Miller | MG057985D | Owner Manual | Miller Mpi 220P CE User manual

Miller Mpi 220P CE User manual
OM-253918J
Processes
Multiprocess Welding
Description
MPi 220P
CE
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: Multiprocess
2018-06
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. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your particular model are also
provided.
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 catalog sheets.
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. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Process/Polarity Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Changing Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Changing Drive Rolls And Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Aligning Drive Rolls and Wire Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Connecting 1-Phase 230 VAC Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Threading Welding Wire And Adjusting Pressure Roll Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Preparing Unit For Stick Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Preparing Unit For TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. 2T − 4T Trigger Mode Selection (TIG Process) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Preparing Unit For Manual MIG (GMAW And FCAW) Welding Process . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Manual MIG Welding Set-Up Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Trigger Mode And Spot Time Selection (MIG Process) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Preparing Unit For Synergic MIG (GMAW And FCAW) Welding Process . . . . . . . . . . . . . . . . . . . . . . .
5-9. Synergic MIG Welding Set-Up Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. Preparing Unit For Synergic Pulsed MIG (GMAW And FCAW) Welding Process . . . . . . . . . . . . . . . .
5-11. Synergic Pulsed MIG Welding Set-Up Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. 4T Trigger Set-Up Menu (Synergic Pulsed MIG Welding Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13. Welding Wire Loading Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14. Resetting Unit To Factory Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15. Loading A Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-16. Operator Point MIG Parameters Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-17. Rated Supply Current I1 = 16 Amps Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-18. Basic Set-Up Menu Parameters Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-19. Weld Parameter Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
4
4
4
5
5
7
8
8
8
8
9
10
11
11
12
13
13
13
14
15
16
17
17
18
20
21
21
22
23
24
25
26
28
29
30
32
34
35
36
37
37
38
39
40
41
TABLE OF CONTENTS
SECTION 6 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Welding Gun And Wire Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Unit Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − GMAW WELDING (MIG) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − STICK WELDING (SMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING
WITH INVERTER MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) . . . . . .
10-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding
Or AC Welding With Inverter Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
42
42
42
43
46
48
56
63
63
64
66
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
ITW Welding Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that the
product(s) identified in this declaration conform to the essent ial requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
Stock Number
MPi 220P 230VAC
059016014
Council Directives:
S
S
S
2014/35/EU Low Voltage
2014/30/EU Electromagnetic Compatibility
2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
S
S
S
IEC 60974−1:2012 Arc Welding Equipment – Part 1: Welding Power Sources
IEC 60974−5:2013 Arc Welding Equipment – Part 5: Wire Feeders
IEC 60974−10:2014+A1:2015 Arc Welding Equipment – Part 10: Electromagnetic Compatibility Requirements
EU Signatory:
May 17 th , 2018
___________________________________________________________________________________
Massimigliano Lavarini
Date of Declaration
ITW WELDING ITALY PRODUCTIONMANAGER
956 172 281
EMF DATA SHEET FOR ARC WELDING POWER SOURCE
Product/Apparatus Identification
Product
Stock Number
MPi 220P CE
059016014
Compliance Information Summary
Applicable regulation
Directive 2014/35/EU
Reference limits
Directive 2013/35/EU, Recommendation 1999/519/EC
Applicable standards
IEC 62822−1:2016, IEC 62822−2:2016
Intended use
☒ for occupational use
☐ for use by laymen
Non−thermal effects need to be considered for workplace assessment
☒ YES
☐ NO
Thermal effects need to be considered for workplace assessment
☐ YES
☒ NO
☒
Data is based on maximum power source capability (valid unless firmware/hardware is changed)
☐
Data is based on worst case setting/program (only valid until setting options/welding programs are changed)
☐
Data is based on multiple settings/programs (only valid until setting options/welding programs are changed)
Occupational exposure is below the Exposure Limit Values (ELVs)
for health effects at the standardized configurations
☒ YES
☐ NO
(if NO, specific required minimum distances apply)
Occupational exposure is below the Exposure Limit Values (ELVs)
for sensory effects at the standardized configurations
☐ n.a
☒ YES
☐ NO
(if applicable and NO, specific measures are needed)
Occupational exposure is below the Action Levels (ALs) at the
standardized configurations
☐ n.a
☐ YES
☒ NO
(if applicable and NO, specific signage is needed)
EMF Data for Non−thermal Effects
Exposure Indices (EIs) and distances to welding circuit (for each operation mode, as applicable)
Head
Standardized distance
ELV EI @ standardized distance
Required minimum distance
Sensory
Effects
Health
Effects
Trunk
Limb (hand)
Limb (thigh)
10 cm
0.15
1 cm
10 cm
0.14
1 cm
10 cm
0.22
1 cm
3 cm
0.13
1 cm
3 cm
0.29
1 cm
Distance where all occupational ELV Exposure Indices fall below 0.20 (20%)
2 cm
Distance where all general public ELV Exposure Indices fall below 1.00 (100%)
Tested by:
956172346
Tony Samimi
Date tested:
2018−05−24
64 cm
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2018−01
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.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC weld output in damp, wet, or confined spaces, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D 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!
D 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).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D 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.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
D 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.
D Turn off unit, disconnect input power, and discharge input capacitors according to instructions in Manual before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-251958 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D 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.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D 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.
D 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.
D 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.
D 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).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D 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.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
OM-251958 Page 2
D 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.
D 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).
D Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
D 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.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D 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.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D 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.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D 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.
D 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.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the proper equipment, correct procedures, and sufficient
number of persons to lift, move, and transport cylinders.
D 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.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use correct procedures and equipment of adequate capacity to lift and support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
BATTERY EXPLOSION can injure.
D 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.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D 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.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
OM-251958 Page 3
H.F. RADIATION can cause interference.
ARC WELDING can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with electronic equipment
perform this installation.
D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D 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.
D
D
D
D
D
D 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-251958 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 − DEFINITIONS
2-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2017−04
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2017−04
Keep your head out of the fumes.
Safe6 2017−04
Use forced ventilation or local exhaust to remove the fumes.
Safe8 2012−05
Use ventilating fan to remove fumes.
Safe10 2012−05
Keep flammables away from welding. Do not weld near flammables.
Safe12 2012−05
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe14 2012−05
Do not weld on drums or any closed containers.
Safe16 2017−04
Do not remove or paint over (cover) the label.
Safe20 2017−04
OM-253918 Page 5
Disconnect input plug or power before working on machine.
Safe5 2017−04
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2017−04
Disconnect input plug or power before working on machine.
Safe30 2012−05
Become trained and read the instructions and labels before working on machine.
Safe35 2012−05
?
?
V
A
Consult rating label for input power requirements.
Safe34 2012−05
Drive rolls can injure fingers.
Safe32 2012−05
Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.
Safe33 2017−04
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe38 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
3
OM-253918 Page 6
1
Move jumper links as shown on inside label to match input voltage at
job site. Include extra length in grounding conductor and connect
grounding conductor first. Connect line input conductors as shown on
inside label. Double-check all connections, jumper link positions, and
input voltage before applying power.
Safe49 2012−05
2-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
A
V
Amperage
Volts
Alternating
Current (AC)
Direct Current
(DC)
Remote
On
U1
I1max
I1eff
U2
I2
X
Line Connection
Single Phase
Static Frequency
ConverterTransformerRectifier
Gas Input
Rated Maximum
Supply Current
Gas Output
Maximum
Effective
Supply Current
Voltage Input
Wire Feed
Conventional Load
Voltage
Rated Welding
Current
Hz
Hertz
Input
Duty Cycle
Program
Off
Protective Earth
(Ground)
Primary Voltage
Percent
U0
IP
Rated No Load
Voltage (OCV)
Degree Of
Protection
Read Operator’s
Manual
Wire Burnback
Control
Diameter
Fuse
Single Phase
Two-Step Trigger
Operation
Gas Metal Arc
Welding (GMAW)
Four-Step Trigger
Operation
Increase/
Decrease
Variable
Inductance
OM-253918 Page 7
SECTION 3 − SPECIFICATIONS
3-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the bottom . 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.
3-2. Unit Specifications
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 4-10 and 4-11 for information on
connecting input power.
Model
MPi
220P
Input Power
Single Phase
AC 50/60 Hz
Voltage
100%
60%
30%
25%
Max. OCV
230 Volts
MIG
110 A
17.5 V
140 A
21.0 V
200 A
24.0 V
−−
35 V
20 - 200 A
15.0 - 24.0 V
230 Volts
STICK
100 A
24.0 V
130 A
25.2 V
200 A
26.8 V
65 V
5 - 200 A
20.2 - 28.0 V
230 Volts
TIG
100 A
14.0 V
130 A
15.2 V
−−
65 V
5 - 200 A
10.0 - 18.0 V
Rated Output
−−
200 A
18 V
Amperage
/Voltage
Range
DC
Dimension
(mm)
Weight
(kg)
L = 548
W = 237
H = 365
16
3-3. Duty Cycle And Overheating
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
250
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
200
175
150
NOTICE − Exceeding duty cycle
can damage unit or gun and void
warranty.
100
50
% DUTY CYCLE
60% Duty Cycle At 140 Amperes
6 Minutes Welding
100% Duty Cycle At 110 Amperes
4 Minutes Resting
Continuous Welding
Overheating
A or V
0
15
Minutes
OR
Reduce Duty Cycle
sduty1 5/95
OM-253918 Page 8
3-4. Volt-Ampere Curves
The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other
settings fall between the curves shown.
