Miller MULTIMATIC 220 AC/DC Owner’s Manual

OM-281426B
Processes
Multiprocess Welding
Description
Arc Welding Power Source
Wire Feeder
®
Multimatic 220
AC/DC
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
File: Multiprocess
2019−02
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety Precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller, you can count on
years of reliable service with proper
maintenance. And if for some reason the unit
needs repair, there’s a Troubleshooting
section that will help you figure out what the
problem is, and our extensive service
network is there to help fix the problem.
Warranty and maintenance information for
your particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Miller Electric manufactures a full line
of welders and welding-related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank1 2019−01
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. 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 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Unit Specifications For MIG (GMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Unit Specifications For TIG (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Unit Specifications For Stick (SMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Duty Cycle And Overheating For MIG (GMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Duty Cycle And Overheating For TIG (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Duty Cycle And Overheating For Stick (SMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Multi−Voltage Plug (MVP) Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-4. Input Power Extension Cord Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-5. Connecting 120 Volt Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-6. Connecting 1-Phase Input Power For 240 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7. Generator / Inverter Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-8. Stick Welding Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-9. TIG Welding Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-10. MIG Welding Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-11. MIG Gun Connection Inside Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-12. Connecting Shielding Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-13. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-14. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-15. Removing MIG Gun To Replace With A Spool Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Controls, TIG Aluminum Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Controls, TIG Steel/Stainless Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Controls, Stick Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Controls, MIG Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Welding Parameter Chart − 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Welding Parameter Chart − 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-8. Entering Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS
6-9. Internal Motor 24 Inch Calibration (Menu 1 Of 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-10. Internal Motor Run-In Speed (Menu 2 Of 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-11. Spoolmatet 24 Inch Calibration (Menu 3 Of 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-12. Spoolmate Run-In Speed (Menu 4 Of 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-13. Process Logs (Menu 5 Of 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-14. Primary Logs (Menu 6 Of 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-15. Error Logs (Menu 7 Of 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-16. Factory Reset (Menu 8 Of 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-17. Display Software (Menu 9 Of 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-18. Control Software (Menu 10 Of 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-19. QuickTech (Menu 11 Of 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-20. TIG Postflow Control (Menu 12 Of 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Changing Drive Roll Or Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − HIGH FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Welding Processes Requiring High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Installation Showing Possible Sources Of HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Recommended Installation To Reduce HF Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 − GUIDELINES FOR TIG WELDING (GTAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Positioning The Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Torch Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3. Positioning Torch Tungsten For Various Weld Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − GMAW WELDING (MIG) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − GUIDELINES FOR STICK WELDING (SMAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Stick Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-2. Electrode And Amperage Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-3. Striking An Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-4. Positioning Electrode Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-5. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-6. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-7. Conditions That Affect Weld Bead Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-8. Electrode Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-9. Welding Lap Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-10. Welding Groove (Butt) Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-11. Welding T-Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-12. Weld Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-13. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-1. Recommended MIG Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-2. Recommended TIG Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 15 − SOFTWARE LICENSE AGREEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPLETE PARTS LIST − Available at www.MillerWelds.com
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2018−01
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
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-281426 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-281426 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.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
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.
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.
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.
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-281426 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-281426 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
som_2018−01_fre
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
AVIS − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Section 2-5. Lire et observer toutes les normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une
personne qualifiée est définie comme celle qui, par la
possession d’un diplôme reconnu, d’un certificat ou d’un
statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec
succès sa capacité à résoudre les problèmes liés à la tâche,
le travail ou le projet et a reçu une formation en sécurité afin
de reconnaître et d’éviter les risques inhérents.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.
UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.
Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est sous
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la
machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec
du fil, le fil, le dérouleur, le bloc de commande du
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement
installé ou mis à la terre de manière incorrecte ou
impropre constitue un danger.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et
sans trous.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou
des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.
D Ne pas utiliser de sortie de soudage CA dans des zones humides
ou confinées ou s’il y a un risque de chute.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !
Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de sécurité).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
Vérifier fréquemment le cordon d’alimentation et le conducteur de
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.
L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.
Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
S’assurer que tous les panneaux et couvercles sont correctement
en place.
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Ne pas raccorder plus d’une électrode ou plus d’un câble de
masse à une même borne de sortie de soudage. Débrancher le
câble pour le procédé non utilisé.
Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.
Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur UNE FOIS
l’alimentation coupée.
D Éteignez l’unité, débranchez le courant électrique, et déchargez
les condensateurs d’alimentation selon les instructions indiquées
dans le manuel avant de toucher les pièces.
OM-281426 Page 5
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant
de travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. Pour déterminer la bonne ventilation, il est recommandé
de procéder à un prélèvement pour la composition et la quantité de
fumées et de gaz auxquelles est exposé le personnel.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets e
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas couper ou souder des jantes ou des roues. Les pneus
peuvent exploser s’ils sont chauffés. Les jantes et les roues réparées peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans
les normes de sécurité.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
gaz ou émanations inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
D Porter un équipement de protection pour le corps fait d’un matériau
résistant et ignifuge (cuir, coton robuste, laine). La protection du
corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
trace d’étincelles incandescentes ni de flammes.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
D Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
les dégraisseurs, les flux et les métaux.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact accidentel de l’électrode avec des
objets métalliques peut provoquer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier
et s’assurer que l’endroit ne présente pas de danger.
OM-281426 Page 6
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Fermer l’alimentation du gaz comprimé en cas
de non utilisation.
D Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur médecin
et le fabricant du dispositif avant de s’approcher de la zone où se
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par
induction.
LE BRUIT peut endommager l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvées pour les
oreilles si le niveau sonore est trop élevé.
LES BOUTEILLES peuvent exploser
si elles sont endommagées.
Les bouteilles de gaz comprimé contiennent du
gaz sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Du fait que
les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter les
bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.
D Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.
D Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer
que les fourches sont suffisamment longues pour dépasser du
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres
personnes ou toute pièce mécanique en engageant le fil de
soudage.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ne pas utiliser l’appareil de soudage pour
charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
de charge de batterie destinée à cet usage.
Les PIÈCES MOBILES peuvent
causer des blessures.
D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
OM-281426 Page 7
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
LE
RAYONNEMENT
HAUTE
FRÉQUENCE
(H.F.)
risque
de
provoquer des interférences.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes,
il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.
2-4. Proposition californienne 65 Avertissements
AVERTISSEMENT : ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2,
from Canadian Standards Association, Standards Sales, 5060 Spec-
trum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02169 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N,
Part 1910 Subpart Q, and Part 1926, Subpart J, from U.S. Government
Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA
Regional Offices—phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd,
Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
OM-281426 Page 8
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
médecin approuve, il est recommandé de suivre les procédures précédentes.
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation − keep hands
and metal objects away.
Safe95 2012−05
Beware of electric shock from wiring.
Safe94 2012−08
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe40 2012−05
V
V
>5min
V
Hazardous voltage remains on input capacitors after power is turned
off. Do not touch fully charged capacitors. Always wait 5 minutes after
power is turned off before working on unit, OR check input capacitor
voltage, and be sure it is near 0 before touching any parts.
Safe43 2017−04
Notes
OM-281426 Page 9
3-2. Miscellaneous Symbols And Definitions
A
V
U0
Amperage
Voltage
Circuit Breaker
Rated No Load
Voltage (OCV)
Positive
Direct Current
(DC)
Negative
Alternating
Current (AC)
U1
U2
I2
Remote
X
Gas Metal Arc
Welding (GMAW)
Duty Cycle
Line Connection
Conventional
Load Voltage
S
Suitable for Some
Hazardous
Locations
Increase
Input Power Or Input Voltage
Gas Input
IP
Internal Protection
Rating
Shielded Metal
Arc Welding
(SMAW)
Shielded Metal
Arc (SMAW)
Electrode Holder
Primary Voltage
Rated Welding
Current
Gas Tungsten Arc
Welding (GTAW)
Torch
Hz
Hertz
Single Phase
Static Frequency
ConverterTransformerRectifier
Gas Metal Arc
Welding (GMAW)
MIG / Gun Control
Self-Shielded Flux
Cored Arc
Welding (FCAW)
Wire Feed Spool
Gun
Gas Tungsten Arc
Welding (GTAW) /
Tungsten Inert
Gas (TIG)
Welding
Gas Postflow
Single Phase
Lift Arc (GTAW)
TIG / Remote
Gas Preflow
Wire Feed Slow
Run-In
Cold Jog (Inch)
Toward Workpiece
Work Connection
Output Enabled
High Frequency
Reverse Polarity
Unlocked
Locked
On- Continuous
Notes
OM-281426 Page 10
. A complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back of unit. Use rating label to determine input power requirements and/or
rated output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Unit Specifications For MIG (GMAW)
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-3, 5-5, and 5-6 for information on
connecting input power.
Rated Welding
Output
Amperage
Range
Maximum OpenCircuit Voltage
DC
Amperes Input at Rated
Load Output, 50/60 Hz,
Single-Phase
105 A @ 19.2 Volts DC
60% Duty Cycle
30 − 125
45
23.6
Solid/Stainless
Flux Cored
Wire Feed Speed Range
.024 - .035 in.
(0.6 - 0.8 mm)
.030 - .035 in.
(0.8 - 0.9 mm)
60 − 600 IPM (1.5 − 15.2 m/min)
30 − 230
45
Input
Voltage
120 VAC
Wire Type
And Diameter
200 A @ 24.0 Volts DC
20% Duty Cycle
240 VAC
27.2
170 A @ 21.5 Volts DC
40% Duty Cycle
Wire Type
And Diameter
21.5
Solid/Stainless
Flux Cored
Wire Feed Speed Range
.024 − .035 in.
(0.6 − 0.9 mm)
.030 − .045 in.
(0.8 − 1.2 mm)
60 − 600 IPM (1.5 − 15.2 m/min)
4-3. Unit Specifications For TIG (GTAW)
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-3, 5-5, and 5-6 for information on
connecting input power.
Input
Voltage
Rated Welding
Output
Amperage
Range
Maximum OpenCircuit Voltage
DC
Amperes Input at Rated
DC Load Output,
50/60 Hz, Single-Phase
120 VAC
130 A @ 15.2 Volts AC/DC
40% Duty Cycle
20 − 140
46
21.2
240 VAC
210 A @ 18.4 Volts AC/DC
20% Duty Cycle
20 − 210
46
22.4
4-4. Unit Specifications For Stick (SMAW)
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-3, 5-5, and 5-6 for information on
connecting input power.
Input
Voltage
Rated Welding
Output
Amperage
Range
Maximum OpenCircuit Voltage
DC
Amperes Input at Rated
DC Load Output,
50/60 Hz, Single-Phase
120 VAC
90 A @ 23.6 Volts AC/DC
40% Duty Cycle
30 − 90
46
24.5
240 VAC
200 A @ 28.4 Volts AC/DC
15% Duty Cycle
30 − 200
46
31.3
4-5. Environmental Specifications
A. IP Rating
IP Rating
IP21
This equipment is designed for indoor use and is not intended to be used or stored outside.
IP21 2014−06
B. Temperature Specifications
Operating Temperature Range*
Storage/Transportation Temperature Range
14 to 104°F (−10 to 40°C)
−4 to 131°F (−20 to 55°C)
*Output is degraded at temperatures above 104°F (40°C).
Temp_2016- 07
OM-281426 Page 11
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4-6. Dimensions And Weight
11 1/4 in.
