Miller MILLERMATIC 255 Owner’s Manual

OM-279299B
2019−01
Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Description
Arc Welding Power Source
Wire Feeder
r
Millermatic 255
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: MIG (GMAW)
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety Precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller, you can count on
years of reliable service with proper
maintenance. And if for some reason the unit
needs repair, there’s a Troubleshooting
section that will help you figure out what the
problem is, and our extensive service
network is there to help fix the problem.
Warranty and maintenance information for
your particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Miller Electric manufactures a full line
of welders and welding-related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank1 2019−01
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1.
1
Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-2.
Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-3.
Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1-4.
California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1.
5
Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
2-2.
Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3.
Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
7
2-4.
2-5.
Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
2-6.
Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1.
9
Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
11
4-1.
Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
4-2.
Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
4-3.
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
4-4.
Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
4-5.
4-6.
Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Static Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
5-1.
Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
5-2.
Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
5-3.
Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
5-4.
Wiring Optional 240 Volt Plug (119172) For Connection To Miller Welder/Generator
With Split-Phase 240 Volt Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
5-5.
5-6.
Generator Or Inverter Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
20
5-7.
Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
5-8.
MIG Welding Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
5-9.
Process/Polarity Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
5-10. MIG Gun Connection Inside Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
5-11. Connecting Shielding Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
24
5-13. Threading Welding Wire For MIG Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
5-14. Connecting Spoolmatic® 15A Or 30A Or Spoolmate 200 Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
5-15. Connecting XR-Aluma-Pro Or XR-Aluma-Pro Lite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
5-16. Threading Welding Wire For XR-Aluma-Pro Or XR-Aluma-Pro Lite . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-17. Threading Welding Wire Through XR Guns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
28
5-18. Threading Welding Wire For Spoolmate 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28
5-19. Threading Welding Wire For Spoolmatic 15/30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
5-20. Calibrating Spoolgun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
TABLE OF CONTENTS
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Using Auto-Set Elite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Using Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Manual MIG Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Setting Crater Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Manual Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Using Optional MDX-250 EZ-Select Gun In Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-9. Pulsed MIG Auto-Set Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Pulsed MIG Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12. Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − WELD PARAMETER CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. MIG And Flux Core Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Changing Drive Roll and Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Aligning Drive Rolls and Wire Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − GMAW WELDING (MIG) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
COMPLETE PARTS LIST − Available at www.MillerWelds.com
31
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34
35
36
37
38
39
40
41
42
43
43
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2018−01
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
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 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC weld output in damp, wet, or confined spaces, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
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).
Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
When making input connections, attach proper grounding conductor first − double-check connections.
Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
Turn off unit, disconnect input power, and discharge input capacitors according to instructions in Manual before touching any parts.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on
equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-279299 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
Keep your head out of the fumes. Do not breathe the fumes.
Ventilate the work area and/or use local forced ventilation at the arc
to remove welding fumes and gases. The recommended way to
determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
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.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
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.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
OM-279299 Page 2
Do not cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
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, sparks, and fire
hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
Use only correct fuses or circuit breakers. Do not oversize or bypass them.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
Wear approved ear protection if noise level is high.
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
Use the proper equipment, correct procedures, and sufficient
number of persons to lift, move, and transport cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
MOVING PARTS can injure.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
FALLING EQUIPMENT can injure.
Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use correct procedures and equipment of adequate capacity to lift and support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
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.
BATTERY EXPLOSION can injure.
Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
MOVING PARTS can injure.
OVERUSE can cause OVERHEATING
Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
Do not block or filter airflow to unit.
FLYING SPARKS can injure.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC 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.
Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
Use only genuine replacement parts from the manufacturer.
Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
OM-279299 Page 3
H.F. RADIATION can cause interference.
ARC WELDING can cause interference.
High-frequency (H.F.) 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.
Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Be sure all equipment in the welding area is electromagnetically
compatible.
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.
1-4. California Proposition 65 Warnings
WARNING: This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65Warnings.ca.gov.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart
N, Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954,
Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-279299 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
som_2018−01_fre
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une
personne qualifiée est définie comme celle qui, par la
possession d’un diplôme reconnu, d’un certificat ou d’un
statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec
succès sa capacité à résoudre les problèmes liés à la tâche,
le travail ou le projet et a reçu une formation en sécurité afin
de reconnaître et d’éviter les risques inhérents.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.
Ne pas toucher aux pièces électriques sous tension.
Porter des gants isolants et des vêtements de protection secs et
sans trous.
S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
Ne pas utiliser de sortie de soudage CA dans des zones humides
ou confinées ou s’il y a un risque de chute.
Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
Éteignez l’unité, débranchez le courant électrique, et déchargez
les condensateurs d’alimentation selon les instructions indiquées
dans le manuel avant de toucher les pièces.
OM-279299 Page 5
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
Ne pas toucher à mains nues les parties chaudes.
Prévoir une période de refroidissement avant
de travailler à l’équipement.
Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
Eloigner votre tête des fumées. Ne pas respirer les fumées.
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquelles est exposé le personnel.
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets e
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
Ne pas couper ou souder des jantes ou des roues. Les pneus
peuvent exploser s’ils sont chauffés. Les jantes et les roues réparées peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans
les normes de sécurité.
Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par exemple).
Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
OM-279299 Page 6
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que
les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
Ne jamais souder une bouteille pressurisée − risque d’explosion.
Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter les
bouteilles.
Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
Ne pas installer l’appareil à proximité de produits inflammables.
Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
Porter un écran facial pour protéger le visage et
les yeux.
Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
Les PIÈCES MOBILES peuvent
causer des blessures.
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.
Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
OM-279299 Page 7
LIRE LES INSTRUCTIONS.
Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
Effectuer régulièrement le contrôle et l’entretien de l’installation.
Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
Si le FCC signale des interférences, arrêter immédiatement l’appareil.
Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes,
il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.
2-4. Proposition californienne 65 Avertissements
AVERTISSEMENT : ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2,
from Canadian Standards Association, Standards Sales, 5060 Spec-
trum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N,
Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government
Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA
Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd,
Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
OM-279299 Page 8
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
médecin approuve, il est recommandé de suivre les procédures précédentes.
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation − keep hands
and metal objects away.
Safe95 2012−05
Beware of electric shock from wiring.
Safe94 2012−08
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
V
V
>5min
V
Hazardous voltage remains on input capacitors after power is turned
off. Do not touch fully charged capacitors. Always wait 5 minutes after
power is turned off before working on unit, OR check input capacitor
voltage, and be sure it is near 0 before touching any parts.
Safe43 2017−04
Notes
OM-279299 Page 9
3-2. Miscellaneous Symbols And Definitions
A
V
U0
Amperage
Locked
Wire Feed Slow
Run-In
Remote
Gas Metal Arc
Welding (GMAW)
Voltage
Rated No Load
Voltage (OCV)
Circuit Breaker
Direct Current
(DC)
Positive
Alternating
Current (AC)
U1
U2
I2
Wire Feed Spool
Gun
Conventional
Load Voltage
X
Internal Protection
Rating
Single Phase
Unlocked
OM-279299 Page 10
Duty Cycle
Gas Postflow
Line Connection
Rated Welding
Current
Gas Preflow
S
Gas Input
Notes
Self-Shielded Flux
Cored Arc
Welding (FCAW)
Negative
Primary Voltage
Input Power Or Input Voltage
IP
Gas Metal Arc
Welding (GMAW)
MIG / Gun Control
Suitable for Some
Hazardous
Locations
Increase
Hz
Hertz
Single Phase
Static Frequency
ConverterTransformerRectifier
Cold Jog (Inch)
Toward Workpiece
Output Enabled
Reverse Polarity
A complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back of unit. Use rating label to determine input power requirements and/or
rated output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Unit Specifications
Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-2 and 5-3 for information on connecting input power.
This equipment will deliver rated output at an ambient air temperature up to 1045F (405C).
Rated Welding Output
Maximum Open-Circuit
Voltage DC
Amperage Range
260 A, 27 volts DC,
40% Duty Cycle
20−350 A
230 A, 25.5 volts DC,
60% Duty Cycle
20−350 A
Wire Type And Diameter
Amperes Input At Rated Load Output,
50/60 Hz, Single Phase
208 VAC
240 VAC
87
47.8
41.1
87
40.6
35
Wire Feed Speed
Solid Steel
Flux Cored
Aluminum
Dual Shield
50−800 IPM
0.024 − 0.045
0.035 − 0.045
0.035 − 3/64
0.045
(13−17.8 mpm)
4-3. Environmental Specifications
A. IP Rating
IP Rating
IP21
This equipment is designed for indoor use and is not intended to be used or stored outside.
IP21 2014−06
B. Temperature Specifications
Operating Temperature Range*
Storage/Transportation Temperature Range
–22 to 122°F (−30 to 50°C)
−40 to 149°F (−40 to 65°C)
*Output is derated at temperatures above 104°F (40°C).
Temp_2016- 07
OM-279299 Page 11
A complete Parts List is available at www.MillerWelds.com
4-4. Dimensions And Weight
Weight
84 lb (38.1 kg)
13.75 in.