A. MIG
70
65
60
55
50
DC Volts
45
40
35
30
25
20
15
10
5
0
0
10
20
30
40
50
60
70
80
90
100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
DC Amperes
B. TIG/Stick
70
65
60
55
50
DC Volts
45
40
35
30
25
20
15
10
5
0
0
10
20
30
40
50
60
70
80
90
100 110 120 130 140 150 160 170 180 190 200 210 220 230 240
DC Amperes
OM-253918 Page 9
3-5. Environmental Specifications
A. IP Rating
IP Rating
IP22S
This equipment is designed for indoor use and is not intended to be used or stored outside.
IP22S 2014−06
B. Temperature Specifications
Operating Temperature Range*
Storage/Transportation Temperature Range
−10 to 40°C (14 to 104°F)
−20 to 55°C (−4 to 131°F)
*Output is derated at temperatures above 40°C (104°F).
Temp_2016- 07
C. Information On Electromagnetic Fields (EMF)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S
S
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
D. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
This equipment does not comply with IEC 61000−3−12. If it is connected to a public low voltage system, it is the responsibility of the installer
or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment can be connected.
IEC/TS 61000-3-4 can be used to guide parties concerned by the installation of arc welding equipment with an input current greater than 16 A
in a low voltage network.
ce-emc 2 2014-07
Notes
OM-253918 Page 10
SECTION 4 − INSTALLATION
4-1. Selecting A Location
Airflow Distance
Requirements
!
Do not move or operate unit
where it could tip.
1
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1
Lift Handle
2
Use handle to lift unit.
2
Line Disconnect Device
Locate unit near correct input power supply.
460 mm
(18 in.)
460 mm
(18 in.)
loc_small 2015-04Ref. 800402-A / 956142881_4-A
OM-253918 Page 11
4-2. Installing 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
2
Remove cap, stand to side of
valve, and open valve slightly. Gas
flow blows dust and dirt from valve.
Close valve.
3
4
3
Cylinder
4
Regulator/Flowmeter
Install so face is vertical.
Argon Gas Or Mixed Gas
OR
1
5
7
2
3
8
9
CO2 Gas
5
Regulator/Flowmeter Gas
Hose Connection
6
Welding Power Source Gas
Hose Connection
Connect supplied gas hose
between regulator/flowmeter gas
hose connection, and fitting on
rear of welding power source.
7
Flow Adjust
Typical flow rate is between 12-15
liters per minute. Check wire
manufacturer’s
recommended
flow rate.
8
9
CO2 Adapter (Customer
Supplied)
O-Ring (Customer Supplied)
Install adapter with O-ring between
regulator/flowmeter and CO2
cylinder.
6
Rear Panel
Ref. 149827-B / Ref. 956142881_1-B
OM-253918 Page 12
4-3. Weld Output Terminals And 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
30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
45 m (150
ft)
30 m (100 ft) or Less
Welding
Amperes
10 − 60%
Duty
Cycle
mm2 (AWG)
60 m (200 ft)
60 − 100%
Duty Cycle
70 m (250
ft)
90 m (300
ft)
105 m (350
ft)
120 m (400
ft)
10 − 100% Duty Cycle
mm2 (AWG)
mm2 (AWG)
100
20 (4)
20 (4)
20 (4)
30 (3)
35 (2)
50 (1)
60 (1/0)
60 (1/0)
150
30 (3)
30 (3)
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
95 (3/0)
200
30 (3)
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
120 (4/0)
250
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70 (2x2/0)
2x70 (2x2/0)
* This
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
***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.
Milan Ref. S-0007-M 2017−08
4-4. 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
. For welding output terminal connections see Sections 5-2 and 5-3 for
typical connection processes.
1
2
Ref. 956142881_A
output term1 2015−02
4-5. Process/Polarity Table
Process
Polarity
Cable Connections
Cable To Gun
Cable To Work
GMAW Solid wire with shielding
gas
DCEP Reverse polarity
Connect to positive (+) output terminal
Connect to negative (−) output
terminal
FCAW Self-shielding wire and no
shielding gas
DCEN Straight polarity
Connect to negative (−) output
terminal
Connect to positive (+) output terminal
OM-253918 Page 13
4-6. Changing Polarity
1
Lead Connections For Direct
Current Electrode Positive
(DCEP)
2
Lead Connections For Direct
Current Electrode Negative
(DCEN)
Always read and follow wire
manufacturer’s
recommended
polarity and see Section 4-5.
956142881_2-A
OM-253918 Page 14
4-7. Installing Wire Spool And Adjusting Hub Tension
1
Wire Spool 5 kg
2
Handwheel
Allows adjustment of hub tension.
Turn handwheel clockwise to increase tension.
3
Spool Holder Cap
Tighten to secure wire spool.
1
3
2
Tools Needed:
956142881_20-B
OM-253918 Page 15
4-8. Changing Drive Rolls And Wire Inlet Guide
1
Setscrew
2
Inlet Wire Guide
Loosen setscrew. Slide tip of guide
as close to drive rolls as possible
without touching. Tighten setscrew.
3
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 welding
wire.
4
Drive Roll Securing Cap
Turn cap clockwise to secure drive
roll.
1
2
4
3
Tools Needed:
2.5 mm
956142881_19-A
OM-253918 Page 16
4-9. Aligning Drive Rolls and Wire Guide
!
3
1
Correct
Incorrect
4
2
5
Turn off and disconnect input power
View is from top of drive rolls
looking down with pressure
assembly open.
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:
2.5 mm
Ref. 800412-A
4-10. 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.
. Power cord supplied with unit is sized for 230 volt operation. Larger power cord may be required for cable length greater than 3 meters. Consult
national or local regulations.
50/60 Hz
1 Phase
Input Voltage (V)
230
Rated Maximum Supply Current I1max (A)
31.2
Maximum Effective Supply Current I1eff (A)
18.5
Max Recommended Standard Fuse Rating In Amperes1
Time-Delay Fuses2
35
Normal Operating Fuses3
45
Min Input Conductor Size In AWG
(mm2) 4
12 (4)
Max Recommended Input Conductor Length In Meters (Feet)
19 (64)
Min Grounding Conductor Size In AWG (mm2) 4
12 (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) 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.
OM-253918 Page 17
4-11. Connecting 1-Phase 230 VAC Input Power
1
3
=GND/PE Earth Ground
7
2
4
L1
L2
5
6
1
Tools Needed:
input4 2012−05 − Ref. 803766-C / 956142881_5-A
OM-253918 Page 18
4-11. Connecting 1-Phase 230 VAC Input Power (Continued)
!
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
See rating label on unit and check input voltage available at site.
1
Input Power Cord
!
Disconnect and lockout/tagout input
power before connecting input conductors from unit. Follow established
procedures regarding the installation
and removal of lockout/tagout
devices.
2
Disconnect Device (switch shown in the
OFF position)
3
Disconnect Device Grounding Terminal
4
Disconnect Device Line Terminals
5
Black And White Input Conductor (L1
And L2)
6
Green Or Green/Yellow Grounding
Conductor
!
Always connect green or green/yellow
conductor to supply grounding terminal first, and never to a line terminal.
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1 and L2 to disconnect device line terminals.
7
Over-Current Protection
Select type and size of over-current protection using Section 4-10 (fused disconnect
switch shown).
Close and secure door on disconnect device.
Follow established lockout/tagout procedures to put unit in service.
input4 2012−05 − 803766-C
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-253918 Page 19
4-12. Threading Welding Wire And Adjusting Pressure Roll Tension
1
2
3
4
5
6
7
Wire Spool
Welding Wire
Inlet Wire Guide
Pressure Adjustment Knob
Drive Roll
Outlet Wire Guide
Gun Conduit Cable
Lay gun cable out straight.
3
4
7
Tools Needed:
1
2
5
6
. Hold wire tightly to keep it
from unraveling.
150 mm
(6 in.)
Open pressure assembly.
Pull and hold wire; cut off end.
. Use pressure indicator
Tighten
scale to set a desired
drive roll pressure.
1
2
3
4
Close and tighten pressure
assembly, and let go of wire.
Push wire thru guides into gun;
continue to hold wire.
Pressure
Indicator
Scale
Remove gun nozzle and contact tip.
Tighten
WOOD
Press gun trigger until wire
comes out of gun. Reinstall
contact tip and nozzle
OM-253918 Page 20
1
2
3
4
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
Cut off wire. Close
and latch door.
Ref. 956142881_3-A
SECTION 5 − OPERATION
5-1. Controls
1
Power Switch S1
Use switch to turn power on and off.
2
Wire Speed/Set-Up
Adjustment Control
Use control to adjust wire speed
and change values while in the
set-up mode.
4
3
5
3
7
2
Use control to adjust welding amperage while in TIG and STICK
mode (see Section 5-2 or 5-3) or
workpiece thickness while in MIG
mode (see Section 5-5).
4
Digital Display Meter
Displays values and parameters for
selected welding process.
5
6
Amperage/Workpiece
Thickness Adjustment Control
Process Selector Switch
Use switch to select process, TIG,
STICK or MIG.