(286 mm)
Weight
56 lb (25.3 kg)
17 1/2 in.
(445 mm)
21 1/2 in.
(546 mm)
275173A
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-281426 Page 12
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4-7. Duty Cycle And Overheating For MIG (GMAW)
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, output stops. Wait
fifteen minutes for unit to cool.
Reduce amperage or duty cycle
before starting to weld again.
240
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
220
Output Amperes
200
180
160
140
240VAC
120VAC 20A
120
100
80
60
40
120VAC 15A
20
0
10
100
50
20
% Duty Cycle
120V Input
60% Duty Cycle At 105A
6 Minutes Welding
4 Minutes Resting
240V Input
40% Duty Cycle At 170A
20% Duty Cycle At 200A
2 Minutes Welding
4 Minutes Welding
8 Minutes Resting
6 Minutes Resting
Overheating
A or V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − Ref. Duty Cycle Charts
OM-281426 Page 13
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4-8. Duty Cycle And Overheating For TIG (GTAW)
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, output stops. Wait
fifteen minutes for unit to cool.
Reduce amperage or duty cycle
before starting to weld again.
240
220
200
Output Amperes
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
240V
180
120V 20A
160
140
120
100
80
120V 15A
60
40
20
0
10
100
50
20
% Duty Cycle
120V Input
40% Duty Cycle At 130A
4 Minutes Welding
6 Minutes Resting
240V Input
20% Duty Cycle At 210A
2 Minutes Welding
8 Minutes Resting
Overheating
A or V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − Ref. Duty Cycle Charts
OM-281426 Page 14
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4-9. Duty Cycle And Overheating For Stick (SMAW)
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, output stops. Wait
fifteen minutes for unit to cool.
Reduce amperage or duty cycle
before starting to weld again.
240
220
Output Amperes
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
240V
200
180
160
140
120
120V 20A
100
80
60
40
20
0
10
120V 15A
50
20
100
% Duty Cycle
120V Input
40% Duty Cycle At 90A
4 Minutes Welding
6 Minutes Resting
240V Input
20% Duty Cycle At 185A
2 Minutes Welding
8 Minutes Resting
Overheating
A or V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − Ref. Duty Cycle Charts
OM-281426 Page 15
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SECTION 5 − INSTALLATION
5-1. Selecting A Location
!
Do not move or operate unit where it could tip.
Movement
1
Location And Airflow
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1
Lifting Handles
2
Use handles to lift unit.
2
Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)
18 in.
(460 mm)
loc_smallmig2 2018-05 161-122
OM-281426 Page 16
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5-2. Multi−Voltage Plug (MVP) Connection
Selecting Plug
2
1
3
4
5
!
6
Do not cut off power cord connector and rewire. The power
cord connector and plugs will
work with standard NEMA receptacles. Modifying power
cord, connector, and plugs will
void product warranty.
7
Connecting Plug To Power Cord
Selecting Plug
1
Power Cord Connector From
Welding Power Source
Select plug for power supply receptacle
available at site. Not all plugs shown are
provided as standard with unit.
2
Plug − NEMA Type 5−15P
3
Receptacle − NEMA Type 5−15R
(Customer Supplied)
4
5
6
7
!
Plug − NEMA Type 5−20P (Optional)
Receptacle − NEMA Type 5−20R
(Customer Supplied)
Plug − NEMA Type 6−50P
Receptacle − NEMA Type 6−50R
(Customer Supplied)
Follow electrical service guide for
240 VAC in Section 5-3. Do not use
plug rating to size branch circuit
protection.
Connecting Plug To Power Cord
Align arrow on plug with arrow on power
cord connector. Push together.
Tighten threaded collar. As threaded collar
is tightened, push plug onto adapter until
collar is completely tight.
Connect plug to receptacle.
MVP Plug1 2010−10 / Ref. 803 812-C
OM-281426 Page 17
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5-3. 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.
Input Voltage (V)
50/60 Hz
1-Phase
50/60 Hz
1-Phase
120
240
Rated Maximum Supply Current I1max (A)
32
A 15 or 20
ampere
individual
branch circuit
protected by
time-delay
fuses or circuit
breaker is
required. See
Section 5-5.
Maximum Effective Supply Current I1eff (A)
Max Recommended Standard Fuse Rating In
Amperes1
Time-Delay Fuses2
Normal Operating Fuses 3
Min Input Conductor Size In AWG (mm2) 4
Max Recommended Input Conductor Length In Feet (Meters)
15
40
45
12
34
(10)
Min Grounding Conductor Size In AWG (mm2) 4
12
Reference: 2017 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167°F (75°C) with not more than
three single current−carrying conductors in a raceway. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table
400.5(A) for flexible cord and cable requirements.
5-4. Input Power Extension Cord Data
Use extension cord only for temporary wiring. Remove extension cord immediately after completing the project.
Input 17 2018-11
Cord Type
Minimum Conductor Size
Number of Conductors
Maximum Cord Length
Heavy Duty (Hard Usage)
12 AWG (4 mm2)
3
50 ft (15 m)
. Read OSHA Standard 1910.334 for more information on the use of cord and plug connected equipment.
Read National Electrical Code (NEC) Article 590 for more information on temporary wiring.
OM-281426 Page 18
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5-5. Connecting 120 Volt Input Power
!
Installation must
meet all
National and Local Codes − have
only qualified persons make this
installation.
!
Special installation may be
required where gasoline or volatile
liquids are present − see NEC
Article 511 or CEC Section 20.
NOTICE − The Auto-Line circuitry in this
unit automatically links the power source
to the primary voltage being applied, either
120 or 240 VAC.
See rating label on unit and check input
voltage available at site.
For 120 volts AC input power, a 15 or 20
ampere individual branch circuit protected
by time-delay fuses or circuit breaker is
required.