(349 mm)
19.25 in.
(489 mm)
26.25 in.
(667 mm)
907734
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-279299 Page 12
A complete Parts List is available at www.MillerWelds.com
4-5. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, output stops. Wait
10 minutes for unit to cool. Reduce
amperage or duty cycle before
starting to weld again.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
40% Duty Cycle At 260A
60% Duty Cycle At 230A
6 Minutes Welding
4 Minutes Welding
4 Minutes Resting
6 Minutes Resting
Overheating
A or V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 / 279044-B
4-6. Static Characteristics
The static (output) characteristics of the welding power source can be described as flat during the GMAW process. Static characteristics are
also affected by control settings (including software), electrode, shielding gas, weldment material, and other factors. Contact the factory for
specific information on the static characteristics of the welding power source.
OM-279299 Page 13
A complete Parts List is available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Selecting A Location
!
Do not move or operate unit where it could tip.
Movement
1
!
Do not lift unit by strap threaded through both handles.
!
Location And Airflow
Do not lift unit with cart attached.
2
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1
Lifting Handles
Use handles to lift unit.
2
Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)
18 in.
(460 mm)
loc_smallmig2 2018-09 161-122
OM-279299 Page 14
A complete Parts List is available at www.MillerWelds.com
5-2. Electrical Service Guide
Elec Serv 2017−01
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
50/60 Hz 1-Phase
Input Voltage (V)
208
240
Rated Maximum Supply Current I1max (A)
86.9
74.6
Maximum Effective Supply Current I1eff (A)
34.1
30.8
Time-Delay Fuses2
90
80
Normal Operating Fuses 3
100
90
Min Input Conductor Size In AWG (mm2) 4
8 (10)
8 (10)
Max Recommended Input Conductor Length In Feet (Meters)
54 (17)
73 (22)
8 (10)
8 (10)
Max Recommended Standard Fuse Rating In
Min Grounding Conductor Size In AWG
Amperes1
(mm2) 4
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table
400.5(A) for flexible cord and cable requirements.
Notes
OM-279299 Page 15
A complete Parts List is available at www.MillerWelds.com
5-3. Connecting 1-Phase Input Power
1
5
=GND/PE Earth Ground
9
4
6
L1
L2
7
8
3
1
2
L2
L1
240 VAC, 1
Tools Needed:
Ref. Input13 2015−08
OM-279299 Page 16
A complete Parts List is available at www.MillerWelds.com
5-3. Connecting 1-Phase Input Power (Continued)
!
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input
power before connecting input conductors from unit. Follow established
procedures regarding the installation
and removal of lockout/tagout
devices.
!
Always connect green or green/yellow
conductor to supply grounding terminal first, and never to a line terminal.
See rating label on unit and check input voltage available at site.
1
Plug (NEMA Type 6-50P)
2
Receptacle
(NEMA Type 6-50R) Customer
Supplied
Wire receptacle according to the direct connection method stated below and as shown,
and connect plug to receptacle or direct connect input power as follows:
3
4
5
6
7
8
Input Power Cord
Disconnect Device (switch shown in the
OFF position)
Disconnect Device Grounding Terminal
Disconnect Device Line Terminals
Black And White Input Conductor (L1
And L2)
Green Or Green/Yellow Grounding
Conductor
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1 and L2 to disconnect device line terminals.
9
Over-Current Protection
Select type and size of over-current protection using Section 5-2 (fused disconnect
switch shown).
Connect plug to receptacle if hard wiring
method is not used.
Close and secure door on disconnect device.
Follow established lockout/tagout procedures to put unit in service.
Ref. Input13 2015−08
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-279299 Page 17
A complete Parts List is available at www.MillerWelds.com
5-4. Wiring Optional 240 Volt Plug (119172) For Connection To Miller Welder/Generator
With Split-Phase 240 Volt Auxiliary Power
3 (Not Used)
Tools Needed:
4
1
Input And Grounding
Conductors
2
Plug Wired for 240 V, 2-Wire
Load
3
Neutral (Brass) Terminal And
Prong (Not Used)
4
Load 1 (Brass)Terminal And
Prong
5
Load 2 (Brass) Terminal And
Prong
6
Ground (Brass) Terminal And
Prong
7
Black And White Input
Conductors
8
Green Or Green/Yellow
Ground Conductor
!
Always connect green or
green/yellow wire to ground
terminal, never to a load
terminal. Connect black (L1)
and white (L2) wires to load
terminals.
5
6
Plug Front
View
2
3
7
4
240V
8
5
6
7
8
1
Green Or
Green/Yellow
Ref. 120 813-D / 907734
OM-279299 Page 18
A complete Parts List is available at www.MillerWelds.com
5-5. Generator Or Inverter Requirements
For maximum output Miller recommends 12kW or greater generator.
Generator settings, if applicable.
!
Engine Control Switch must be set at “RUN”
position − not “RUN/IDLE”.
!
Set generator Voltage/Amperage
Control to 10 (or max) for maximum
auxiliary power.
Notes
OM-279299 Page 19
A complete Parts List is available at www.MillerWelds.com
5-6. Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
Welding
Amperes
10 − 60%
Duty
Cycle
AWG (mm2)
150 ft
(45 m)
200 ft
(60 m)
60 − 100%
Duty Cycle
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
10 − 100% Duty Cycle
AWG (mm2)
AWG (mm2)
100
4 (20)
4 (20)
4 (20)
3 (30)
2 (35)
1 (50)
1/0 (60)
1/0 (60)
150
3 (30)
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
3/0 (95)
200
3 (30)
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
4/0 (120)
250
2 (35)
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x2/0 (2x70)
300
1 (50)
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
350
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x3/0 (2x95)
2x4/0 (2x120)
400
1/0 (60)
2/0 (70)
3/0 (95)
4/0 (120)
2x2/0 (2x70)
2x3/0 (2x95)
2x4/0 (2x120)
2x4/0 (2x120)
* This
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**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.
( ) = mm2 for metric use.
***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding
Society at http://www.aws.org.
Ref. S-0007-M 2017−08
5-7. Weld Output Terminals
!
Turn off power before connecting
to weld output terminals.
!
Do not use worn, damaged, undersized, or repaired cables.
1
Positive (+) Weld Output Terminal
2
Negative (−) Weld Output Terminal
See Section 5-8 for
information on
connecting to weld output terminals
and standard connection diagrams.
1
2
OM-279299 Page 20
output term1 2015−02
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5-8. MIG Welding Connections
1
1
2
3
3
4
2
4
FCAW-S − DCEN
(Direct Current Electrode Negative)
MIG/FCAW-G − DCEP
(Direct Current Electrode Positive)
8
5
7
6
280401B / Ref. 275167A / 282987A
!
Turn off unit and disconnect input
power before making connections.
1 Positive Weld Output Receptacle
2 Negative Weld Output Receptacle
3 Wire Drive Assembly Cable
4 Work Clamp And Cable
Ensure all connections are tight.
5 Gun End
Connect gun end to drive assembly (see
Section 5-10).
6 Trigger Control Cable
7 Four Pin Trigger Control Cable
Receptacle
Route trigger control cable through MIG
gun hole.
Connect plug on end of cable to four pin
receptacle inside unit.
8
MIG Shielding Gas Connection
Connect supplied gas hose between regulator/flowmeter gas hose connection and
fitting on rear of welding power source.
See Section 11-16 for gas selection.
5-9. Process/Polarity Table
Cable Connections
Process
Polarity
Wire Drive Assembly Cable
Work Cable
GMAW − Solid wire with shielding gas
DCEP − Reverse polarity
Connect to positive (+)
output receptacle
Connect to negative (−)
output receptacle
FCAW-S − Self-shielding wire − no
shielding gas
DCEN − Straight Polarity
Connect to negative (−)
output receptacle
Connect to positive (+)
output receptacle
FCAW-G − Flux-cored wire with shielding gas
DCEP − Reverse Polarity
Connect to positive (+)
output receptacle
Connect to negative (−)
output receptacle
OM-279299 Page 21
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5-10. MIG Gun Connection Inside Unit
1
2
3
4
Gun Securing Knob
Gun Block
Gun Outlet Wire Guide
Gun End
Loosen knob. Insert end of gun through
opening in front panel until gun end
bottoms against gun block. Tighten
knob.
3
1
4
2
Be sure that gun end is tight against drive assembly.
4
4
Correct
Incorrect
282950A
OM-279299 Page 22
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5-11. Connecting Shielding Gas Supply
Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.
1
1
Cap
2
Cylinder Valve
Remove cap, stand to side of valve,
and open valve slightly. Gas flow
blows dust and dirt from valve.
Close valve.
2
3
Cylinder
4
Regulator/Flowmeter
Install so face is vertical.
3
Mixed Gas
1
1
9
2
2
8
3
3
5
Regulator/Flowmeter Gas
Hose Connection
6
Welding Power Source Gas
Hose Connection
7
Flow Adjust
Typical flow rate for shielding gas is
20 to 30 CFH (cubic feet per hour).