6
Program/Sequencer Switch
Use switch to select programs and
scroll through sequencer parameters while in MIG mode (see Section
5-5).
7
8
Sequencer Selector Switch
Use switch to scroll through sequencer parameter while in MIG
mode.
8
MIG Torch Connection
Connection for Euro style MIG gun.
9
9
10
11
Negative Weld Output
Receptacle
For Stick and MIG welding, connect
work cable to this receptacle. For
TIG welding, connect torch to this
receptacle.
10 Gun Trigger Receptacle
11 Positive Weld Output
Receptacle
1
For Stick welding, connect electrode cable to this receptacle. For
TIG welding, connect work cable to
this receptacle.
956142881_6-B
OM-253918 Page 21
5-2. Preparing Unit For Stick Welding
1
2
3
8
4
5
9
6
7
10
11
8
9
10
11
12
13
Positive Weld Output Terminal
Gun Trigger Receptacle
Negative Weld Output
Terminal
Hot Start Adjustment Knob
Amperage Adjustment Control
Knob
Digital Meter Display
Process Selector P1 Push
Button
Welding Amperage
Welding Voltage
Stick Welding Symbol
Set Amperage (Output On)
Hot Start Adjustment Switch
Sequencer Set-Up P2 Push
Button
Prepare unit for Stick welding as follows:
Press And Release
P1
Press And Release
P2
Press And Release
P2
6
Connect electrode holder to positive weld output receptacle.
Connect work clamp to negative
weld output terminal.
Turn power on. Allow time for unit to
complete it start up cycle.
5
7
4
12
Press and release Process selector P1 push button to select Stick
welding. Corresponding symbol is
displayed.
. While in Stick mode, the output
13
is set to off. Output is turned on/
off by pressing and releasing
Sequencer set-up P2 push button.
When output is turned on, use amperage adjustment knob to set desired amperage value. Rotate knob
clockwise to increase amperage
(min - max).
Hot Start Setting
1
Use Hot Start to increase output
amperage at the start of a weld to
help prevent electrode sticking.
To change Hot Start setting, proceed as follows:
3
2
Use the Amperage Adjustment
control knob or switch to change
amperage from 0 to 50 percent of
the preset amperage value, with 20
percent being the default value, The
maximum Hot Start amperage
value is 250 amperes.
Example: if preset amperage is 90
amperes, 0% = 90 amperes, 50% =
135 amperes.
Ref. 956142881_7-B
OM-253918 Page 22
5-3. Preparing Unit For TIG Welding
1
2
3
8
Positive Weld Output Terminal
Gun Trigger Receptacle
Negative Weld Output
Terminal
4 Hot Start Adjustment Knob
5 Amperage Adjustment Control
Knob
6 Digital Meter Display
7 Process Selector Switch
8 Welding Amperage
9 Welding Voltage
10 TIG Welding Symbol
11 Set Amperage
12 Hot Start Adjustment Switch
9
10
11
Prepare unit for TIG welding as follows:
Connect electrode holder to negative weld output receptacle.
Connect work clamp to positive
weld output terminal.
Turn power on. Allow time for unit
complete its start up cycle.
6
5
7
4
12
Press and release Process selector switch to select TIG welding.
Corresponding symbol is displayed. Use amperage adjustment
control knob to set desired amperage value. Rotate knob clockwise
to increase amperage (min - max).
Slope Down Setting
To change Slope Down setting, proceed as follows:
Use the Amperage Adjustment
control knob or switch to reduce
amperage over a set period of time
(0 - 20 seconds) at the end of the
weld. The default setting is 2
seconds.
Application
1
3
Slope Down should be used while
TIG welding materials that are
crack sensitive, and/or the operator
wants to eliminate the crater at the
end of the weld.
2
Ref. 956142881_7-B
OM-253918 Page 23
5-4. 2T − 4T Trigger Mode Selection (TIG Process)
1
2
3
4
Process Selection P1 Push
Button
Sequencer Set-Up P2 Push
Button
Sequencer Adjustment P3
Push Buttons
Wire Feed Speed (WFS)
Adjustment Knob
While in TIG mode, select desired
trigger mode as follows:
Press and release P2 push button
to enter in trigger mode set-up
menu. Select desired trigger mode
by using P3 push buttons or WFS
adjustment knob.
5
Slope Up Time
Use control to select amount of time
that it takes to slope up/down from
initial amperage to weld amperage.
To disable, set to 0. When this item
is selected, use the Wire Feed
Speed adjustment knob or Sequencer adjustment P3 push buttons to
change value. Default = 2 seconds
(min = 0 sec, max = 20.0 sec).
Trigger Mode
Setup Menu
6
2T
1
4
Slope Down Time
Use control to select amount of time
that it takes to slope up/down from
weld amperage to final amperage.
To disable, set to 0. When this item
is selected, use the Wire Feed
Speed adjustment knob or Sequencer adjustment P3 push buttons to
change value. Default = 2 seconds
(min = 0 sec, max = 20.0 sec).
Press P1 push button to save and
exit from set-up menu.
3
Application
Slope Down time should be used
while TIG welding materials that are
crack sensitive, and/or the operator
wants to eliminate the crater at the
end of the weld.
2
Press And Release
7
SCROLL THROUGH SEQUENCERS (2T And 4T Trigger Mode)
2T
4T
5
5
6
0.5S
6
7
0.5S
0.6S
0.6S
40A
Final Current
Use control to select amperage to
which weld amperage will either
slope up or down. When this item is
selected, use the Wire Feed Speed
adjustment knob or Sequencer adjustment P3 push button to change
the value. Default = 20 amperes
(min = 0A, max = 200A). Press P1
to save and exit from set-up menu.
3
4
2
Ref. 956142881_21-B
OM-253918 Page 24
5-5. Preparing Unit For Manual MIG (GMAW And FCAW) Welding Process
To select MIG welding proceed as
follows:
Prepare unit according to Section 4.
Use a cable with correct adapter,
connect gun to the MIG gun connector.
For GMAW process:
Connect wire drive lead to positive
output terminal. Connect work
clamp lead to negative output terminal. See Section 4-5 for GMAW
solid wire with shielding gas process. See Section 4-2 for installing
gas supply.
For FCAW process:
Connect wire drive lead to negative
output terminal. Connect work
clamp lead to positive output terminal. See Section 4-5 for FCAW
self-shielding wire no shielding gas
process.
1
2
3
4
4
SYN OFF
1
5
3
Use knob to select desired welding
voltage. Rotate knob clockwise to
increase the output voltage value
(min = 10 volts DC, max = 35 volts
DC).
5
2
Press And Release
Process Selection P1 Push
Button
Sequencer Set-Up P2 Push
Button
Sequencer
Adjustment/Operator Point
Setting P3 Push Buttons (See
Section 5-16)
Welding Voltage Adjustment
Knob
Wire Feed Speed (WFS)
Adjustment Knob
Use knob to select desired WFS.
Rotate knob clockwise to increase
WFS value (min = 0 mpm, max =
20.9 mpm).
Set MIG welding process using process selection P1 push button. To
enter in manual MIG mode, press
and release sequencer set-up P2
push button. Use sequencer adjustment P3 push buttons until
SYN−OFF is displayed. Press and
release P2 again to confirm selection.
. In manual MIG mode, the oper-
ator may need to adjust main
welding parameters for specific
arc characteristics. Wire feed
speed and arc voltage will appear on digital meter display.
Ref. 956142881_8-A
OM-253918 Page 25
5-6. Manual MIG Welding Set-Up Menu
To enter MIG welding set-up menu,
proceed as follows:
1
2
Sequencer Set-Up P2 Push
Button
Wire Feed Speed (WFS)
Adjustment Knob
While in the set-up menu, use knob
to change sequencer parameters.
3
4
Sequencer
Adjustment/Operator Point
Setting P3 Push Buttons (See
Section 5-16)
Process Selection P1 Push
Button
Press and hold P2 push button to
enter into the set-up menu. Sequencers will be displayed on the
digital meter display. To change
parameters, use P3 push buttons
or Wire Feed Speed (WFS) adjustment knob. To scroll through sequencers, press and release P2
push button. To exit from set-up
menu, press and release process
selection P1 push button and desired parameters will be stored.
5
Trigger Mode (2T/4T)
Use the Wire Feed Speed adjustment knob or Sequencer adjustment P3 push buttons to change
the value (see Section 5-7).
6
4
2
3
1
Press And Hold
7
SCROLL THROUGH SEQUENCERS
8
6
0.02S
3
3
0
0
3
0
7
0
8
0.0S
3
Burnback Time (BBT)
Time that welding wire stays
energized after trigger is released.
This is a predetermined value in
MIG mode and cannot be changed.
5
2T
Slope Time
Use control to select amount of time
that it takes to slope up/down from
initial amperage to weld amperage.
To disable, set to 0. When this item
is selected, use the Wire Feed
Speed adjustment knob or Sequencer adjustment P3 push buttons to
change the value. Default = 0.2
seconds (min = 0 sec, max = 1.5
sec).
9
Weld Output Inductance
Use control to select inductance
value. When this is selected, use
the Wire Feed Speed adjustment
knob or Sequencer adjustment P3
push buttons to change value. Default = 0 (min = 0, max = 11). Low inductance is used for most short arc
applications. High inductance is for
stainless steel and spray arc applications.