1
Multi-Voltage Plug And Power Cord
Connector (NEMA Type 5−15P Plug
Shown)
For multi−voltage plug connections, see
Section 5-2.
2
Receptacle − NEMA Type 5−15R
(Customer Supplied)
1
2
Input6 2011−03 275173A / Ref. 805 474-A
OM-281426 Page 19
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5-6. Connecting 1-Phase Input Power For 240 VAC
1
3
=GND/PE Earth Ground
7
2
4
L1
L2
5
6
1
8
L1
L2
240 VAC, 1
Tools Needed:
input4 2012-05 − 803 766-C / Ref. 802 443-A / 275173A
OM-281426 Page 20
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5-6. Connecting 1-Phase Input Power For 240 VAC (Continued)
!
Installation must meet all National and
Local Codes − have only qualified persons make this installation.
!
Disconnect and lockout/tagout input
power before connecting input conductors from unit. Follow established
procedures regarding the installation
and removal of lockout/tagout
devices.
!
Always connect green or green/yellow
conductor to supply grounding terminal first, and never to a line terminal.
NOTICE − The Auto-Line circuitry in this unit
automatically links the power source to the
primary voltage being applied, either 120 or
240 VAC.
See rating label on unit and check input voltage available at site.
1
Input Power Cord
2
Disconnect Device (switch shown in the
OFF position)
3
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
Disconnect Device Grounding Terminal
Select type and size of over-current
protection using Section 5-3 (fused
disconnect switch shown).
4
Disconnect Device Line Terminals
8
5
Black And White Input Conductor (L1
And L2)
6
Green Or Green/Yellow Grounding
Conductor
Receptacle (NEMA 6-50R)
Customer Supplied
Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.
input4 2012−05 − 803 766-C
5-7. Generator / Inverter Requirements
Minimum auxiliary power requirement at rated load is 10 KW continuous/12.5 KW peak at 240 volts AC
for full output. Smaller generators
will reduce output capability.
Generator settings, if applicable.
!
Engine Control Switch must be set at “RUN”
position − not “RUN/IDLE”.
!
Set generator Fine Adjustment Control
to 10 for maximum auxiliary power.
OM-281426 Page 21
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5-8. Stick Welding Connections
!
Turn off unit and disconnect
input power before making
connections.
!
Do not use worn, damaged,
undersized, or repaired
cables.
1
2
3
Weld Output Receptacle
Work Clamp Receptacle
Stick Electrode Holder And
Cable
Work Clamp And Cable
4
Connect stick electrode holder
cable to the electrode output
receptacle, and connect work
clamp to work output receptacle.
Turn connectors clockwise.
Ensure all connections are tight.
1
2
3
4
Ref. 282724A
OM-281426 Page 22
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5-9. TIG Welding Connections
!
Turn off unit and disconnect
input power before making
connections.
!
Do not use worn, damaged,
undersized, or repaired
cables.
1
2
3
4
Weld Output Receptacle
Work Clamp Receptacle
TIG Torch And Cable
Work Clamp And Cable
Connect TIG torch cable to the
electrode receptacle and connect
work cable to work receptacle. Turn
connectors clockwise.
Ensure all connections are tight.
5
6
7
Foot Control
Remote Control Cable
Remote Control Receptacle
Connect foot control to remote
control receptacle.
8
TIG Shielding Gas
Connection
Use Argon gas for TIG welding (see
Section 5-12).
7
6
5
1
2
3
4
8
Ref. 282724A / Ref. 282719A
OM-281426 Page 23
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5-10. MIG Welding Connections
3
1
2
4
6
5
8
7
Ref. 275172A / Ref. 275167A / Ref. 275168A
!
Turn off unit and disconnect input
power before making connections.
!
Do not use worn, damaged, undersized, or repaired cables.
Weld Output Receptacle
Work Clamp Receptacle
MIG Gun
Work Clamp And Cable
1
2
3
4
OM-281426 Page 24
Connect work cable to work receptacle.
Turn connector clockwise.
Ensure all connections are tight.
5 Gun End
Connect gun end to drive assembly (see
Section 5-11).
6 Trigger Control Cable
7 Four Pin Trigger Control Cable
Receptacle
Route trigger control cable through MIG
gun hole.
Connect plug on end of cable to four pin
receptacle inside unit.
8 MIG Shielding Gas Connection
Use 75/25 mix or CO2 shielding gas for
solid wire. Use Argon shielding gas for
aluminum wire with spool gun (see Section
5-12).
. A complete Parts List is available at www.MillerWelds.com
5-11. MIG Gun Connection Inside Unit
2
5
4
3
1
6
Ref. 275167A
1
Gun Securing Knob
2
Gun Block
3
Gun Outlet Wire Guide
Loosen knob. Insert end of gun through
opening in front panel until gun end
bottoms against gun block. Tighten
knob.
4
Gun End
5
6
Four Pin Trigger Control Cable
Receptacle
Route trigger control cable through MIG
gun hole.
Connect plug on end of cable to four pin
receptacle inside unit.
Trigger Control Cable
. Be sure that gun end is tight against drive assembly.
4
CORRECT
4
INCORRECT
Ref. 267807A
OM-281426 Page 25
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5-12. Connecting Shielding Gas Supply
Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.
1
Cap
2
Cylinder Valve
Remove cap, stand to side of valve,
and open valve slightly. Gas flow
blows dust and dirt from valve.
Close valve.
1
3
Cylinder
4
Regulator/Flowmeter
Install Regulator/Flowmeter
face is vertical.
2
5
Regulator/Flowmeter Gas
Hose Connection
6
Welding Power Source CO2
And Mixed Gas Hose
Connection
Welding Power Source Argon
Gas Hose Connection
3
1
Mixed Gas
1
2
9
10
2
3
3
Argon Gas
CO2 Gas
4
4
8
8
so
7
Connect gas hose between
regulator/flowmeter gas hose
connection, and the appropriate
fitting for the gas type on rear of
welding power source.