Check
wire
manufacturer’s
recommended flow rate.
8
9
CO2 Gas
Argon Gas
4
CO2 Adapter (Customer
Supplied)
O-Ring (Customer Supplied)
Install adapter with O-ring between
regulator/flowmeter
and
CO2
cylinder.
7
5
6
Tools Needed:
Ref. 804 654-A / 282987A
OM-279299 Page 23
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5-12. Installing Wire Spool And Adjusting Hub Tension
Hand tighten knob clockwise.
When a slight force is needed
to turn spool, tension is set.
To install either a 1 lb or 2 lb wire
spool, follow the procedure as
shown in the illustration.
Installing 1 Or 2 lb Wire Spool
Spindle
Remove these
components
from spindle.
Spindle
Order two additional 5/8 washers
Part No. 605941
Install these
components
onto spindle.
Order additional spring
Part No. 186437
282945A
OM-279299 Page 24
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5-13. Threading Welding Wire For MIG Gun
1
2
3
4
5
6
7
4
Wire Spool
Welding Wire
Inlet Wire Guide
Pressure Adjustment Knob
Drive Roll
Outlet Wire Guide
Gun Conduit Cable
Lay gun cable out straight.
7
Tools Needed:
1
6
2
3
5
Hold wire tightly to keep it
from unraveling.
6 in.
(150 mm)
Open pressure assembly.
Pull and hold wire; cut off end.
Use pressure indicator scale to set a desired
Tighten
drive roll pressure. Begin with a setting of 2.
If necessary, make additional adjustments
after trying this initial setting.
1
2
3
4
Close and tighten pressure
assembly, and let go of wire.
Push wire through guides into gun;
continue to hold wire.
Pressure
Indicator
Scale
Remove gun nozzle and contact tip.
Turn On.
Tighten
WOOD
Press gun trigger or jog button
until wire comes out of gun.
Reinstall contact tip and nozzle
1
2
3
4
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
Cut off wire. Close
and latch door.
801083 / Ref. 800924-D / 282950-A
OM-279299 Page 25
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5-14. Connecting Spoolmatic) 15A Or 30A Or Spoolmate 200 Gun
1
Gun Trigger Plug
Insert plug into receptacle, and tighten
threaded collar.
2
3
2
Weld Cable
Shielding Gas Hose
Route weld cable and gas hose
through opening in panel.
4
7
Remove the 3/4 in. bolt from the drive
casting. Use bolt to connect spoolgun
weld cable to drive casting.
6
5
5
6
7
8
2
8
1/2-13 x 3/4 in. Bolt (282942)
Lock Washer (602216)
Washer (602247)
Gas Hose Routing Hole
To route gas hose through rear panel,
drill 1 in. hole through bottom of rear
plastic bezel. Align drill with pilot dimple in plastic bezel visible from inside
wire drive compartment.
3
9
9
4
Gas Hose Fitting
Route shielding gas hose through wire
drive compartment, out opening in rear
panel, and up to regulator/flowmeter.
Connect gas hose fitting to
regulator/flowmeter.
Tools Needed:
3/4 in.
Drive Casting
1
1 in.
3
282999
5-15. Connecting XR-Aluma-Pro Or XR-Aluma-Pro Lite
1
2
3
Tools Needed:
Gun End
Gun Liner
Wire Outlet Guide
Trim excess liner from end of gun
so no more than 3/32 in. (2.4 mm) of
liner extends past wire outlet guide.
Be sure to trim liner to proper extension.
4
Gun Securing Knob
Loosen securing knob. Insert gun
end through opening until it bottoms
against drive assembly (make sure
gun end does not touch drive rolls).
Tighten knob.
Be sure to change drive rolls to the
proper size and type.
5
3/32 in.
(2.4 mm)
Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
1
2
3
5
4
803463 / 282952A
OM-279299 Page 26
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5-16. Threading Welding Wire For XR-Aluma-Pro Or XR-Aluma-Pro Lite
1
2
3
4
5
6
7
2
6
1
Wire Spool
Welding Wire
Inlet Wire Guide
Drive Roll
Outlet Wire Guide
Pressure Adjustment Knob
Gun Conduit Cable
Lay gun cable out straight.
7
Tools Needed:
3
4
5
Thread hub tension
nut loosely.
Hold wire tightly to keep
it from unraveling.
6 in.
(150 mm)
Pull and hold wire;
cut off end.
Open pressure assembly.
Use pressure indicator scale to
Tighten
Pressure
Indicator
Scale
Push wire thru guides into gun;
continue to hold wire.
1
2
3
4
set a desired drive roll pressure. Begin with a setting of 2.
If necessary, make additional
adjustments after trying this initial setting.
Close and tighten pressure
assembly, and let go of wire.
See Section 5-17 for threading
welding wire through XR guns.
282952-A / S-0627-A
OM-279299 Page 27
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5-17. Threading Welding Wire Through XR Guns
!
For XR-Aluma-Pro Gun:
1
1
Welding wire is electrically live
when gun trigger is used to jog
wire.
Refer to Section 5-16 for instructions
on feeding wire through welding power source.
Pressure Roll Assembly
Lay gun cable out straight.
Open top cover, and open pressure roll assembly. Remove nozzle and contact tip.
Press gun trigger until about 4 in. (102 mm)
of wire is sticking out front of gun. Install
nozzle and contact tip.
Turn On
Welding Power
Source.
Close top cover on gun. Press trigger
switch until about 6 in. (152 mm) of wire is
sticking out end of contact tip. Cut off wire.
Close and latch door.
XR-Aluma-Pro and XR-Aluma-Pro
Lite gun drive roll pressure should be
set to match the alloy being used.
Tools Needed:
801 556 / Ref. 804 544-B
5-18. Threading Welding Wire For Spoolmate 200
Tools Needed:
7
1
2
3
Cover
Canister
Thumbscrew (Cover)
Loosen thumbscrew, and rotate
cover open.
6
4
Wire Spool
Loosen wire from spool, cut off bent
wire, and pull 6 in (150 mm) of wire
off spool.
5
5
3
Pressure Roll Assembly
Press arm inward to open pressure
roll assembly.
1
6
7
8
2
9
4
Wire Inlet Guide
Drive Roll Groove
Contact Tip
Thread wire through wire inlet
guide, along drive roll groove, and
out contact tip.
Install spool so wire feeds off top.
9
Spool Brake Thumbnut
If necessary, turn thumbnut
counterclockwise slightly to install
spool.
Close cover and secure with
thumbscrew.
8
Ref. 243 740-C
OM-279299 Page 28
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5-19. Threading Welding Wire For Spoolmatic 15/30A
1
2
3
4
6
8
Tools Needed:
7
Top Cover
Canister
Canister Cover
Thumbscrew (Canister Cover)
Loosen thumbscrew and remove cover.
5
Wire Spool
Loosen wire from spool, cut off bent wire,
and pull 6 in. (150 mm) of wire off spool.
6
Pressure Roll Assembly
Lift arm and open pressure roll assembly.
7
8
2
For wire sizes .035 in. (0.9 mm) and
10
1
Canister Inlet Guide
Drive Roll Groove
11
smaller use small groove, and .047
in. (1.2 mm) and 1/16 in (1.6 mm) use
large groove.
3
9
Contact Tip
Thread wire through canister inlet guide,
along drive roll groove, and out contact
tip.
Install spool so wire feeds off bottom.
10 Spool Brake Thumbnut
If necessary, turn thumbnut counterclockwise slightly to install spool.
5
4
11 Thumbscrew (Canister Rotation)
Loosen thumbscrew to rotate canister.
Close and secure pressure roll assembly.
9
Reinstall top cover and canister cover.
150 436-F
Notes
OM-279299 Page 29
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5-20. Calibrating Spoolgun
1
6
5
4
2
3
7
8
9
297061-D
Spoolmatic
15/30A and Spoolmate
200 motors are unique to this welding
power source. Motor calibration is
necessary any time a different Spoolmatic 15/30A or Spoolmate 200 is connected to the Multimatic 255.
1
Settings Menu
2
Slow Speed Calibration Menu
3
Fast Speed Calibration Menu
4
Home
5
6
Spg Cal (Spoolgun Cal)
Right Knob
7
Gun Type
8
Next
9
Save
Connect spoolgun to unit. Cut wire flush at
OM-279299 Page 30
nozzle.
Follow instructions in Section 6-5 to enter
the setup menu.
SPG CAL will only be displayed as the
fifth tab when a spoolgun is connected.
Press SPG CAL to access slow speed calibration menu.
Press Gun Type to select the spoolgun being used.
To begin the slow speed calibration, pull the
spoolgun trigger. The wire will feed and automatically stop.
Cut wire flush at nozzle and measure
run-out. If wire length is not 24 in., use right
knob to enter the amount that the wire was
short/long.