2
1
Press And Release
Ref. 956142881_9-A
OM-253918 Page 26
5-6. Manual MIG Welding Set-Up Menu (Continued)
. In short circuit GMAW welding,
an increase in inductance will
decrease the number of short
circuit transfers per second
(provided no other changes are
made) and increase the arc-on
time. The increased arc-on
time makes the welding puddle
more fluid.
9
Postflow Time
Use control to set length of time gas
flows after welding stops to protect
the weld puddle. When this item is
selected, use the Wire Feed Speed
adjustment knob to change value.
Default = 0.3 seconds (min = 0 sec,
max = 3 sec).
OM-253918 Page 27
5-7. Trigger Mode And Spot Time Selection (MIG Process)
. Always select a trigger mode.
1
2
3
1
4
3
Digital Display Meter
Sequencer Set-Up P3 Push
Buttons
Wire Feed Speed (WFS)
Adjustment Knob
Sequencer
Adjustment/Operator Point
Setting P2 Push Button
2
To select trigger mode and spot
weld timer, proceed as follows:
4
Press and hold P2 push button to
enter into the set-up menu. Sequencers will be displayed on the
digital meter display. To change
parameters, use the P3 push buttons or Wire Feed Speed (WFS) adjustment knob.
5
2T Trigger Mode
When trigger is pressed, welding
starts. When trigger is released,
welding stops.
6
4T Trigger Mode
When trigger is pressed welding
starts. When trigger is released,
welding continues. When trigger is
pressed and released a second
time, welding stops.
5
2T
6
4T
7
7
Spot Weld Time
Use control to set time that welding
arc is active before shutting off
automatically. When this is selected, use the Wire Feed Speed adjustment knob or Sequencer P3
push buttons to change value. Default = 2.2 seconds (min = 0 sec,
max = 10 sec).
. After turning On unit, display
meter will show the latest trigger mode selected. Default is
2T.
Ref. 956142881_10-A
OM-253918 Page 28
5-8. Preparing Unit For Synergic MIG (GMAW And FCAW) Welding Process
To select MIG welding process,
proceed as follows:
Prepare unit according to Section 4.
Use a cable with correct adapter,
connect gun to the MIG gun connector.
For GMAW process:
Connect wire drive lead to positive
output terminal. Connect work lead
to negative output terminal. See
Section 4-5 for GMAW solid wire
with shielding gas process. See
Section 4-2 for installing gas supply.
For FCAW process:
Connect wire drive lead to negative
output terminal. Connect work
clamp lead to positive output terminal. See Section 4-5 for FCAW
self-shielding wire no shielding gas
process.
1
2
3
Program Selection
(See Section 5-15)
Wire Type
And Gas
4
1
SYN MIG
3
Arc Length Knob
Adjustment
2
Press And Release
Use knob to select desired workpiece thickness. Rotate knob
clockwise to increase the thickness
value.
5
Workpiece
Thickness
5
4
Process Selection P1 Push
Button
Sequencer Set-Up P2 Push
Button
Sequencer
Adjustment/Operator Point
Setting P3 Push Buttons (See
Section 5-16)
Workpiece Thickness
Adjustment Knob
Arc Length Control Knob
Use knob to select desired arc
length value. It is the distance from
end of wire electrode to the
workpiece. Rotate knob clockwise
to increase the arc length value
(min = −40, max = +40). It allows
setting inductance in MIG mode. In
Pulse mode, this adjustment
changes the arc cone by adjusting
the preprogrammed factory pulse
data.
Set MIG welding process using process selection P1 push button. To
enter synergic MIG mode, press
and release sequencer set-up P2
push button. Use sequencer adjustment P3 push buttons until
SYN-MIG is displayed. Press and
release P2 again to confirm setting.
. In Synergic MIG mode, the op-
erator may need to adjust welding data (wire type, wire diameter and gas type) and only
one weld parameter. Generally, wire feed speed is adjusted and the synergic process
automatically sets appropriate
weld voltage. Synergic welding
also sets many secondary
welding parameters automatically for improved weld quality.
956142881_11-A
OM-253918 Page 29
5-9. Synergic MIG Welding Set-Up Menu
To enter MIG welding set-up menu,
proceed as follows:
1
2
Sequencer Set-Up P2 Push
Button
Arc Length Control Knob
While in the set-up menu, use knob
to change sequencer parameters.
3
4
Sequencer
Adjustment/Operator Point
Setting P3 Push Buttons (See
Section 5-16)
Process Selection P1 Push
Button
Press and hold P2 push button to
enter the set-up menu. Sequencers
will be displayed on the digital meter
display. To change parameters, use
P3 push buttons or arc length control knob. To scroll through sequencers, press and release P2 push
button. To exit set-up menu, press
and release process selection P1
push button. Desired parameters
will be stored.
5
SET-UP MENU
6
2
3
7
Burnback Time (BBT)
Use Arc Length control knob to select amount of time that welding
wire stays energized after trigger is
released. When selected, use Arc
Length control knob to change
value. Default = 5 (min = 0, max =
10)
1
Press And Hold
SCROLL THROUGH SEQUENCERS
2T
Slope Time
Use Arc Length control knob to select amount of time that it takes to
slope up/down from initial amperage to weld amperage. To disable,
set to 0. When selected, use Arc
Length control knob or Sequencer
adjustment P3 push buttons to
change value, Default = 0.2
seconds (min = 0 sec, max = 1.5
sec).
4
5
Trigger Mode (2T/4T)
Use arc length control knob or sequencer adjustment P3 push buttons to change value (see Section
5-7).
6
0.02S
3
3
3
0
0
0
7
0%
8
0S
3
9
2
1
Press And Release
Ref. 956142881_12-A
OM-253918 Page 30
5-9. Synergic MIG Welding Set-Up Menu (Continued)
8
Percentage Of Weld Output
Inductance
Use Arc Length control knob to select the percentage of welding inductance value. When selected,
use the knob or sequencer P3 push
buttons to change value. Default =
0% (min = −10%, max = +10%).
Low inductance is used for most
short arc applications, High inductance is for stainless steel and spray
arc applications.
. In short circuit GMAW welding,
an increase in inductance will
decrease the number of short
circuit transfers per second
(provided no other changes are
made) and increase the arc-on
time. The increased arc-on
time makes the welding puddle
more fluid.
9
Postflow Time
Use Arc Length control knob to set
length of time gas flows after welding stops to protect the weld puddle.
When this item is selected, use the
Wire Feed Speed adjustment knob
to change value. Default = 0.3
seconds (min = 0 sec, max = 3 sec).
OM-253918 Page 31
5-10. Preparing Unit For Synergic Pulsed MIG (GMAW And FCAW) Welding Process
To select MIG welding process,
proceed as follows:
Prepare unit according to Section 4.
Use a cable with correct adapter,
connect gun to the MIG gun connector.
For GMAW process:
Connect wire drive lead to positive
output terminal. Connect work lead
to negative output terminal. See
Section 4-5 for GMAW solid wire
with shielding gas process. See
Section 4-2 for installing gas supply.
For FCAW process:
Connect wire drive lead to negative
output terminal. Connect work
clamp lead to positive output terminal. See Section 4-5 for FCAW
self-shielding wire no shielding gas
process.
1
2
3
Program Selection
(See Section 5-15)
Wire Type
And Gas
4
1
PULSED
Workpiece
Thickness
5
3
Arc Length Knob
Adjustment
2
Press And Release
4
Process Selection P1 Push
Button
Sequencer Set-Up P2 Push
Button
Sequencer
Adjustment/Operator Point
Setting P3 Push Buttons (See
Section 5-16)
Workpiece Thickness
Adjustment Knob
Use Workpiece Thickness adjustment knob to select desired workpiece thickness. Rotate knob
clockwise to increase the thickness
value.
5
Arc Length Control Knob
Use knob to select desired arc
length value. It is the distance from
end of wire electrode to the
workpiece. Rotate knob clockwise
to increase the arc length value
(min = −40, max = +40). It allows
setting inductance in MIG mode. In
Pulse mode, this adjustment
changes the arc cone by adjusting
the preprogrammed factory pulse
data.
Ref. 956142881_13-A
OM-253918 Page 32
5-10. Preparing Unit For Synergic Pulsed MIG (GMAW And FCAW)
Welding Process (Continued)
Set MIG welding process using process selection P1 push button. To
enter synergic pulsed MIG mode,
press and release sequencer
set-up P2 push button. Use sequencer adjustment P3 push buttons until PULSED is displayed.
Press and release P2 again to confirm setting.
. Synergic Pulsed MIG welding
is a high quality welding process that produces vary little
spatter because the wire does
not touch the weld puddle. Applications best suited for
pulsed MIG are those currently
using the short circuit transfer
method for welding steel, 14
gauge (1.8 mm) and up. This
process works well on thin
metals such as stainless steel
and aluminum.
. In Pulsed Synergic MIG mode,
the operator may need to adjust welding data (wire type,
wire diameter and gas type)
and only one weld parameter.
Generally, wire feed speed is
adjusted and the synergic process automatically sets appropriate weld voltage. Synergic
welding also sets many secondary welding parameters
automatically for improved
weld quality.