8
Flow Adjust
Typical flow rate for CO2 shielding
gas and MIG (GMAW) welding is 15
to 30 CFH (cubic feet per hour) and
mixed gas is 25 to 45 CFH.
Typical flow rate for Argon shielding
gas and TIG (GTAW) welding is 15
to 25 CFH and aluminum MIG
(GMAW) welding is 35 to 45 CFH.
Check
wire
manufacturer’s
recommended flow rate.
9
CO2 Adapter (Customer
Supplied)
10 O-Ring (Customer Supplied)
5
MIG
5
Install adapter with O-ring between
regulator/flowmeter
and
CO2
cylinder.
TIG
6
7
Tools Needed:
Ref. 804 654-A / 282718A
OM-281426 Page 26
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5-13. Installing Wire Spool And Adjusting Hub Tension
1
2
Wire Spool
Retaining Nut − For 8 in.
(203 mm) Spool Only
Tools Needed:
1/2 in.
1
2
Warning
Installing 4 in. (102 mm) Wire Spool
When a slight force is needed
to turn spool, tension is set.
Installing 8 in. (203 mm) Wire Spool
Adapter and
retaining ring
When a slight force is
needed to turn spool, tension is set.
Align locking hole in
spool with locking
pin on spool hub.
Ref. 282721A / 803 012 / 803 013 -B / Ref. 802 444-C
OM-281426 Page 27
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5-14. Threading Welding Wire
1
2
3
4
5
6
7
4
2
Wire Spool
Welding Wire
Inlet Wire Guide
Pressure Adjustment Knob
Drive Roll
Outlet Wire Guide
Gun Conduit Cable
Lay gun cable out straight.
7
Warning
Tools Needed:
1
3
5
6
. Hold wire tightly to keep it
from unraveling.
6 in.
(150 mm)
Warning
Warning
Open pressure assembly.
Pull and hold wire; cut off end.
Push wire through guides into gun;
continue to hold wire.
. Use pressure indicator scale to set a desired
Tighten
drive roll pressure. Begin with a setting of 2.
If necessary, make additional adjustments
after trying this initial setting.
1
2
3
4
Pressure
Indicator
Scale
Warning
Close and tighten pressure
assembly, and let go of wire.
Remove gun nozzle and contact tip.
Turn On.
Tighten
WOOD
Press gun trigger until wire
comes out of gun. Reinstall
contact tip and nozzle
1
2
3
4
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
Cut off wire. Close
and latch door.
Ref. 282721A / 275167A / 801 083 / Ref. 800 924-D
OM-281426 Page 28
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5-15. Removing MIG Gun To Replace With A Spool Gun
Tools Needed:
Open Pressure Assembly.
Cut Off End Of Wire.
Turn Off Power.
Knob
. Hold wire tightly to keep it
from unraveling.
Rewind Wire Onto Spool, Fasten
End Of Wire To Spool.
Warning
Loosen Knob, Disconnect Gun Trigger Plug,
And Remove Gun From Unit.
Warning
Insert Power Pin, Connect Spool Gun
Trigger Plug, And Tighten Knob.
282718A / Ref. 802982A / Ref. 282722A / Ref. 282721A
OM-281426 Page 29
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SECTION 6 − OPERATION
6-1. Controls
3
1
4
2
6
6
5
7
8
Rear View
Ref. 281252A / 282718A
1
Process Select Buttons
Press the up and down buttons to select desired welding process.
2
Auto-Set Button
select the size of wire, rod, or tungsten for
the selected process.
. When MIG Aluminum process is se-
lected, Wire/Rod/Tungsten buttons are
used to select type of spool gun being
used.
Press button to turn Auto-Set On or Off. Auto-Set is On when illuminated.
3
Wire/Rod/Tungsten Buttons
Press the Plus (+) or Minus (−) button to
OM-281426 Page 30
4
Material Thickness Buttons
Press the Plus (+) or Minus (−) button to
select material thickness for the selected
process.
5 Display
6 Adjustment Knobs
7 TIG Arc Start Select Buttons
Press the up and down buttons to select desired TIG arc start.
8 Power Switch
Use switch to turn unit On or Off.
. A complete Parts List is available at www.MillerWelds.com
6-2. Controls, TIG Aluminum Manual Mode
1
Auto-Set Button
Press button to turn Auto-Set feature On or Off. Auto-Set is On when
illuminated.
2
1
2
3
Tungsten Size Buttons
Press the Plus (+) or Minus (-) button to adjust up or down.
3
Balance Adjustment Buttons
Press the Plus (+) or Minus (-) button to adjust up or down. The range
is 60-80%. Pro-Set value is 75%
(See tip below).
4
Frequency Adjustment Knob
Frequency range is 60-150 Hz.
Pro-Set value is 120 Hz (See tip below).
5
6
Amperage Adjustment Knob
TIG Arc Start Select Buttons
Press the up and down buttons to
select desired TIG arc start. Lift-Arc
not available for TIG aluminum.
4
5
6
TIP: AC Frequency controls the
width of the arc cone. Increasing
the AC Frequency provides a more
focused arc and increased directional control.
Note: Decreasing the AC Frequency softens the arc and broadens the
weld puddle for a wider weld.
TIP: AC Balance controls the
cleaning action. If floating black
spots appear in the puddle the balance setting is too high. Turn the
balance down until the puddle becomes clear.
Ref. 281252A
Notes
OM-281426 Page 31
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6-3. Controls, TIG Steel/Stainless Manual Mode
1
2
Auto-Set Button
Press button to turn Auto-Set feature On or Off. Auto-Set is On when
illuminated.