Pull spoolgun trigger again to verify the adjustment. Repeat these steps until satisfied
with accuracy.
Press Next to access fast speed calibration.
To begin the fast speed calibration, pull the
spoolgun trigger. The wire will feed wire
and automatically stop.
Cut wire flush at nozzle and measure
run-out. If wire length is not 24 in., use right
knob to enter the amount that the wire was
short/long.
Pull spoolgun trigger again to verify the adjustment. Repeat these steps until satisfied
with accuracy.
Press Save to complete the calibration
procedure and be returned back to the settings menu.
Press Home to return to weld mode.
A complete Parts List is available at www.MillerWelds.com
SECTION 6 − OPERATION
6-1. Controls
1
3
6
2
4
7
5
8
297061-D
1 Auto-Set Button
Press to turn Auto-Set On or Off.
2 Pulse Button
Press to turn Pulse On or Off in MIG
process.
3 USB Port
Use for software upgrade and collecting error codes.
The USB
port can also be used to
charge cell phones and similar devices.
4
Power Switch
Use switch to turn unit On or Off.
5
Color LCD Display
6
Left Knob
Use left knob to adjust voltage in MIG
mode, arc length in Pulsed MIG mode, or
change parameter values in Setup Mode.
7 Right Knob
Use right knob to adjust wire feed speed or
change parameter values in Setup Mode.
8 Soft Keys
Multiple functions depending on which
screen is being displayed.
OM-279299 Page 31
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6-2. Special Features
A. MIG Mode
In MIG mode, the left knob is used to adjust welding voltage within a range of 12 to 32 volts. The right knob is used to adjust wire feed speed within a
range of 50 to 800 IPM. Refer to weld chart inside the wire drive compartment for proper parameter settings according to wire type, shielding gas, and
material type and thickness.
B. Jog Mode
If gun trigger is pressed and held for more than 3 seconds without striking an arc, unit will automatically shut off weld power and shielding gas. Trigger
error will be displayed after preset length of wire is fed, dependent on MIG gun selected. See Section 8-5.
C. Weld Status
When trigger is released on a MIG gun, spool gun, or push-pull gun, the last actual amperage and voltage are shown on the display for 5 seconds. If a
programmed value requires adjustment after the arc is extinguished and during the 5-second display of actual values, turning either knob will cause
actual values in the displays to be replaced by programmed values for adjustment purposes.
D. MIG Gun-On-Demand
MIG guns, spool guns, and push-pull guns can be used with this unit. To switch from one gun to another, momentarily press the trigger on the desired
unused gun to make it the active gun. Once the trigger is pressed, the unit will recall stored data and both displays will show the last programmed values
for that particular gun. If the unit is powered down and back on again, the gun last used will become the current active gun.
E. Pulsed MIG Mode Voltage Adjustment
In Pulsed MIG mode there is no manual voltage adjustment; instead, voltage is synergically aligned with the proper wire feed speed. Arc Length adjustment is used to adjust actual arc length, which automatically adjusts the voltage. See weld chart in front compartment for proper wire feed speed
adjustment according to wire size and type.
Notes
OM-279299 Page 32
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6-3. Using Auto-Sett Elite
1
2
12
10
11
8
9
3
1 Auto-Set Button
Press to turn Auto-Set On or Off.
2 Pulse Button
Press to turn Pulse On or Off.
3 Material/Gas Left Button
4 Material/Gas Right Button
Press to select material and gas. Left button moves cursor to the left, right button
moves cursor to the right.
5 Diameter Button
Selects the size of the wire.
4
5
6
6
Material Thickness Left Button
7
Material Thickness Right Button
Use to select material thickness. Left button moves cursor to the left, right button
moves cursor to the right.
8
Left Knob
Use left knob to fine tune voltage in MIG
mode or arc length in Pulsed MIG mode.
9
Right Knob
Use right knob to fine tune wire feed speed.
7
297061-D
When using a spoolgun or push-pull
gun in Auto-Set, the potentiometer on
the gun is deactivated. Wire feed
speed is controlled on the front panel.
10 Welding Output Icon
When visible, indicates weld output is on.
11 Improper Weld Polarity Icon
When visible, indicates electrode and work
cables need to be switched.
12 Bullseye Indicator
Represents factory default settings.
OM-279299 Page 33
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6-4. Using Manual Mode
1
7
3
2
4
5
8
6
297061-D
1 Auto-Set Button
Press Auto-Set to turn Auto-Set Off.
2 Pulse Button
Press to turn Pulse On or Off.
3 Setup Button
Press Setup to optimize arc performance or
to add timers to weld sequence. See Section 6-5.
4 Program Button
OM-279299 Page 34
Press Program to save favorite weld programs, up to four programs per weld
process. See Section 6-7.
5 Jog Button
Feed wire without turning on weld output
and energizing gas solenoid. See Section
6-2.
6 Purge Button
Energizes gas solenoid without turning on
weld output or feeding wire.
7
Left Knob
Use left knob to adjust voltage in MIG mode
or arc length in Pulsed MIG mode.
8
Right Knob
Use right knob to adjust wire feed speed.
When using spoolgun or push-pull gun,
wire feed speed is controlled at the gun
and the right knob is deactivated.
A complete Parts List is available at www.MillerWelds.com
6-5. Manual MIG Setup Mode
1
2
3
4
297061-D
1
Setup Button
2
Left Knob
3
Right Knob
4
Home Button
To enter the Setup menu from the Manual
Mode home screen, press Setup.
Once in the Setup menu, rotate the left knob
to find a particular item, and rotate the right
knob to change setting or status.
Press Home to save settings and return to
welding mode.
Items that can be adjusted from this menu are:
Wire and Gas Type: Optimize arc starts and
weld performance by selecting the wire type
and gas being used.
Wire Diameter: Optimize arc starts and weld
performance by selecting the wire diameter
that matches the wire being used.
Inductance: Changes the fluidity of the weld
puddle. Increasing inductance produces a
more fluid, softer arc. Decreasing inductance
produces a stiffer arc. Inductance settings
range from 0 to 99. The default setting is 50.
Preflow: The amount of time that the shielding gas will flow after the trigger is depressed
and before the welding arc can start. Preflow
settings range from Disabled to 5 seconds.
Postflow: The amount of time that the shielding gas will flow after the arc has been shut off.
Postflow settings range from Disabled to 5
seconds.
Run-In: The speed of the wire prior to the
welding arc being struck. Auto is the default
setting. The other options are Disabled or
Manual. Manual settings range from 5 to
150% of the welding wire feed speed.
FasTackt: Enabling FasTack reduces arc
start time by automatically increasing the
run-in speed when doing repetitive arc starts.
FasTack automatically uses a slower wire
feed speed when the wire is cool and a faster
wire feed speed when the wire is hot. Default
setting is Disabled.
Crater: The amount of time the welding arc
stays on after the welding gun trigger is re-
leased. This feature is used to fill the void or
crater at the end of the weld. Crater settings
range from 0.1 to 5 seconds. See Section 6-6.
Spot Timer: The amount of time that the arc
can be active before it shuts off automatically.
Spot timer setting range is from Disabled to
120 seconds. Spot timer is reset upon release
of welding gun trigger.
Stitch Timer: Used in conjunction with the
spot timer and while the trigger is continuously
depressed. Controls the amount of time that
the arc will be inactive after the spot timer
times out. Stitch time setting range is from 1
to 120 seconds.
Set Up Push Motor Torque (SUP): This feature is only displayed when an AlumaPro Lite
gun is connected to the welding power
source. The SUP setting adjusts the over
torque limit of the push motor inside the welding power source. The range is 0 to 250, and
the default value is 130. The AlumaPro Lite
SUP value can be found on the back end of
the gun. Set the SUP value on the machine to
match the value on the gun.
OM-279299 Page 35
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6-6. Setting Crater Time
2
1
3
297061-D
1
Left Knob
Crater Wire Feed Speed: Wire feed
speed range is 50 to 800 ipm.
Right Knob
In the Setup menu, rotate the left knob to
highlight Crater, and rotate the right knob
to select Manual.
2
3
Home Button
The following Crater variables can be adjusted:
Crater Delay: This setting is for spot or
stitch welding without crater fill if the arc
time is less than the set time. Time range
is 0 to 5 seconds. (If crater delay is set for
2 seconds, weld operation will not go into
crater if gun trigger is released before 2
seconds.)
The crater setting is the amount of time the
welding arc stays on after the welding gun
trigger is released. This feature is used to
fill the void or “crater” at the end of the
weld.
OM-279299 Page 36
Crater Time: Time range is 0.1 to 5 seconds.
Crater Voltage (MIG settings) or Arc
Length (Pulse settings): Voltage range is
10 to 32 volts. Arc length range is 0 to 99.
A complete Parts List is available at www.MillerWelds.com
6-7. Manual Program Mode
1
3
4
5
2
1
2
3
4
5
Program Button
Program Soft Keys
Left Knob
Right Knob
Home Button
The unit can store four programs. The programs have default setting saved when the
machines come from the factory.