OM-253918 Page 33
5-11. Synergic Pulsed MIG Welding Set-Up Menu
To enter MIG welding set-up menu,
proceed as follows:
1
2
Sequencer Set-Up P2 Push
Button
Arc Length Control Knob
While in the set-up menu, use knob
to change sequencer parameters.
3
4
Sequencer
Adjustment/Operator Point
Setting P3 Push Buttons (See
Section 5-16)
Process Selection P1 Push
Button
Press and hold P2 push button to
enter the set-up menu. Sequencers
will be displayed on the digital meter
display. To change parameters, use
P3 push buttons or arc length control knob. To scroll through sequencers, press and release P2 push
button. To exit set-up menu, press
and release process selection P1
push button. Desired parameters
will be stored.
5
SET-UP MENU
6
Slope Time
Use Arc Length control knob to select amount of time that it takes to
slope up/down from initial amperage to weld amperage. To disable,
set to 0. When selected, use Arc
Length control knob or Sequencer
adjustment P3 push buttons to
change value, Default = 0.2
seconds (min = 0 sec, max = 1.5
sec).
4
2
3
7
Burnback Time (BBT)
This value is set to 1 second.
1
8
SCROLL THROUGH SEQUENCERS
5
0S
6
8
0.02S
Postflow Time
Use Arc Length control knob to set
length of time gas flows after welding stops to protect the weld puddle.
When this item is selected, use the
Wire Feed Speed adjustment knob
to change value. Default = 0.3
seconds (min = 0 sec, max = 3 sec).
Press And Hold
2T
Trigger Mode (2T/4T)
Use arc length control knob or sequencer adjustment P3 push buttons to change value (see Section
5-7).
. In Synergic Pulsed MIG, welding inductance cannot be set.
1
7
3
2
1
Press And Release
Ref. 956142881_14-A
OM-253918 Page 34
5-12. 4T Trigger Set-Up Menu (Synergic Pulsed MIG Welding Only)
To enter 4T trigger set-up menu:
Follow instructions listed in Section
5-7.
1
2
Postflow Time (See Section
5-11)
Arc Power (Hot Start)
Percentage
Percent increase of welding current
to make arc start easier. When this
item is selected, use the Arc Length
control knob or Sequencer adjustment P3 push buttons to change
value. Default = 120% (min = 100%,
max = 150%).
3
Welding Current Percentage
Percent reduction of welding current during the crater fill process.
When this item is selected, use the
Arc Length control knob or Sequencer adjustment P3 push buttons to
change value. Default = 80% (min =
30%, max = 100%).
4
Slope Down Time
Time necessary for current decrease when using slope down
control. When this item is selected,
use the Arc Length control knob or
Sequencer adjustment P3 push
buttons to change value. Default =
0.5 seconds (min = 0.1 sec, max =
2.0 sec).
SET-UP MENU
Press And Release
SCROLL THROUGH PARAMETERS
3.0S
1
2
12.6%
48%
3
1.4S
4
Press And Release
Ref. 956142881_15-A
OM-253918 Page 35
5-13. Welding Wire Loading Settings
Prepare unit for welding wire loading as follows:
S Install wire spool and adjust hub
tension (see Section 4-7).
S Use proper drive rolls and wire
guide (see Section 4-8).
S Thread welding wire and adjust
pressure roll tension (see Section
4-12).
Without starting a weld, press and
hold torch trigger for three seconds
to load welding wire.
. After pressing and holding the
torch trigger, gas valve is disabled. Welding wire will be
loaded at a wire feed value of
about 11 mpm. The wire feed
speed is only measured in
meters per minute.
To stop loading wire, release torch
trigger.
Ref. 956142881_16-A
OM-253918 Page 36
5-14. Resetting Unit To Factory Default Settings
. This procedure will delete all
operator specified parameters
and recall all factory parameters.
1
P2
H
Power Switch
Use power switch to turn unit on.
When Miller appears on the display,
press and release sequencer
set-up P2 push button. Basic set-up
menu will be displayed. Press and
hold P2 until OK is displayed by resetting parameters. Factory defaults are now restored.
Press And Hold
1
956142881_24-B
5-15. Loading A Program
Program Number
P3
PULSED
P2
0.6
PRG#001
PRG#001
To load programs, press and
release sequencer set-up P2 push
button (see Section 5-8 and Section
5-10) until program number is
displayed.
Use
sequencer
adjustment P3 push buttons to
select desired program. Press P2
push button to confirm selected
program.
0
Press And Release
Ref. 956142887-A
OM-253918 Page 37
5-16. Operator Point MIG Parameters Loading
. This setting is only available in
MIG mode. It allows the operator to load and save desired
specified weld parameters and
recall them when required.
Store parameters:
P1
Press and release P3 push buttons
simultaneously to enter the operator point set-up menu. Use P3 push
buttons to select desired position
where parameters will be stored.
Press and hold Sequencer P2 push
button for about 10 seconds to save
parameters. Saving OK will be displayed on the digital meter. Press
and release process selection P1
push button to exit set-up menu.
P3
P2
Recall parameters:
Press and release P3 push buttons
simultaneously to enter the operator point set-up menu. Use P3 push
buttons to select desired stored
parameters. Press and release Sequencer P2 push button to load
parameters.
Press And Release
(Entering In Set-Up Menu)
Press And Hold
(Save Program)
OR
Press And
Release
Press And
Release
Press And Release
(Loading A Program)
Ref. 956142881_22-A
OM-253918 Page 38
5-17. Rated Supply Current I1 = 16 Amps Setting
This setting allows the operator to
use the unit with a maximum of 16
amperes of rated supply current I1.
Before setting the rated supply current I1,
1
P1
!
Follow the Electromagnetic
Compatibility (EMC) information according to Section
3-5D.
P3
!
Connect single phase input
power according to Section
4-11.
. By setting a lower rated supply
current I1 , the unit cannot have
the same performance then
that listed in Section 3-2 and
4-10 under normal operating
conditions.
P2
1
Power Switch
Use power switch to turn unit on.
When Miller appears on the display,
press and release sequencer
set-up P2 push button. Unit is at default setting of H (high rated supply
current I1). Use sequencer parameters adjustment P3 push buttons
to set unit to L (low rated supply current I1, max value = −16 amperes).
Press and release P2 to confirm
setting. Press and release process
selection P1 push button to exit
menu.
H
L
The next time the unit is turned on,
the latest settings will be retained.
. To return to factory default settings, see Section 5-14.
OR
Press And Release
(Entering In Set-Up Menu)
Press And
Release
Press And
Release
(To Change Parameter)
Ref. 956142881_23-B
OM-253918 Page 39
5-18. Basic Set-Up Menu Parameters Settings
1
Power Switch
Use power switch to turn unit on.
When Miller appears on the display,
press and release sequencer
set-up P2 push button. Basic set-up
menu will be displayed.
1
P1
2
Initial Wire Feed Speed
(WFS) Settings
Press and release P2 push button
to select desired parameter. Use
P3 push buttons to change value.
This value is either “reduced” or
“normal”. Default is set to “reduced”.
P3
3
P2
Wire Feed Speed (WFS) Unit
Of Measurement Settings
Press and release P2 push button
to select desired parameter. Use
P3 push buttons to change value.
Available units of measurement are
either MPM (meters per minute) or
IPM (inches per minute). Default is
set to “MPM”.
4
See
Section 5-17
H
RESETTING
See
Section 5-17
L
2
3
4
5
6
Press and release P2 push button
to select desired parameter. Use
P3 push buttons to change value.
This value is either “OFF” or “ON”.
Default is set to “ON”.
5
Digital Meter Display Setting
Press and release P2 push button
to select desired parameter. Use
P3 push buttons to change value.
This value is either “OFF” or “ON”.
Default is set to “ON”.
6
LCD Contrast Settings
Press and release P2 push button
to select desired parameter. Use
P3 push buttons to change value.
Default is set to “51” (min = 30, max
= 63).
OR
Press And Release
(Entering In Set-Up Menu)
Voltage Reduction Device
(VRD) Settings
Press And
Release
Press And
Release
(To Change Parameter)
Press and release process selection P1 push button to exit menu.
The next time the unit is turned on,
the latest settings will be retained.
. To return to factory default settings, see Section 5-14.
Ref. 956142881_23-B
OM-253918 Page 40
5-19. Weld Parameter Chart
956.142.897-A
OM-253918 Page 41
SECTION 6 − MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
l = Replace
Reference
Every
3
Months
l Unreadable Labels
Every
6
Months
~ Weld Terminals
nl Weld Cables
n Apply Light Coat Of Oil
Or Grease To Drive Motor
Shaft
~ Clean Drive Rolls
OR
~ Inside Unit
6-2. Welding Gun And Wire Drive Assembly
1
Welding Gun
Check gun liner for blockage or
kinks.
2
Wire Drive Assembly
Check for jammed wire, binding
drive gear or misaligned drive rolls.
Allow cooling period. Close door.
1
2
956142881_3-A
6-3. Unit Overload
Thermal switches TP1 and TP2 located on the primary and secondary heatsink protect the unit from damage due to overheating. If TP1 and/or TP2
have opened due to overheating, wait for unit to cool allowing fan motor to run before trying to weld. If unit is cool and no weld output continues, contact
Factory Authorized Service Agent.
OM-253918 Page 42
6-4. Troubleshooting
A. MIG (GMAW) Welding
Trouble
Remedy
No weld output; wire does not feed.