1
2
Tungsten Size Buttons
Press the Plus (+) or Minus (-) button to adjust up or down.
3
Pulse Adjustment Knob
The range is OFF - 150 PPS (Pulses per Second). Pro-Set value is
100 PPS (See tips below).
4
5
Amperage Adjustment Knob
TIG Arc Start Select Buttons
Press the up and down buttons to
select desired TIG arc start.
TIPS: Low-Speed Pulse: 1 to 10
pulses per second (PPS) will produce a distinct ripple pattern in the
weld bead. It can be used to time
filler addition, reduce distortion and
improve control.
3
4
5
High Speed Pulse: 100 pulses per
second (PPS) and higher helps to
focus the arc for increased stability,
penetration and travel speed. Increased puddle agitation improves
weld microstructure.
Ref. 281252A
6-4. Controls, Stick Manual Mode
1
Auto-Set Button
Press button to turn Auto-Set feature On or Off. Auto-Set is On when
illuminated.
1
2
DIG Adjustment Knob
The range is Off - 99%. Pro-Set value is 30% for 7018 electrodes. (See
tip below).
3
Amperage Adjustment Knob
TIP: DIG (Arc Force Control) controls the amount of additional amperage at low voltage (short arc
length) conditions. Adjust the DIG
percentage for different joint configurations and electrodes.
2
3
Ref. 281252A
OM-281426 Page 32
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6-5. Controls, MIG Manual Mode
1
1
2
Auto-Set Button
Press button to turn Auto-Set feature On or Off. Auto-Set is On when
illuminated.
2
3
3
Volts Adjustment Knob
Wire Feed Speed Adjustment
Knob
Ref. 281252A
Notes
OM-281426 Page 33
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6-6. Welding Parameter Chart − 120V
Ref. 282870-A
OM-281426 Page 34
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6-7. Welding Parameter Chart − 240V
Ref. 282870-A
OM-281426 Page 35
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6-8. Entering Setup Menu
1
4
2
3
Ref. 281252A
1
2
3
4
Wire/Rod/Tungsten Minus (−) Button
Material Thickness Minus (−) Button
Material Thickness Plus (+) Button
Display
To enter the setup menu, simultaneously
Notes
OM-281426 Page 36
press then release the Wire/Rod/Tungsten
Minus (−) button and Material Thickness
Plus (+) button. After entering the setup
menu, the Material Thickness light will flash.
To move to the next setup menu, press the
Material Thickness Plus (+) button.
To move to the previous setup menu, press
the Material Thickness Minus (−) button.
To exit the setup menu, simultaneously
press then release the Wire/Rod/ Tungsten
Minus (−) button and the Material Thickness
Plus (+) button.
. A complete Parts List is available at www.MillerWelds.com
6-9. Internal Motor 24 Inch Calibration (Menu 1 Of 12)
1
4
3
2
5
Ref. 281252A
. The unit’s internal drive motor is calibrated
setup menu.
To perform a motor calibration 24 in. run-out
test at 100 ipm, turn left Adjustment knob, and
verify that a check mark appears next to 100
ipm.
Be sure wire is cut flush at nozzle, then trigger
the MIG gun. Motor will feed approximately 24
in. of wire through gun.
Cut wire flush at nozzle and measure run-out.
If length of run-out is not 24 in., turn left Adjustment knob to increase/decrease length of
run-out.
To perform a motor calibration 24 in. run-out
test at 500 ipm, turn right Adjustment knob,
at the factory. No calibration is needed unless drive motor or control board is
changed.
1
Wire/Rod/Tungsten Minus (−) Button
2
Material Thickness Plus (+) Button
3
Material Thickness Minus (−) Button
4
Left Adjustment Knob
5
Right Adjustment Knob
Cut wire flush at nozzle.
Follow instructions in Section 6-8 to enter the
and verify that a check mark appears next to
500 ipm.
Be sure wire is cut flush at nozzle, then trigger
the MIG gun. Motor will feed approximately 24
in. of wire through gun.
Cut wire flush at nozzle and measure run-out.
If length of run-out is not 24 in., turn right Adjustment knob to increase/decrease length of
run-out.
To exit menu, simultaneously press and release the Wire/Rod/Tungsten Minus (−) button
and Material Thickness Plus (+) button, or turn
unit off and on.
6-10. Internal Motor Run-In Speed (Menu 2 Of 12)
1
2
3
1
2
3
Wire/Rod/Tungsten Minus (−)
Button
Auto-Set Button
Material Thickness Plus (+)
Button
Follow instructions in Section 6-8 to
enter the setup menu.
To change the run−in setting, press
the Auto−Set button.
Run−in is the wire speed prior to the
welding arc being struck. When set
to Automatic, the welder determines the optimal run−in speed for
each start. When set to disabled,
the run−in speed is the same as the
weld wire speed.
To exit the menu, simultaneously
press and release the Wire/Rod/
Tungsten Minus(−) button and Material Thickness Plus (+) button, or
turn unit off and on.
Ref. 281252A
OM-281426 Page 37
. A complete Parts List is available at www.MillerWelds.com
6-11. Spoolmatet 24 Inch Calibration (Menu 3 Of 12)
1
2
1
3
2
3
4
5
Wire/Rod/Tungsten Minus (−)
Button
Material Thickness Plus (+)
Button
Material Thickness Minus (−)
Button
Left Adjustment Knob
Right Adjustment Knob
. Spoolmate 100 and 150 drive
motors are unique to this welding power source. Motor calibration is necessary any time a
different Spoolmate 100 or 150
is connected to the Multimatic
220.
Connect Spoolmate to unit.
Cut wire flush at nozzle.
Follow instructions in Section 6-8 to
enter the setup menu.