Saving Programs In Manual Mode
To enter the Program menu from the Manual Mode home screen, press the Program
button.
White Program tabs will appear above four
of the soft keys.
Determine where you would like to save the
settings. Push and hold that Program soft
key for two seconds. The display will show
“Saved” when the program has been successfully saved.
Saving Programs From Auto-Set Mode
Program mode cannot be accessed from
Auto-Set mode. To save settings, note the
weld parameters and return to Manual
mode to access Program mode.
Recalling Programs
Push the Program button to select desired
program. The selected Program tab will
turn blue and the proper setting will be displayed.
297061-D
Weld parameters may be changed while
using the program with the left and right
knobs. If the settings are changed, the program tab will turn white and the lettering will
turn black. To save the new settings, press
and hold the Program button again for two
seconds.
If you change the setting but do not wish to
save it, press the Program button again to
recall the original settings.
Exiting Program Mode
Press the Home button to exit Program
mode and return to Manual mode.
To use optional MDX-250 EZ-Select
MIG gun with Program mode, see Section 6-8.
OM-279299 Page 37
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6-8. Using Optional MDX-250 EZ-Selectt Gun In Program Mode
2
1
Ref. 800797-A
1
Trigger Switch
2
Program LEDs
The optional MDX−250 EZ-Select gun
gives the operator the ability to change weld
programs at the gun. When the MDX−250
is connected, “EZ Select” is displayed in the
last tab. Push the soft key below the EZ Select tab to enable.
OM-279299 Page 38
When this feature is enabled, the 4 LEDs on
the MDX−250 gun handle indicate which
program is active. Tap the gun trigger to select the program. The number of lit LEDs on
the gun indicates the selected program and
allows the operator to know which program
is being used without going back to or seeing the machine.
Tap the trigger once. LED 1 on the gun illuminates. Program 1 is selected.
Tap the trigger twice. LEDs 1 and 2 on the
gun illuminate. Program 2 is selected.
Tap the trigger three times. LEDs 1, 2, and 3
on the gun illuminate. Program 3 is selected.
Tap the trigger 4 times. LEDs 1, 2, 3, and 4 on
the gun illuminate. Program 4 is selected.
When the EZ-Select feature is disabled on the
welder, LEDs 1 and 4 on the gun are illuminated.
A complete Parts List is available at www.MillerWelds.com
6-9. Pulsed MIG Auto-Sett Mode
1
2
7
6
3
4
5
297061-D
Pulsed MIG is a spray transfer that produces less heat input than conventional
spray transfer, resulting in less warping,
distortion, and spatter. Pulsed MIG is often
used for MIG welding aluminum.
1
Auto-Set Button
2
Pulse Button
Press Auto-Set and Pulse buttons.
3
Wire And Gas Buttons
4
Use soft key to select wire diameter.
5
Material Thickness
Arc Length
Arc length can be adjusted from 0-99. All
Pulse MIG programs are set with a value of
50. Adjusting the Arc Length will vary the
length of the welding arc cone.
Use soft keys to move cursor to left or right
to select material thickness.
(0 Setting)
6
(99 Setting)
Left Knob
Use left knob to fine tune arc length. Arc
length defaults to 50.
7
Use soft keys to select wire and gas for
Pulsed MIG.
Wire Diameter
Right Knob
Use right knob to fine tune wire feed speed.
Low Setting
High Setting
If a gas is used other than what is listed on
the Pulse MIG welding program chart, the
Arc Length can be adjusted to help customize your arc to the gas being used.
OM-279299 Page 39
A complete Parts List is available at www.MillerWelds.com
6-10. Pulsed MIG Manual Mode
1
4
3
2, 5
297061-D
1
2
3
4
5
Pulse Button
Set Up Button
Left Knob
Right Knob
Home Button
Press Pulse and Set Up buttons.
In the Setup menu, rotate left knob to highlight material and gas. Rotate right knob to
select material and gas being used.
Rotate left knob to highlight wire diameter.
Rotate right knob to select wire diameter
being used.
Press Home to return to welding mode.
to Pulse MIG welding chart for proper Wire
Speed setting for metal and metal thickness being welded. All Pulse MIG programs are set up with the gases listed in the
Pulse MIG welding chart. If alternate gases
are used, adjust arc length and/or arc control to adjust arc characteristics.
Arc Length
Arc length can be adjusted from 0-99. All
Pulse MIG programs are set with a value of
50. Adjusting the arc length will vary the
length of the welding arc cone.
OM-279299 Page 40
Arc Control
Press Setup button to enter Setup menu.
Rotate left knob to select Arc Control. The
setting can be adjusted from 0 to 50. All
Pulse MIG welding programs are designed
with a setting of 25. Using the right knob to
adjust the Arc Control setting will vary the
width of the welding arc cone.
(0 Setting)
(0 Setting)
Low Setting
Low Setting
(50 Setting)
(99 Setting)
Operation
Adjust right knob for proper wire feed speed
and adjust left knob to change arc length if
required. Arc length will default to 50. Refer
Arc Length can be adjusted to help customize your arc to the gas being used.
High Setting
If a gas is used other than what is listed on
the Pulse MIG welding program chart, the
High Setting
If a gas is used other than what is listed on
the Pulse MIG welding program chart, the
Arc Control can be adjusted to help customize your arc to the gas being used.
A complete Parts List is available at www.MillerWelds.com
6-11. System
1
2
3
4
5
297061-D
From the System Setting screen, the operator can monitor how the unit is being used,
view system software information, restore
the unit to factory default settings, and select optional welding guns.
Access the System information screen
from the manual MIG home screen by
pressing Setup, then System. See Section
6-5.
System Screen
The System screen displays four or five
tabs above the soft keys, depending on
which welding gun is connected.
1 Back
Press soft key to return to Setup screen.
2 Counters
Press soft key to access timer logs with a
USB thumb drive. In the counters menu,
there are two options:
4
Reset Log: Press soft key to reset all system timers.
5
Save Log: Insert USB thumb drive into
USB port on front of welder. Press soft key
to download all system timers to the drive.
This system information can then be loaded into an Excel spreadsheet.
3
Software
Press soft key to display the system software versions. This information is used by
factory authorized service agents.
License: Press soft key to display Miller Licensing Agreement.
Reset
Press soft key to reset unit to original factory settings
EZ Select
This tab is only present when using the optional EZ Select MIG gun or an AlumaPro
or AlumaPro Lite push pull gun.
EZ Selectt: The system detects that the
optional EZ Select MIG gun is connected
to the system. Press soft key to enable or
disable the trigger tap program select feature of the EZ Select gun.
PPG: Press soft key to match the
push-pull gun being used. The selected
gun, AlumaPro or AlumaPro Lite, appears
above the blue tab.
OM-279299 Page 41
A complete Parts List is available at www.MillerWelds.com
6-12. Support
The Support screen allows the operator to quickly access the Miller website and phone number to obtain
more product information or get service support.
Access the Support screen from the
manual MIG home screen by pressing Setup, then Support. See Section
6-5.
297061-D
OM-279299 Page 42
A complete Parts List is available at www.MillerWelds.com
SECTION 7 − WELD PARAMETER CHARTS
7-1. MIG And Flux Core Parameters
282495-D
OM-279299 Page 43
A complete Parts List is available at www.MillerWelds.com
SECTION 8 − MAINTENANCE &TROUBLESHOOTING
8-1. Routine Maintenance
!
Disconnect power before maintaining.
Maintain more often during severe conditions.
= Check
= Change
= Clean
* To be done by Factory Authorized Service Agent
= Replace
Every
3
Months
Damaged Or Unreadable
Labels
Repair Or Replace Cracked
Weld Cable
Clean And Tighten Weld
Terminals
Check Gun Cable
Clean Drive Rolls
Apply Light Coat Of Oil Or
Grease To Drive Motor Shaft
OR
Every
6
Months
Inside Unit
8-2. Changing Drive Roll and Wire Inlet Guide
1
2
2
Securing Screw
Inlet Wire Guide
Loosen screw. Slide tip as close to
drive rolls as possible without
touching. Tighten screw.
3
4
1
Drive Roll
The drive roll consists of two
different sized grooves. The
stamped markings on the end
surface of the drive roll refers to the
groove on the opposite side of the
drive roll. The groove closest to the
motor shaft is the proper groove to
thread (see Section 5-13).
4
Drive Roll Securing Nut
Turn nut one click to secure drive
roll.
Tools Needed:
3
7/16 in.
907728
8-3. Overheating
Thermistors RT1, RT2, and the thermistors contained within the inverter module PM1 protect the unit from damage due to overheating. If the output
diode heatsink, output inductor L2, and/or inverter module PM1 get too hot, they command the weld controller to disable the output. The fan keeps
running to cool the unit. Wait several minutes before trying to weld.