Be sure line disconnect switch is On (see Section 4-11).
Replace building line fuse or reset circuit breaker if open (see Section 4-11).
Secure gun trigger connections (see welding gun Owner’s Manual).
Check continuity of power switch S1 and replace if necessary.
Have Factory Authorized Service Agent check main transformer T1 for signs of winding failure. Check
continuity across windings and check for proper connections. Check secondary voltages. Replace T1
if necessary.
Have Factory Authorized Service Agent check continuity of thermostats TP1 and TP2. Replace TP1
and/or TP2 if necessary.
Have Factory Authorized Service Agent check main control board PC2 and connections, and replace if
necessary.
Have Factory Authorized Service Agent check all board connections and main control board.
No weld output; wire feeds.
Connect work clamp to get good metal to metal contact.
Replace contact tip (see welding gun Owner’s Manual).
An overload condition occurred (see Section 6-3).
Have Factory Authorized Service Agent check primary and secondary power circuit of the unit.
Have Factory Authorized Service Agent check main transformer T1 for signs of winding failure. Check
continuity across windings and check for proper connections. Check secondary voltages. Replace T1
if necessary.
Have Factory Authorized Service Agent check voltage switch(es), and replace if necessary.
Low weld output.
Connect unit to proper input voltage or check for low line voltage (see Section 4-11).
Low, high, or erratic wire speed.
Readjust front panel settings (see Section 5).
Change to correct size drive rolls (see Section 4-8).
Readjust drive roll pressure (see Section 4-12).
Replace inlet guide, contact tip, and/or liner if necessary (see welding gun Owner’s Manual).
Have Factory Authorized Service Agent check Wire Speed control, and replace if necessary.
Have Factory Authorized Service Agent check motor control board PC4 and connections, and replace
if necessary.
No wire feed.
Rotate Wire Speed control to higher setting (see Section 5).
Clear obstruction in gun contact tip or liner (see welding gun Owner’s Manual).
Readjust drive roll pressure (see Section 4-12).
Change to correct size drive rolls (see Section 4-8).
Rethread welding wire (see Section 4-12).
Check gun trigger and leads. Repair or replace gun if necessary.
Have Factory Authorized Service Agent check main control board.
OM-253918 Page 43
B. Stick (SMAW) Welding
Trouble
Remedy
Hard starts, poor welding characterist- Use proper type and size of electrode.
ics, unusual spattering.
Check electrode polarity and reverse in necessary; check and correct poor connections
Make sure a remote control is not connected.
C. TIG (GTAW) Welding
Trouble
Remedy
Wandering arc, hard starts, poor welding Use proper type and size of tungsten.
characteristics, spattering problems.
Use properly prepared tungsten.
Check electrode polarity and reverse if necessary.
Tungsten electrode oxidizing and not Shield weld zone from drafts.
remaining bright after welding.
Check for correct type shielding gas.
Check and tighten gas fittings.
Check electrode polarity and reverse if necessary.
OM-253918 Page 44
Notes
OM-253918 Page 45
SECTION 7 − ELECTRICAL DIAGRAMS
Figure 7-1. Circuit Diagram For Welding Power Source
OM-253918 Page 46
956142882-B
OM-253918 Page 47
SECTION 8 − GMAW WELDING (MIG) GUIDELINES
8-1. 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 2018−01 (GMAW Only) − Ref. 801909-A
8-2.
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-253918 Page 48
ipm = inches per minute; mpm = meters per minute
8-3.
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
8-4.
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-253918 Page 49
8-5.
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
8-6.
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
5
8-7.
S-0053-A
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-253918 Page 50
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
S-0052-B
8-8.
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.
8-9.
Check polarity required by welding wire, and change to correct polarity at welding power source.
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.
8-10. Troubleshooting − Excessive Penetration
Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.
Excessive Penetration Good Penetration
Possible Causes
Excessive heat input.
S-0639
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase travel speed.
OM-253918 Page 51
8-11. 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.
8-12. 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.
8-13. 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-253918 Page 52
8-14. 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.
8-15. 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.
Possible Causes
Excessive heat input.
S-0642
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-253918 Page 53
8-16. 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
Argon
Spray Arc
Aluminum
Short
Circuiting
Aluminum
GMAW-P
All Positions
All Positions
All Positions
Argon + 1% O2
Flat &
Horizontal Fillet
Flat &
Horizontal Fillet
All Positions
Argon + 2% O2
Flat &
Horizontal Fillet
Flat &
Horizontal Fillet
All Positions
Argon + 5%
CO2
Flat &
Horizontal Fillet
Argon + 10%
CO2
Flat &
Horizontal Fillet
All Positions
All Positions
All Positions
Argon + 25%
CO2
All Positions
Argon + 50%
CO2
All Positions
CO2
All Positions
Helium
All Positions1
Argon +
Helium
All Positions1
Tri-Mix2
1
Heavy Thicknesses
2
90% HE + 7-1/2% AR + 2-1/2% CO2
OM-253918 Page 54
All Positions
8-17. 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-253918 Page 55
SECTION 9 − STICK WELDING (SMAW) GUIDELINES
9-1.
Stick Welding Procedure
!
Weld current starts when
electrode touches workpiece.
!
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.
Equipment Needed:
Tools Needed:
. Always wear appropriate per1
sonal protective clothing.
Workpiece
Make sure workpiece is clean before welding.
2
Constant Current
Welding Power Source
Work Clamp
Place as close to the weld as
possible.
3
Electrode
Before striking an arc, insert an
electrode in the electrode holder. A
small diameter electrode requires
less current than a large one. Follow recommendations of the electrode manufacturer when setting
weld amperage (see Section 9-2).
5
4
2
3
6
1
7
4
Insulated Electrode Holder
5
Electrode Holder Position
6
Arc Length
Arc length is the distance from the
electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound. Correct
arc length is related to electrode diameter. Examine the weld bead to
determine if the arc length is correct.
Arc length for 1/16 and 3/32 in. diameter electrodes should be about
1/16 in. (1.6 mm); arc length for 1/8
and 5/32 in. electrodes should be
about 1/8 in. (3 mm).
7
Slag
Use a chipping hammer and wire
brush to remove slag. Remove
slag and check weld bead before
making another weld pass.
stick 2018-01 − 151593
OM-253918 Page 56
7014
7018
7024
Ni-Cl
308L
3/32
1/8
5/32
3/16
7/32
1/4
1/16
5/64
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
7/32
1/4
3/32
1/8
5/32
3/16
3/32
1/8
5/32
DEEP
ALL
DEEP
6013
EP,EN
ALL
LOW
GENERAL
7014
EP,EN
ALL
MED
7018
EP
ALL
MED
SMOOTH, EASY,
FAST
LOW HYDROGEN,
STRONG
7024
EP,EN
FLAT
HORIZ*
LOW
SMOOTH, EASY,
FASTER
NI-CL
EP
ALL
LOW
CAST IRON
308L
EP
ALL
LOW
STAINLESS
USAGE
ALL
EP
AC
EP
6011
DC*
6010
ELECTRODE
450
400
350
300
250
200
150
PENETRATION
6013
POSITION
6010
&
6011
100
50
DIAMETER
AMPERAGE
RANGE
Electrode And Amperage Selection Chart
ELECTRODE
9-2.
MIN. PREP, ROUGH
HIGH SPATTER
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Ref. S-087 985-A
9-3.
Striking An Arc
1
!
Weld current starts when electrode touches workpiece.
1
2
3
Electrode
Workpiece
Arc
Scratch Technique
2
Drag electrode across workpiece like
striking a match; lift electrode slightly
after touching work. If arc goes out,
electrode was lifted too high. If electrode sticks to workpiece, use a quick
twist to free it.
Tapping Technique
3
Bring electrode straight down to
workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.
1
2
3
S-0049 / S-0050
OM-253918 Page 57
9-4.
Positioning Electrode Holder
1
2
End View Of Work Angle
Side View Of Electrode
Angle
After learning to start and hold
an arc, practice running beads
of weld metal on flat plates using
a full electrode.
1
10°-30°
90°
Hold the electrode nearly perpendicular to the work, although
tilting it ahead (in the direction of
travel) will be helpful.
2
90°
. To produce the best results,
hold a short arc, travel at a
uniform speed, and feed the
electrode downward at a
constant rate as it melts.
Groove Welds
10°-30°
45°
1
2
45°
Fillet Welds
S-0060
9-5.
Poor Weld Bead Characteristics
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
4
2
3
5
1
S-0053-A
9-6.
Good Weld Bead Characteristics
1
2
3
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
2
3
4
5
4
5
No Overlap
Good Penetration into Base
Metal
1
S-0052-B
OM-253918 Page 58
9-7.
Conditions That Affect Weld Bead Shape
. Weld bead shape is affected
by electrode angle, arc length,
travel speed, and thickness of
base metal.
Angle Too Small
Correct Angle
10° - 30°
Angle Too Large
Electrode Angle
Drag
Spatter
Arc Length
Too Short
Normal
Too Long
Slow
Normal
Fast
Travel Speed
S-0061
9-8.
Electrode Movement During Welding
. Normally,
2
1
1
2
3
3
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 work better.
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. Do not let weave width exceed 2-1/2 times diameter of
electrode.
S-0054-A
9-9.