To perform a Spoolmate calibration
24 in. run-out test at 200 ipm, turn
left Adjustment knob, and verify that
a check mark appears next to 200
ipm.
Cut wire flush at nozzle and then
trigger the Spoolmate.
4
5
Spoolmate will feed approximately
24 in. of wire through gun.
Cut wire flush at nozzle and measure run−out.
If wire length is not 24 in., use left
Adjustment knob to increase/decrease length of the run-out.
To perform a Spoolmate calibration
24 in. run-out test at 500 ipm, turn
right Adjustment knob and verify
that a check mark appears next to
500 ipm.
Cut wire flush at nozzle and then
trigger the Spoolmate.
Spoolmate will feed approximately
24 in. of wire through gun.
Cut wire flush at nozzle and measure run−out.
If wire length is not 24 in., use right
Adjustment knob to increase/decrease length of the run−out.
To exit menu, simultaneously press
and release the Wire/Rod/Tungsten Minus (−) button and Material
Thickness Plus (+) button, or turn
unit off and on.
Ref. 281252A
OM-281426 Page 38
. A complete Parts List is available at www.MillerWelds.com
6-12. Spoolmate Run-In Speed (Menu 4 Of 12)
1
2
3
1
2
3
Wire/Rod/Tungsten Minus (−)
Button
Auto-Set Button
Material Thickness Plus (+)
Button
Follow instructions in Section 6-8 to
enter the setup menu.
To change the run−in setting, press
the Auto−Set button.
Run−in is the speed of the wire prior
to the welding arc being struck.
When set to Automatic, the welder
determines the optimal run−in
speed for each start.
When set to Disabled, the run−in
speed is the same as the weld wire
speed.
To exit menu, simultaneously press
and release the Wire/Rod/Tungsten Minus (−) button and Material
Thickness Plus (+) button, or turn
unit off and on.
Ref. 281252A
6-13. Process Logs (Menu 5 Of 12)
1
2
1
2
3
Material Thickness Minus (−)
Button
Material Thickness Plus (+)
Button
Process Select
Follow instructions in Section 6-8 to
enter the setup menu.
Process Logs menu displays manual time, Auto−Set time, weld cycles, and Auto−Set cycles for the
selected process.
To view other processes, use the
Process Select buttons to select
the desired weld process.
To exit menu, simultaneously press
and release the Wire/Rod/Tungsten Minus (−) button and Material
Thickness Plus (+) button, or turn
unit off and on.
3
Ref. 281252A
OM-281426 Page 39
. A complete Parts List is available at www.MillerWelds.com
6-14. Primary Logs (Menu 6 Of 12)
1
2
1
2
Material Thickness Minus (−)
Button
Material Thickness Plus (+)
Button
Follow instructions in Section 6-8 to
enter the setup menu.
Primary Logs menu displays power
cycles, 120 volt time, and 240 volt
time.
To exit menu, simultaneously press
and release the Wire/Rod/Tungsten Minus (−) button and Material
Thickness Plus (+) button, or turn
unit off and on.
Ref. 281252A
6-15. Error Logs (Menu 7 Of 12)
1
2
1
2
Material Thickness Minus (−)
Button
Material Thickness Plus (+)
Button
Follow instructions in Section 6-8 to
enter the setup menu.
Error Logs screen displays welder
over−temperature errors, shorted
output errors, shorted trigger errors, motor current errors, and
stuck electrode errors.
To exit menu, simultaneously press
and release the Wire/Rod/Tungsten Minus (−) button and Material
Thickness Plus (+) button, or turn
unit off and on.
Ref. 281252A
OM-281426 Page 40
. A complete Parts List is available at www.MillerWelds.com
6-16. Factory Reset (Menu 8 Of 12)
1
2
3
1
2
3
Material Thickness Minus (−)
Button
Material Thickness Plus (+)
Button
Auto-Set Button
. A Factory Reset will reset the
primary logs data, process logs
data, error logs data, selected
process, and all process settings. Motor calibration settings, Spoolmate Calibration
settings, and software information will all be retained.
Follow instructions in Section 6-8 to
enter the setup menu.
To perform a Factory Reset, press
the Auto−Set button.
To exit menu, simultaneously press
and release the Wire/Rod/Tungsten Minus (−) button and Material
Thickness Plus (+) button, or turn
unit off and on.
Ref. 281252A
6-17. Display Software (Menu 9 Of 12)
. Display Software information is
for factory and service use
only.
Follow instructions in Section 6-8 to
enter the setup menu.
To exit menu, simultaneously press
and release the Wire/Rod/Tungsten Minus (−) button and Material
Thickness Plus (+) button, or turn
unit off and on.
Ref. 281252A
OM-281426 Page 41
. A complete Parts List is available at www.MillerWelds.com
6-18. Control Software (Menu 10 Of 12)
. Control Software information is
for factory and service use
only.
Follow instructions in Section 6-8 to
enter the setup menu.
To exit menu, simultaneously press
and release the Wire/Rod/Tungsten Minus (−) button and Material
Thickness Plus (+) button, or turn
unit off and on.
Ref. 281252A
6-19. QuickTech™(Menu 11 Of 12)
1
2
3
1
2
3
Wire/Rod/Tungsten Minus (−)
Button
Auto-Set Button
Material Thickness Plus (+)
Button
Follow instructions in Section 6-8 to
enter the setup menu.
To enable or disable QuickTech™,
press the Auto-Set button.
QuickTech automatically selects
the right process and polarity. Just
hit the trigger or foot control and the
machine automatically switches to
the correct process recalling the
last process settings used.
To exit menu, simultaneously press
and release the Wire/Rod/Tungsten Minus (−) button and Material
Thickness Plus (+) button, or turn
unit off and on.