OM-279299 Page 44
A complete Parts List is available at www.MillerWelds.com
8-4. Aligning Drive Rolls and Wire Guide
!
Turn Off power.
View is from top of drive rolls
looking down with pressure
assembly open.
Correct
3
Incorrect
4
2
1
5
1
2
3
4
5
Drive Roll Securing Nut
Drive Roll
Wire Guide
Welding Wire
Drive Gear
Insert screwdriver, and turn screw
in or out until drive roll groove lines
up with wire guide.
Close pressure roll assembly.
Tools Needed:
Ref. 800 412-A
8-5. Error Messages
Message
Error
Remedy
Overtemp
Please wait while the welder cools
down
Inverter Module Output Rectifier
Secondary Magnetics
Internal temperature of welder has exceeded the
maximum limit.
Wait for unit to cool down. If the fan is not running, contact authorized Miller service center.
Trigger Error
Release MIG gun trigger
MIG gun trigger is engaged on power up.
Release 4-pin trigger to clear error.
MIG gun is held during jog for more than 17 feet
of wire.
MIG gun trigger is engaged for more than 1 second after the arc is broken.
After an overtemp error, the MIG gun trigger is
held after the welder has completed cooling.
MIG gun trigger is engaged while another
process is selected.
MIG gun trigger leads are shorted together.
OM-279299 Page 45
A complete Parts List is available at www.MillerWelds.com
Message
Error
Trigger Error
Release Spool Gun Trigger / Release
Push-Pull Gun Trigger
Trigger is engaged on power up.
Remedy
Release 10-pin trigger to clear error.
Trigger held too long during jog mode. Spool gun
for more than 10 seconds. Push-pull gun for
more than 37 feet of wire.
Trigger is engaged for more than 1 second after
the arc is broken.
After an overtemp error, the trigger is held after
the welder has completed cooling.
Trigger is engaged while another process is selected.
Trigger leads are shorted.
Gun Error
XR-A Python
XR Edge
XR-A AlumaPro Plus
XR A
Shorted Output
First remove short then pull trigger to
clear error
System parameters do not support this
equipment.
Replace with compatible MIG gun.
The welding wire came into contact with the
workpiece while jogging wire.
Remove short and pull trigger, or wait 30 seconds
to clear error.
MIG gun or spool gun contact tip came into contact with the workpiece while welding.
The weld voltage is less than 10 volts for more
than 0.2 seconds while welding.
Output rectifier is damaged.
Contact authorized Miller service center.
Control board is damaged.
Motor or Motor Tach Error
Internal motor has stalled
Internal motor has drawn too much
current
Remote motor has stalled
Motor tach is running too slow or is
damaged
Fan Error
Either the top fan or the bottom fan is
running too slow or is damaged
Too much pressure on pressure adjust knob.
Reduce pressure on the pressure adjust knob.
The gun liner is obstructed.
Clear obstruction or replace gun liner.
The gun contact tip is obstructed.
Clear obstruction or replace contact tip.
The welding wire is entangled.
Untangle welding wire.
The control board is damaged.
Contact authorized Miller service center.
The fan blades are obstructed.
Clear obstruction from fan.
The fan wiring harness is disconnected.
Contact authorized Miller service center.
The fan is damaged.
The control board is damaged.
Thermal Error
Inverter module thermistor shorted
The inverter module thermistor is reading too
high for a valid temperature.
Contact authorized Miller service center.
The control board is damaged.
Thermal Error
Inverter module thermistor open
Ambient temperature is too cold for valid reading.
Place unit in environment warmer than –30°F
(–22°C).
The inverter module thermistor is reading too low
for a valid temperature.
Contact authorized Miller service center.
The control board is damaged.
Thermal Error
Secondary magnetics thermistor
shorted
The secondary magnetics thermistor is reading
too high for a valid temperature.
The control board is damaged.
OM-279299 Page 46
Contact authorized Miller service center.
A complete Parts List is available at www.MillerWelds.com
Message
Error
Remedy
Thermal Error
Secondary magnetics thermistor open
Ambient temperature is too cold for valid reading.
Place unit in environment warmer than –30°F
(–22°C).
The secondary magnetics thermistor is unplugged.
Contact authorized Miller service center.
The secondary magnetics thermistor is reading
too low for a valid temperature.
The control board is damaged.
Thermal Error
Output rectifier thermistor shorted
The output rectifier thermistor is reading too high
for a valid temperature.
Contact authorized Miller service center.
The control board is damaged.
Thermal Error
Output rectifier thermistor open
Ambient temperature is too cold for valid reading.
Place unit in environment warmer than –30°F
(–22°C).
The output rectifier thermistor is unplugged.
Contact authorized Miller service center.
The output rectifier thermistor is reading too low
for a valid temperature.
The control board is damaged.
Cycle power to clear error +15V or
–15V
Primary Error
The primary boost has not successfully been established.
Cycle power to clear error. If error persists after a
power cycle, contact authorized Miller service
center.
Over Voltage
Cycle power to clear error
Primary voltage is above 288 volts.
Reduce primary voltage below 288 volts.
Under Voltage
Cycle power to clear error
The primary voltage is below 150 volts.
Increase primary voltage above 150 volts.
Network Error
Inverter communications down
The two microcontrollers on the control board are
no longer communicating.
Cycle power to clear error. If this error persists
after a power cycle, contact authorized Miller service center.
The wiring harness between the control board
and interface board is damaged.
Contact authorized Miller service center.
The control board is damaged.
Cycle power to clear error. If this error persists
after a power cycle, contact authorized Miller service center.
Network Error
Primary communications down
Network Error
UI-Control communications down
The interface board is damaged.
The wire feed housing cable is not attached to
either the positive stud or negative stud of the
power source.
Connect wire drive assembly cable to either the
positive or negative stud.
The control board is damaged.
Contact authorized Miller service center.
Transformer Saturation Error
Release trigger to clear OR
Cycle power to clear
Main transformer has detected an overcurrent
condition.
If problem persists, contact authorized Miller service center.
Missing UI Membrane Switch Overlay
UI membrane is not detected as plugged in.
Contact authorized Miller service center.
UI Membrane Switch Overlay
Doesn’t match arc controller program
Detected UI membrane is not detected as matching the type reported by the main control board.
Contact authorized Miller service center.
CAN Data Version Incompatible
The UI and the Control are not compatible, perhaps due to a partial firmware upgrade.
Restart the firmware upgrade process.
Cable Error
Connect wire feed housing cable to
clear error
Contact authorized Miller service center.
OM-279299 Page 47
A complete Parts List is available at www.MillerWelds.com
8-6. Troubleshooting
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position.
Check and replace line fuse(s), if necessary, or reset supplementary protector.
Be sure power cord is plugged in and that receptacle is receiving input power.
No weld output; unit is on.
Check and secure loose weld cable(s) into receptacle(s).
Check and correct poor connection of work clamp to workpiece.
Erratic or improper welding arc or
output.
Use proper size and type of weld cable (see your Distributor).
Clean and tighten weld connections.
Verify electrode polarity; check and correct poor connections to workpiece.
Fan not operating.
Unit not warmed up enough to require fan cooling.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor and control circuitry.
Notes
OM-279299 Page 48
A complete Parts List is available at www.MillerWelds.com
SECTION 9 − PARTS LIST
9-1. MDX-250 MIG Gun Consumables And Recommended Spare Parts
Part No.
. . . . . . . . . . . . . . . . . . . T-A023CH
. . . . . . . . . . . . . . . . . . . T-A030CH
. . . . . . . . . . . . . . . . . . . T-A035CH
. . . . . . . . . . . . . . . . . . . T-A039CH
. . . . . . . . . . . . . . . . . . . T-A045CH
. . . . . . . . . . . . . . . . . . . N-A5800C
. . . . . . . . . . . . . . . . . . . . D-MA250
. . . . . . . . . . . . . . . . . . . . . T-M023
. . . . . . . . . . . . . . . . . . . . . T-M030
. . . . . . . . . . . . . . . . . . . . . T-M035
. . . . . . . . . . . . . . . . . . . . . T-M045
. . . . . . . . . . . . . . . . . . . . . T-M047
. . . . . . . . . . . . . . . . . . N-M1200C
. . . . . . . . . . . . . . . . . . N-M1218C
. . . . . . . . . . . . . . . . . . N-M5800C
. . . . . . . . . . . . . . . . . . N-M5818C
. . . . . . . . . . . . . . . . . . N-M58XTC
. . . . . . . . . . . . . . . . . . . . LM1A-15
. . . . . . . . . . . . . . . . . . . . LM2A-15
. . . . . . . . . . . . . . . . . . . . LM3A-15
Quantity
Description
. . AccuLock Contact Tip, .023 in. (0.6 mm) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AccuLock Contact Tip, .030 in. (0.8 mm) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AccuLock Contact Tip, .035 in. (0.9 mm) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AccuLock Contact Tip, .039 in. (1.0 mm) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . AccuLock Contact Tip, .045 in. (1.2 mm) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nozzle, Copper, 5/8 in. Orifice, Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Diffuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Contact Tip, .023 in. (0.6 mm) (Package of 10) . . . . . . . . . . . . . . . . . . . . .