Welding Lap Joints
1
2
Electrode
Single-Layer Fillet Weld
Move electrode in circular motion.
30°
Or Less
30°
Or Less
1
1
2
3
Multi-Layer Fillet Weld
Weld a second layer when a heavier fillet is needed. Remove slag before making another weld pass.
Weld both sides of joint for maximum strength.
3
S-0063 / S-0064
OM-253918 Page 59
9-10. Welding Groove (Butt) Joints
1
Tack Welds
Prevent butt joint distortion by tack
welding the materials in position
before final weld.
Workpiece distortion occurs when
heat is applied locally to a joint.
One side of a metal plate will curl
up toward the weld. Distortion will
also cause the edges of a butt joint
to pull together ahead of the electrode as the weld cools.
1
2
1/16 in.
(1.6 mm)
Square Groove Weld
3
Single V-Groove Weld
4
Double V-Groove Weld
Materials up to 3/16 in. (5 mm)
thick can often be welded without
special preparation using the
square groove weld. However,
when welding thicker materials it
may be necessary to prepare the
edges (V-groove) of butt joints to
ensure good welds.
30°
The single or double V-groove
weld is good for materials 3/16 −
3/4 in. (5-19 mm) thick. Generally,
the single V-groove is used on materials up to 3/4 in. (19 mm) thick
and when, regardless of thickness,
you can weld from one side only.
Create a 30 degree bevel with oxyacetylene or plasma cutting equipment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.
4
3
2
S-0062
9-11. Welding T-Joints
1
2
Electrode
Fillet Weld
Keep arc short and move at definite rate of speed. Hold electrode
as shown to provide fusion into the
corner. Square edge of the weld
surface.
For maximum strength weld both
sides of upright section.
3
1
2
45°
Or
Less
1
2
Multi-Layer Deposits
Weld a second layer when a heavier fillet is needed. Use any of the
weaving patterns shown in Section
9-8. Remove slag before making
another weld pass.
3
S-0060 / S-0058-A / S-0061
OM-253918 Page 60
9-12. Weld Test
1
2
3
Strike the weld joint in the direction shown. A good weld
bends over but does not break.
3
If the weld breaks, examine it to determine the cause.
If the weld is porous (many holes), the arc length was
probably too long.
3
If the weld contains bits of slag, the arc may have been
too long or the electrode was moved incorrectly which
allowed molten slag to be trapped in the weld. This may
happen on a V-groove joint made in several layers and
calls for additional cleaning between layers.
2 To 3 in.
(51-76 mm)
1/4 in.
(6.4 mm)
Vise
Weld Joint
Hammer
2
2 To 3 in.
(51-76 mm)
2
1
1
If the original beveled surface is visible the material was
not fully melted which is often caused by insufficient
heat or too fast a travel speed.
S-0057-B
9-13. Troubleshooting
Porosity − small cavities or holes resulting from gas pockets in weld metal.
Possible Causes
Corrective Actions
Arc length too long.
Reduce arc length.
Damp electrode.
Use dry electrode.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.
Possible Causes
Corrective Actions
Amperage too high for electrode.
Decrease amperage or select larger electrode.
Arc length too long or voltage too high.
Reduce arc length or voltage.
Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding
weld bead.
Possible Causes
Corrective Actions
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
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.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
OM-253918 Page 61
Lack Of Penetration − shallow fusion between weld metal and base metal.
Lack of Penetration
Good Penetration
Possible Causes
Corrective Actions
Improper joint preparation.
Material too thick. Joint preparation and design must provide access to bottom of groove.
Improper weld technique.
Keep arc on leading edge of weld puddle.
Insufficient heat input.
Increase amperage. Select larger electrode and increase amperage.
Reduce travel speed.
Excessive Penetration − weld metal melting through base metal and hanging underneath weld.
Excessive Penetration Good Penetration
Possible Causes
Corrective Actions
Excessive heat input.
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Burn-Through − weld metal melting completely through base metal resulting in holes where no
metal remains.
Possible Causes
Corrective Actions
Excessive heat input.
Select lower amperage. Use smaller electrode.
Increase and/or maintain steady travel speed.
Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.
Possible Causes
Corrective Actions
Unsteady hand.
Use two hands. Practice technique.
Distortion − contraction of weld metal during welding that forces base metal to move.
Base metal moves
in the direction of
the weld bead.
Possible Causes
Corrective Actions
Excessive heat input.
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower amperage for electrode.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-253918 Page 62
SECTION 10 − SELECTING AND PREPARING A TUNGSTEN
FOR DC OR AC WELDING WITH INVERTER MACHINES
gtaw_Inverter_2018-01
Whenever possible and practical, use DC weld output instead of AC weld output.
10-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten )
A. Select Tungsten Electrode.
. Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference
the product packaging to identify the tungsten you are using.
Amperage Range - Gas Type♦ - Polarity
Electrode Diameter
(DCEN) − Argon
AC − Argon
Direct Current Electrode Negative
Unbalanced Wave
(For Use With Aluminum)
(For Use With Mild Or Stainless Steel)
2% Ceriated, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens
.010 in. (.25 mm)
Up to 15
Up to 15
.020 in. (.50 mm)
5-20
5-20
.040 in. (1 mm)
15-80
15-80
1/16 in. (1.6 mm)
70-150
70-150
3/32 in. (2.4 mm)
150-250
140-235
1/8 in. (3.2 mm)
250-400
225-325
5/32 in. (4.0 mm)
400-500
300-400
3/16 in (4.8 mm)
500-750
400-500
1/4 in. (6.4 mm)
750-1000
500-630
♦Typical argon shielding gas flow rates are 10 to 25 CFH (cubic feet per hour).
Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS).
B. Electrode Composition.
Tungsten Type
2% Cerium
(Grey *)
1.5−2% Lanthanum
(Yellow/Blue)
2% Thorium
(Red)
Pure Tungsten
(Green)
Application Notes
Good all−around tungsten for both AC and DC welding.
Excellent low amp starts for AC and DC welding.
Commonly used for DC welding, not ideal for AC.
Not Recommended for inverters!
For best results in most applications use a sharpened cerium or lanthanum electrode for AC and DC welding.
* Color may vary depending on manufacturer, please refer to manufacturer’s guide for color designation.
OM-253918 Page 63
10-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding
Or AC Welding With Inverter Machines
Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires.
Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety
information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust
from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an
environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.
1
Radial Grinding
Causes Wandering Arc
1-1/2 To 4 Times
Electrode Diameter
2
Grinding Wheel
Grind end of tungsten on fine grit, hard
abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated causing lower weld quality.
2
Tungsten Electrode
A 2% ceriated tungsten is recommended.
4
3
15° to 30°
3
Ideal Grind Angle Range: 15° to 30°
. 30 degrees is the recommended electrode grind angle.
1
Wrong Tungsten
Preparation
Notes
OM-253918 Page 64
Ideal Tungsten Preparation − Stable Arc
4
Straight Ground
Grind lengthwise, not radial.
Notes
Welding Tip:
Securely connect work clamp to a clean area
close to the weld joint.
SECTION 11 − PARTS LIST
. Hardware is common and
51
52
34
35
30
21
1
2
3
56
4
24
28
23
29
22
18
19
31
32
20
16
17
8
7
6
5
27
10
11
26
33
12
25
13
14
15
36
37
38
54
55
39
53
40
41
42
48
49
43
47
50
46
39
45
44
not available unless listed.
956142881_17-D
Figure 12-1. Main Assembly
OM-253918 Page 66
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-1. Main Assembly
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
. . . . . . . . . . . . . . 207233 .
. . . . . . . . . . 156034005 .
. . . . . . . . . . 156034007 .
. . . . . . . . . +156007045 .
. . . . . . . . . +156015027 .
. . . . . . . . . . 056020078 .
. . . . . . . . . . 156032145 .
. . . . . . . . . . 156009134 .
.......................
. . . . . . . . . . 656102009 .
. . . . . . . . . . 656009004 .
. . . . . . . . . . 156012173 .
. . . . . . . . . +156122090 .
. . . . . . . . . . 000155436 .
. . . . . . . . . . . . . . 176106 .
. . . . . . . . . . 956142877 .
. . . . . . . . . . 057094073 .
. . . . . . . . . . 056020079 .
. . . . . . . . . . 116039031 .
. . . . . . . . . . 000178937 .
. . . PC5 . . 057084174 .
. . . . . . . . . . 057021025 .
. . . . . . . . . . 556090045 .
. . . . . . . . . . 057052052 .
. . . . . . . . . . 356029245 .
. . . . . . . . . . 056076270 .
. . . . . . . . . . 056076271 .
. . . . . . . . . . 956142876 .
. . . . . . . . . . 156118081 .
. . . . . . . . . . 156118079 .
. . . . . . . . . . . . . . 193919 .
. . . . . . . . . . 356029244 .
. . . PC3 . . 057084175 .
. . . . . . . . . . 156006080 .
. . . PC2 . . 028069126 .
. . . PC1 . . 057084176 .
. . . PC4 . . 057084177 .
. . . GSV . 056061071 .
. . . . . . . . . . 156005146 .
. . . . . . . . . +156118086 .
. . . . . . . . . . 956172254 .
. . . . . . . . . . 356029246 .
. . . . . . . . . . 656089046 .
