Cycle

10

100%

Duty

Cycle

irf~~TiEEEiT

0

7~

~

,k

100

4

4

4

3

2

1

1/0

1/0

150

200

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

250

2

1

1/0

2/0 3/0 4/0

2-2/0

2-2/0

300

1

1/0

2/0 3/0

4/0

2-2/0

2-3/0

2-3/0

350

1/0

2/0

3/0

4/0 2-2/0

2-3/0

2-3/0

2-4/0

400

1/0

2/0

3/0

4/0 2-2/0

2-3/0

2-4/0

2-4/0

Ref.

ST-800

312-A

500

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

2

3

hoses

under

bar.

Tools

Needed:

~

5/8,1-1/8in

3-4.

Weld

Output

Terminals

And

Selecting

Cable

Sizes

OM-183

173

Page

8

3-5.

Remote

14

Receptacle

Information

3-6.

Electrical

Service

Guide

A

24

volts

ac.

f~

~

OWVUT

(c0NTPCTOR)

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

14

Max

Recommended

Input

Conductor

Length

In

Feet

(Meters)

132(40)

102

(31)

Mm

Grounding

Conductor

Size

In

AWGIKcmiI

12

14

Reference:

1996

National

Electrical

Code

(NEC).

S-0092J

Socket*

Information

C

Command

reference;

0

to

+10

volts

dc

output

to

remote

control.

A

AMPERAGE

D

Remote

control

circuit

common.

The

remaining

sockets

are

not

used.

Ref.

ST-800

312-A

E

K

0

to

+10

volts

dc

input

command

signal

from

remote

control.

Circuit

Common

OM-183

173

Page

9

3-7.

Placing

Jumper

Links

2

Tools

Needed:

c::::::3:==n

3/8

in

Check

input

voltage

available

at

site.

Ref.

ST-BOO

314

1

Primary

Terminal

Board

2

Jumper

Link

Label

Move

jumper

links

to

match

input

voltage,

and

label

on

unit.

Proceed

to

Section

3-8.

OM-183

173

Page

10

3-8.

Connecting

Input

Power

1

Input

And

Grounding

Conductors

See

Section

3-6.

2

Line

Disconnect

Device

See

Section

3-6.

Reinstall

rear

cover.

Tools

Needed:

3/8,

1/2,

7/16

in

input3

3/96

-

Ret.

ST-601

654

OM-183

173

Page

11

4-1.

Controls

SECTION

4-

OPERATION

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.

1

2

2

\

3

\\

4

5

\

3

6

\

7

I

n

4

8

I

Light

9

I

e

10

/

5

/

11

/

/

/

6

/

Mode

Switch

(See

Section

4-3)

Amperage

Switch

(See

Section

4-6)

Output

Switch

And

(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)

10

High

Temperature

Shutdown

Light

I

7

(1)

p/-~

8

0

_

12

9

13

11

Over

Voltage

Shutdown

Light

See

Section

5-2)

12

Postt

low

Time

Control

(See

Section

4-10)

13

AC

Balance

Controls

(See

Section

4-8)

14

Power

On/Off

Switch

(See

Section

4-12)

14

A

Wear

approved

ear

muffs

or

ear

plugs

if

noise

exposure

exceeds

OSHA

limits.

4-2.

Polarity

Switch

And

Pilot

Lights

ST-800

312-A

+1-

Ret.

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

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.

A

V

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.

2

I

1

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,

pushbutton

does

not

need

to

be

pressed

to

ad

just

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

+150

A

Electrode

Positve

Output

=



250

A

Electrode

Negative

Ref.

ST-169

496-A/

Ref.

S-0865

0

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:

15

~ffl

AMPERAGE/PRESET

~soffl

AMPERAGE/PRESET

A~

OM-183

173

Page

14

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Miller KG194818 Owner's manual

Brand: Miller

Model: KG194818

Category: Welding System

Type: Owner's manual

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