. . Contact Tip, .030 in. (0.8 mm) (Package of 10) . . . . . . . . . . . . . . . . . . . . .
. . Contact Tip, .035 in. (0.9 mm) (Package of 10) . . . . . . . . . . . . . . . . . . . . .
. . Contact Tip, .045 in. (1.2 mm) (Package of 10) . . . . . . . . . . . . . . . . . . . . .
. . Contact Tip, .047 in. (1.2 mm) (Package of 10) . . . . . . . . . . . . . . . . . . . . .
. . Nozzle, Copper, 1/2 in., Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nozzle, Copper, 1/2 in., 1/8 in. Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nozzle, Copper, 5/8 in., Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nozzle, Copper, 5/8 in., 1/8 in. Recess . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nozzle, Copper, 5/8 in., 1/8 in. Stickout . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Liner, 15 ft, .023/.025 in. (0.6 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Liner, 15 ft, .030/.035 in. (0.8/0.9 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Liner, 15 ft, .035/.045 in. (0.9/1.2 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
. . . . . . . . . . . . . . . . . . . . . 277663 . . Lens Cover, Replaceable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 079974 . . O-Ring, .500 Id X .103 Cs Rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
9-2. Drive Roll And Wire Guide Kits
Base selection of drive rolls upon the following recommended usages:
1
2
3
4
5
V-Grooved rolls for hard wire.
U-Grooved rolls for soft and soft shelled cored wires.
U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
V-Knurled rolls for hard shelled cored wires.
Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved).
Wire Diameter
Drive Roll
Part No.
Type
Inlet Wire
Guide
087131
087130
V-Grooved
056192
204579
203526
V-Grooved
056192
0.8 mm
079594
053695
V-Grooved
056192
0.9 mm
079595
053700
V-Grooved
056192
1.2 mm
079596
053697
V-Grooved
056193
Fraction
Decimal
Metric
0.023/0.025 in.
0.023/0.025 in.
0.6 mm
0.030/0.035 in.
0.030/0.035 in.
0.8/0.9 mm
0.030 in.
0.030 in.
0.035 in.
0.035 in.
0.045 in.
0.045 in.
Kit No.
OM-279299 Page 49
SECTION 10 − ELECTRICAL DIAGRAM
Figure 10-1. Circuit Diagram
OM-279299 Page 50
279043-B
OM-279299 Page 51
SECTION 11 − GMAW WELDING (MIG) GUIDELINES
11-1. Typical GMAW (MIG) Process Connections
!
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
Regulator/
Flowmeter
Wire Feeder/
Welding Power Source
Gun
Shielding Gas
Gas
Workpiece
Work Clamp
GMAW1 2018−12 (GMAW Only) − Ref. 801909-A
11-2. Typical GMAW (MIG) Process Control Settings
These settings are guidelines only. Material
and wire type, joint design, fitup, position,
shielding gas, etc. affect settings. Test welds to
be sure they comply to specifications.
1
1/16 or
0.0625 in.
1
Material Thickness
Material thickness determines weld parameters.
Convert material thickness to amperage (A):
0.001 in. (0.025 mm) = 1 ampere
0.0625 in. (1.59 mm) ÷ 0.001 = 62.5 A
2
Select Wire Size
See table below.
3
2
Select Wire Feed Speed (Amperage)
Wire feed speed (amperage) controls weld penetration.
See table below.
4
Select Voltage
Voltage controls height and width of weld bead.
Low Voltage: wire stubs into work
High Voltage: arc is unstable (spatter)
Set voltage midway between high and low voltage.
4
3
Wire Size
Amperage Range
Recommended Wire Feed Speed
Wire Feed Speed*
0.023 in. (0.58 mm)
30−90 A
3.5 in. (89 mm) per amp
3.5 x 62.5 A = 219 ipm (5.56 mpm)
0.030 in. (0.76 mm)
40−145 A
2 in. (51 mm) per amp
2 x 62.5 A = 125 ipm (3.19 mpm)
0.035 in. (0.89 mm)
50−180 A
1.6 in. (41 mm) per amp
1.6 x 62.5 A = 100 ipm (2.56 mpm)
*62.5 A based on 1/16 in. (1.6 mm) material thickness.
OM-279299 Page 52
ipm = inches per minute; mpm = meters per minute
11-3. Holding And Positioning Welding Gun
Welding wire is energized when
gun trigger is pressed. Before
lowering helmet and pressing trigger, be sure wire is no more than
1/2 in. (13 mm) past end of nozzle,
and tip of wire is positioned correctly on seam.
1
1
3
2
Hold Gun and Control Gun
Trigger
Workpiece
Work Clamp
Electrode Extension (Stickout)
Solid Wire − 3/8 to 1/2 in.
(9 to 13 mm)
Cradle Gun and Rest Hand on
Workpiece
2
3
4
5
4
5
0°-15°
90°
0°-15°
45°
90°
45°
End View of Work Angle
Side View of Gun Angle
End View of Work Angle
Groove Welds
Side View of Gun Angle
Fillet Welds
S-0421-A
11-4. Conditions That Affect Weld Bead Shape
Weld bead
10°
10°
Push
shape depends
on gun angle, direction of
travel, electrode extension
(stickout), travel speed,
thickness of base metal, wire
feed speed (weld current),
and voltage.
Drag
Perpendicular
Gun Angles And Weld Bead Profiles
Short
Normal
Long
Electrode Extensions (Stickout)
Slow
Short
Normal
Long
Fillet Weld Electode Extensions (Stickout)
Normal
Fast
Gun Travel Speed
S-0634
OM-279299 Page 53
11-5. Gun Movement During Welding
Normally,
1
a single stringer
bead is satisfactory for most
narrow groove weld joints;
however, for wide groove weld
joints or bridging across gaps,
a weave bead or multiple
stringer beads works better.
2
1
2
3
3
Stringer Bead − Steady
Movement Along Seam
Weave Bead − Side To Side
Movement Along Seam
Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
S-0054-A
11-6. Poor Weld Bead Characteristics
1
2
3
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
4
S-0053-A
5
11-7. Good Weld Bead Characteristics
1
2
3
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
1
4
5
2
3
No Overlap
Good Penetration into Base
Metal
4
5
OM-279299 Page 54
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
S-0052-B
11-8. Troubleshooting − Excessive Spatter
Excessive Spatter − scattering of molten metal particles that
cool to solid form near weld bead.
S-0636
Possible Causes
Corrective Actions
Wire feed speed too high.
Select lower wire feed speed.
Voltage too high.
Select lower voltage range.
Electrode extension (stickout) too long.
Use shorter electrode extension (stickout).
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Insufficient shielding gas at welding arc.
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
Incorrect polarity.
Check polarity required by welding wire, and change to correct polarity at welding power source.
11-9. Troubleshooting − Porosity
Porosity − small cavities or holes resulting from gas pockets
in weld metal.
S-0635
Possible Causes
Insufficient shielding gas at welding arc.
Corrective Actions
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in. (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas.
Use welding grade shielding gas; change to different gas.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of nozzle.
Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
11-10. Troubleshooting − Excessive Penetration
Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.
Excessive Penetration Good Penetration
S-0639
Possible Causes
Excessive heat input.
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase travel speed.
OM-279299 Page 55
11-11. Troubleshooting − Lack Of Penetration
Lack Of Penetration − shallow fusion between weld metal and base metal.
Lack of Penetration
Good Penetration
S-0638
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.
Improper weld technique.
Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
Insufficient heat input.
Select higher wire feed speed and/or select higher voltage range.
Reduce travel speed.
Incorrect polarity.
Check polarity required by welding wire, and change to correct polarity at welding power source.
11-12. Troubleshooting − Incomplete Fusion
Incomplete Fusion − failure of weld metal to fuse completely with
base metal or a preceeding weld bead.
S-0637
Possible Causes
Corrective Actions
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Insufficient heat input.
Select higher voltage range and/or adjust wire feed speed.
Improper welding technique.
Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Use correct gun angle of 0 to 15 degrees.
11-13. Troubleshooting − Burn-Through
Burn-Through − weld metal melting completely through base metal
resulting in holes where no metal remains.
S-0640
Possible Causes
Excessive heat input.
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
OM-279299 Page 56
11-14. Troubleshooting − Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
S-0641
Possible Causes
Corrective Actions
Welding wire extends too far out of nozzle.
Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
Unsteady hand.
Support hand on solid surface or use two hands.
11-15. Troubleshooting − Distortion
Distortion − contraction of weld metal during welding that forces
base metal to move.
Base metal moves
in the direction of
the weld bead.
S-0642
Possible Causes
Excessive heat input.
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
Notes
OM-279299 Page 57
11-16. Common GMAW (MIG) Shielding Gases
This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed
over the years. The most commonly used shielding gases are listed in the following table.