. . . . . . . . . . 256071014 .
. . . . . . . . . . . . . . 220805 .
. . . . S1 . . . . . . 124511 .
. . . . . . . . . . 156008044 .
. . . . . . . . . . 057035022 .
. . . . . . . . . . . . . . 208015 .
. . . . . . . . . +156122092 .
. . . . . . . . . . . . . . 207291 .
. . . . . . . . . . 656110015 .
. . . . . . . . . . 057052053 .
. . . . . . . . . . 256124039 .
. . . . . . . . . . 656043048 .
. . . . . . . . . . 956142897 .
Label, General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slide Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hinge, Plastic, 40x40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Threaded Ring, Spool Holder, 5kg Spool, D. 50 . . . . . . . . . . . . . . . . . . . . . . .
Handwheel, Reel, w/Ring M8x20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, 17x2, 6x5sp.L=28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamp, Holder 16X39 − 5 mm Thick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number Not Used
Spool Holder, C/W 5kg Thread Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Disc, PVC 17x70, Reel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spool Holder Shaft D. 50 5kg D. 16 L=53 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning Changing Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Gas/No Gas Change Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Lobes d.30 Handwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Box Protection, PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Drive System, c/w 0.8−1.0 Rolls, 4 Rolls (see Fig. ) . . . . . . . . . . . . . . .
Wire Guide, 2x5, L69, Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector, Mini−Euro, Quick Female, L17 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, MPi 220 Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dinse, Socket, Female, 25MMQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle, 2P, Gun Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Mpi 220P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bezel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Mpi 220 Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Power Interconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Inverter Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Motor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Corner Seal, Plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rating Plate, Mpi 220P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Rear, Mpi 220P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strain Relief, M 25x1.5, Primary Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary Cable, 3 Core 2,5 Mq . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spacer, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan, 120x120 24VDC c/w Wire Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Primary Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foot, Rubber Mount, D.45 H=25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, Connector, ⅝” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plug, 2P, TIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cap, Plastic D.8,5−14 Head D.16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Weld Parameters Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
4
1
1
1
1
4
1
1
1
1
+ When ordering a component originally displaying a precautionary label, the label should also be ordered.
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.
OM-253918 Page 67
See Drive Roll And Wire Guide Kits
. Hardware is common and
not available unless listed.
956142881_18-A
Figure 12-2. Wire Drive Assembly
OM-253918 Page 68
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 12-2. Wire Drive Assembly
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056126081
156018121
556075033
156033035
656003014
156012154
156017161
156018126
156012142
156003035
156012140
156003034
156003039
156019776
356052009
156012155
156023172
156012145
356052010
156019777
156009136
156013050
156033036
156003036
156053112
156019805
756009061
656033010
656021268
156053109
156003037
156013051
156023165
156019779
156090026
156023173
156019806
356052011
156090027
656064004
156032138
156032134
056020075
656033009
356052012
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Motor, Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, Hex M5, Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cover, Rear, Gear Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, d.10x14, Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft, Central Gear/Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Snap Ring, TR.PL AL ES.12 L=54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing, d.10x26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, Hex M4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, d.4x25 SM.0,3x45∅ C40 RETT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear, Reducer, D32Z30 D17Z12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, d.4x35 SM.0,3x45∅ C40 RETT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear, Reducer, D24Z30 D14Z12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear, Reducer, D23Z38 D12Z14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M4x10, Zinc Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing, Adapter Gun/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Housing, Adapter Gun/Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O−Ring, 10x16x0,2 DIN 988 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, Drive Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper RH Pressure Arm Housing, Die Cast . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M4x8, Pan Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, d.10,5x4, Brass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key, Upper Drive Roll Assembly, 3x3 L=15 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bushing, Upper Drive Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear, Upper Drive Roll Assembly, d.17x32.5 . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Roll, Upper Pressure Arm Housing, d.17x30 . . . . . . . . . . . . . . . . . . . . .
Bolt, M5x25, Through Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer, Insulator Drive Assembly Through Bolt . . . . . . . . . . . . . . . . . . . . . . .
Thumb Screw, Drive Roll Locator, d. M4x8 . . . . . . . . . . . . . . . . . . . . . . . . . . .
O−Ring, d.7,2x1,78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Drive Roll, d.30, See Figure 12-2 and Table 12-1 . . . . . . . . . . . . . . . . .
Gear, Lower Drive Roll Assembly d.10x32,5, Drive Roll . . . . . . . . . . . . . . . .
Key, Lower Drive Roll Assembly d. 3x3 L=20 . . . . . . . . . . . . . . . . . . . . . . . . .
C−Clip, Gear/Shaft, d.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M4x4, Wire Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Inlet Guide, See Figure 12-2 and Table 12-1 . . . . . . . . . . . . . . . . . . . . .
C−Clip, Tension Arm, d.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screw, M4 Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, Tension Arm Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, d.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tension Arm, Pinned . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sleeve, d.7x7 Spring Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spring, 10x1.3 L 30, Wire Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Adjustment Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut, Locating, Tension Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper LH Pressure Arm Housing, Die Cast . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
4
1
2
2
2
2
1
1
1
2
1
1
3
1
2
2
2
1
4
4
2
2
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
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.
OM-253918 Page 69
Table 12-1. Drive Roll And Wire Guide Kits
. Base selection of drive rolls upon the following recommended usages:
1.
2.
3.
4.
V-Grooved rolls for hard wire.
U-Grooved rolls for soft and soft shelled cored wires.
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
Wire Guide
Metric
Fraction
Decimal
Part No.
Type
0.6/0.8 mm*
0.023/0.030 in.
0.023/0.030 in.
156053051
V
0.8/1.0 mm*
0.030/0.035 in.
0.030/0.035 in.
156053109
V
1.0/1.2 mm*
0.035/0.045 in.
0.035/0.045 in.
156053052
V
0.8/1.0 mm**
0.030/0.045 in.
0.030/0.035 in.
156053053
U
0.8/1.0 mm*
0.030/0.045 in.
0.030/0.035 in.
156053121
U
1.2/1.6 mm**
0.045/0.065 in
0.035/0.065 in
156053054
U
1.0/1.2 mm*
0.035/0.045 in.
0.035/0.045 in.
156053110
V-K
Inlet
156090026
*Available in steel 30 mm diameter
**Available in nylon 30 mm diameter
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-253918 Page 70
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
Notes
Effective January 1, 2018
(Equipment with a serial number preface of MJ or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
below, ITW Welding Products Italy warrants to its original retail
purchaser that new Miller equipment sold after the effective date
of this limited warranty is free of defects in material and
workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed. If notification is submitted as an
online warranty claim, the claim must include a detailed
description of the fault and the troubleshooting steps taken to
identify failed components and the cause of their failure.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the date the
equipment was delivered to the original retail purchaser or one
year after the equipment is shipped to a European distributor or
twelve months after the equipment is shipped to an International
distributor.
1. 5 Years Parts — 3 Years Labor
*
2.
3 Years — Parts and Labor
*
*
*
*
*
3.
Auto-Darkening Helmet Lenses (No Labor)
Migmatic 175
HF Units
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
5.
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
Inverter Power Sources (Unless Otherwise Stated)
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Transformer/Rectifier Power Sources
2 Years — Parts
*
*
*
4.
Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules with
exclusion of STR, Si, STi, STH and MPi series.
Automatic Motion Devices
Field Options
(NOTE: Field options are covered under True
Blue) for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
Motor-Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Powered Air Purifying Respirator (PAPR) Blower
Unit (No Labor)
Racks
Running Gear and Trailers
Subarc Wire Drive Assemblies
Water Cooling Systems
Work Stations/Weld Tables (No Labor)
6.
90 Days — Parts
*
*
*
*
*
*
*
*
Accessory (Kits)
Canvas Covers
Induction Heating Coils and Blankets
MIG Guns
Remote Controls
Replacement Parts (No Labor)
Spoolmate Spoolguns
Cables and Non-Electronic Controls
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, switches, slip
rings, relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL AND
INDUSTRIAL USERS TRAINED AND EXPERIENCED IN THE
USE AND MAINTENANCE OF WELDING EQUIPMENT.
The exclusive remedies for warranty claims are, at Miller’s
option, either: (1) repair; or (2) replacement; or, if approved in
writing by Miller, (3) the pre-approved cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon use). Products may not be returned
without Miller’s written approval. Return shipment shall be at
customer’s risk and expense.
The above remedies are F.O.B., Factory at ITW Welding
Products Group Europe or Miller’s authorized service facility.
Transportation and freight are the customer’s responsibility. TO
THE EXTENT PERMITTED BY LAW, THE REMEDIES HEREIN
ARE THE SOLE AND EXCLUSIVE REMEDIES REGARDLESS
OF THE LEGAL THEORY. IN NO EVENT SHALL MILLER BE
LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY
WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
WARRANTY,
GUARANTY,
OR
REPRESENTATION,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, ARE EXCLUDED AND DISCLAIMED BY MILLER.
6 Months — Parts
*
Batteries
milan_warr 2018-01
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
Country
Zip/Postal Code
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
Service and Repair
Replacement Parts
Owner’s Manuals
ITW Welding Italy S.r.l.
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
© 2018 Miller Electric Mfg. LLC 2018−01
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39 (0) 2982901
Fax: 39 (0) 298290-203
email: miller@itw−welding.it
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