Application
Gas
Spray Arc
Steel
Short
Circuiting
Steel
Spray Arc
Stainless
Steel
Short
Circuiting
Stainless
Steel
GMAW-P
Stainless
Steel
All
Positions
Argon
Argon + 1% O2
Flat &
Horizontal
Fillet
All
Positions
Flat &
Horizontal
Fillet
Argon + 2% O2
Flat &
Horizontal
Fillet
All
Positions
Flat &
Horizontal
Fillet
Argon + 5%
CO2
Flat &
Horizontal
Fillet
All
Positions
Argon + 10%
CO2
Flat &
Horizontal
Fillet
All
Positions
Argon + 25%
CO2
All
Positions
Argon + 50%
CO2
All
Positions
CO2
All
Positions
Spray Arc
Aluminum
Short
Circuiting
Aluminum
GMAW-P
Aluminum
All
Positions
All
Positions
All
Positions
All
Positions
Helium
All
Positions1
Argon +
Helium
All
Positions1
90% HE +
7-1/2% AR +
2-1/2% CO2
65% AR + 33%
HE + 2% CO2
1
GMAW-P
Steel
Heavy Thicknesses
OM-279299 Page 58
All
Positions
All
Positions
11-17.
Troubleshooting Guide For Semiautomatic Welding Equipment
Problem
Probable Cause
Wire feed motor operates, but Too little pressure on wire feed rolls.
wire does not feed.
Incorrect wire feed rolls.
Wire curling up in front of the
wire feed rolls (bird nesting).
Wire feeds, but no gas flows.
Remedy
Increase pressure setting on wire feed rolls.
Check size stamped on wire feed rolls, replace to match
wire size and type if necessary.
Wire spool brake pressure too high.
Decrease brake pressure on wire spool.
Restriction in the gun and/or assembly.
Check and replace cable, gun, and contact tip if
damaged. Check size of contact tip and cable liner,
replace if necessary.
Too much pressure on wire feed rolls.
Decrease pressure setting on wire feed rolls.
Incorrect cable liner or gun contact tip size.
Check size of contact tip and check cable liner length
and diameter, replace if necessary.
Gun end not inserted into drive housing properly.
Loosen gun securing bolt in drive housing and push gun
end into housing just enough so it does not touch wire
feed rolls.
Dirty or damaged (kinked) liner.
Replace liner.
Gas cylinder empty.
Replace empty gas cylinder.
Gas nozzle plugged.
Clean or replace gas nozzle.
Gas cylinder valve not open or flowmeter not adjusted.
Open gas valve at cylinder and adjust flow rate.
Restriction in gas line.
Check gas hose between flowmeter and wire feeder, and
gas hose in gun and cable assembly.
Loose or broken wires to gas solenoid.
Have Factory Authorized Service Agent repair wiring.
Gas solenoid valve not operating.
Have Factory Authorized Service Agent replace gas
solenoid valve.
Incorrect primary voltage connected to welding power Check primary voltage and relink welding power source
source.
for correct voltage.
Welding arc not stable.
Wire slipping in drive rolls.
Adjust pressure setting on wire feed rolls. Replace worn
drive rolls if necessary.
Wrong size gun liner or contact tip.
Match liner and contact tip to wire size and type.
Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
welding power source.
Loose connections at the gun weld cable or work cable. Check and tighten all connections.
Gun in poor shape or loose connection inside gun.
Repair or replace gun as necessary.
OM-279299 Page 59
Notes
Notes
Notes
Effective January 1, 2019
(Equipment with a serial number preface of MK or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
* Subarc Wire Drive Assemblies
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to
* TIG Torches (No Labor)
authorized distributors that new Miller equipment sold after the
* Tregaskiss Guns (No Labor)
effective date of this limited warranty is free of defects in material
* Water Cooling Systems
and workmanship at the time it is shipped by Miller. THIS
* Wireless Remote Foot/Hand Controls and Receivers
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Work Stations/Weld Tables (No Labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
5. 6 Months — Parts
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Batteries
Within the warranty periods listed below, Miller will repair or replace 6. 90 Days — Parts
any warranted parts or components that fail due to such defects in
* Accessories (Kits)
material or workmanship. Miller must be notified in writing within
* Canvas Covers
thirty (30) days of such defect or failure, at which time Miller will
* Induction Heating Coils and Blankets, Cables, and
provide instructions on the warranty claim procedures to be
Non-Electronic Controls
followed. Notifications submitted as online warranty claims must
* M-Guns
provide detailed descriptions of the fault and troubleshooting steps
* MIG Guns, Subarc (SAW) Torches, and External
taken to diagnose failed parts. Warranty claims that lack the
Cladding Heads
required information as defined in the Miller Service Operation
* Remote Controls and RFCS-RJ45
Guide (SOG) may be denied by Miller.
* Replacement Parts (No labor)
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
below in the event of a defect within the warranty coverage time
periods listed below. Warranty time periods start on the delivery Miller’s True Blue® Limited Warranty shall not apply to:
date of the equipment to the end-user purchaser, or 12 months 1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
after the equipment is shipped to a North American distributor, or
station table tops and welding curtains, or parts that
18 months after the equipment is shipped to an international
fail due to normal wear. (Exception: brushes and
distributor, whichever occurs first.
relays are covered on all engine-driven products.)
1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs, 2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
Diodes, and Discrete Rectifier Modules
covered by the manufacturer’s warranty, if any.
2. 3 Years — Parts and Labor Unless Specified
* Auto-Darkening Helmet Lenses (No Labor) (See 3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
Classic Series Exception Below)
improperly operated or misused based upon industry
* Engine Driven Welder/Generators
standards, or equipment which has not had reasonable
(NOTE: Engines are Warranted Separately by the
and necessary maintenance, or equipment which has
Engine Manufacturer.)
been used for operation outside of the specifications for
* Insight Welding Intelligence Products
the equipment.
* Inverter Power Sources
4. Defects caused by accident, unauthorized repair, or
* Plasma Arc Cutting Power Sources
improper testing.
* Process Controllers
MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL
* Semi-Automatic and Automatic Wire Feeders
AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN
* Transformer/Rectifier Power Sources
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
3. 2 Years — Parts and Labor
The exclusive remedies for warranty claims are, at Miller’s
* Auto-Darkening Helmet Lenses − Classic Series Only option, either: (1) repair; or (2) replacement; or, if approved in
(No Labor)
writing by Miller, (3) the pre-approved cost of repair or
* Auto-Darkening Weld Masks (No Labor)
replacement at an authorized Miller service station; or (4)
* Fume Extractors − Capture 5, Filtair 400 and Industrial payment of or credit for the purchase price (less reasonable
Collector Series
depreciation based upon use). Products may not be returned
4. 1 Year — Parts and Labor Unless Specified
without Miller’s written approval. Return shipment shall be at
* AugmentedArc and LiveArc Welding Systems
customer’s risk and expense.
* Automatic Motion Devices
The above remedies are F.O.B. Appleton, WI, or Miller’s
* Bernard BTB Air-Cooled MIG Guns (No Labor)
authorized service facility. Transportation and freight are the
* CoolBelt and CoolBand Blower Unit (No Labor)
customer’s responsibility. TO THE EXTENT PERMITTED BY
LAW, THE REMEDIES HEREIN ARE THE SOLE AND
* Desiccant Air Dryer System
EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL
* Field Options
(NOTE: Field options are covered for the remaining THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR
SPECIAL,
INCIDENTAL OR
warranty period of the product they are installed in, DIRECT, INDIRECT,
or for a minimum of one year — whichever is CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY
greater.)
WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
* RFCS Foot Controls (Except RFCS-RJ45)
WARRANTY, GUARANTY, OR REPRESENTATION,
* Fume Extractors − Filtair 130, MWX and SWX Series
INCLUDING
ANY
IMPLIED
WARRANTY
OF
* HF Units
MERCHANTABILITY OR FITNESS FOR PARTICULAR
* ICE/XT Plasma Cutting Torches (No Labor)
PURPOSE, ARE EXCLUDED AND DISCLAIMED BY
* Induction Heating Power Sources, Coolers
MILLER.
(NOTE: Digital Recorders are Warranted
Some US states do not allow limiting the duration of an implied
Separately by the Manufacturer.)
warranty or the exclusion of certain damages, so the above
* Load Banks
limitations may not apply to you. This warranty provides
* Motor-Driven Guns (except Spoolmate Spoolguns)
specific legal rights, and other rights may be available
* PAPR Blower Unit (No Labor)
depending on your state. In Canada, some provinces provide
* Positioners and Controllers
additional warranties or remedies, and to the extent the law
* Racks (For Housing Multiple Power Sources)
prohibits their waiver, the limitations set out above may not
* Running Gear/Trailers
apply. This Limited Warranty provides specific legal rights, and
* Spot Welders
other rights may be available, but may vary by province.
mil dom warr 2019-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2019 Miller Electric Mfg. LLC
2019−01