Ref. 281252A
OM-281426 Page 42
. A complete Parts List is available at www.MillerWelds.com
6-20. TIG Postflow Control (Menu 12 Of 12)
1
2
3
1
2
3
4
Wite/Rod/Tungsten Minus (−)
Button
Auto-Set Button
Material Thickness Plus (+)
Button
Right Encoder
Follow instructions in Section 6-8 to
enter the setup menu.
To adjust TIG postflow, turn right
encoder.
Postflow can be adjusted from Auto-25 seconds.
To exit menu, simultaneously press
and release the Wire/Rod/Tungsten Minus (−) button and Material
Thickness Plus (+) button, or turn
unit off and on.
4
Ref. 281252A
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-281426 Page 43
. A complete Parts List is available at www.MillerWelds.com
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
7-1. Routine Maintenance
!
n = Check
Z = Change
~ = Clean
* To be done by Factory Authorized Service Agent
Disconnect power
before maintaining.
l = Replace
. Maintain more often
during severe conditions.
Reference
Every
3
Months
l Damaged Or Unreadable
Labels
Every
6
Months
l Repair Or Replace
Cracked Weld Cable
OR
~ Inside Unit
~ Clean Drive Rolls
7-2. Overload Protection
1
Supplementary Protector CB1
CB1 protects unit from overload. If
CB1 opens, unit shuts down.
Reset supplementary protector.
1
282718A
OM-281426 Page 44
. A complete Parts List is available at www.MillerWelds.com
7-3. Changing Drive Roll Or Wire Inlet Guide
1
Inlet Wire Guide
Remove guide by pressing on
barbed area or cutting off one end
near housing and pulling it out of
hole. Push new guide into hole from
rear until it snaps in place.
2
Drive Roll
The drive roll includes three
different sized grooves. The text
aligned with the drive roll retaining
pin indicates the selected groove.
3
Retaining Pin
To secure drive roll, locate open slot
and push drive roll completely over
retaining pin, then rotate drive roll to
desired slot.
. See Section 14-1 for optional
drive rolls.
1
3
2
.024 Groove
.030−.035 Groove
.030-.035 V-Knurled Groove
Table 7-1. Drive Roll Grooves And Wire Type Compatibility
Groove
.024
Compatible Wire
.024 Solid Wire
.030−.035
.030−.035 Solid Wire
.030−.035 V-Knurled
.030−.035 Flux-Core
267893A
OM-281426 Page 45
. A complete Parts List is available at www.MillerWelds.com
7-4. Error Messages
Message
Error
Remedy
Overtemp−Please wait while the
welder cools down.
Internal temperature of welder has exceeded the
maximum limit.
Wait for unit to cool down. If the fan is not running,
contact Miller Electric Mfg. LLC service department.
Shorted trigger−Release 4−pin
trigger to clear error.
MIG gun or spool gun trigger is engaged on power
up.
Release 4−pin trigger to clear error.
MIG gun trigger is held during jog for more than 16
feet of wire.
Spool gun trigger is held during jog for more than 10
seconds.
MIG gun or spool gun trigger is engaged for more
than 1 second after the arc is broken.
After an overtemp error, the MIG or spool gun trigger is held after the welder has completed cooling.
MIG gun or spool gun trigger is engaged while the
process is changed to Flux Cored or a MIG
process.
MIG gun or spool gun trigger lead voltage exceeds
9 volts caused by the electrode being shorted to the
trigger lead.
Fix or replace damaged gun.
MIG gun or spool gun trigger leads are shorted together.
Shorted trigger-Release trigger to
clear error.
The 14−pin trigger is engaged on power up.
Release the 14−pin trigger.
The 14−pin trigger is held during TIG preflow for
more than 15 seconds.
Shorted output-First remove
short, then pull trigger to clear
error.
The welding wire came into contact with the
workpiece while jogging wire.
Remove short and pull trigger, or wait 30 seconds to
clear error.
MIG gun or spool gun contact tip came into contact
with the workpiece while welding.
The weld voltage is less than 10 volts for more than
0.2 seconds while welding.
Output rectifier is damaged.
Contact Miller Electric Mfg. LLC service department
The secondary control board is damaged.
The primary control board is damaged.
Stuck electrode-Free stuck electrode to clear error.
Stick welding electrode has become stuck in weld
puddle and turned output off.
Remove Stick welding electrode from workpiece
and output will turn back on after about one second.
Stuck electrode-Free tungsten to
clear error.
Tungsten electrode has become stuck in weld puddle and turned output off.
Remove the tungsten from workpiece and output
will turn back on after about one second.
Tungsten has contacted workpiece for more than 5
seconds without starting an arc.
Motor error−Motor has drawn too
much current.
OM-281426 Page 46
Too much pressure on pressure adjust knob.
Reduce pressure on the pressure adjust knob.
The gun liner is obstructed.
Clear obstruction or replace gun liner.
The gun contact tip is obstructed.
Clear obstruction or replace contact tip.
The welding wire is entangled.
Untangle welding wire.
The internal motor is damaged.
Contact Miller Electric Mfg. LLC service department.
. A complete Parts List is available at www.MillerWelds.com
Message
Error
Remedy
Motor error−Motor has drawn too
much current.
The primary control board is damaged.
Contact Miller Electric Mfg. LLC service department.
Motor error−Motor has drawn too
much current.
The spool gun motor is damaged.
Fix or replace damaged gun.
Fan error-The fan is running too
slow or is damaged.
The fan blades are obstructed.
Clear obstruction from fan.
The fan wiring harness is disconnected.
Contact Miller Electric Mfg. LLC service department
The fan is damaged.
The primary control board is damaged.
Thermal error−Primary thermistor
range error.
The primary circuit thermistor is unplugged.
Contact Miller Electric Mfg. LLC service department
The primary circuit thermistor is reading too high or
too low for a valid temperature.
The primary control board is damaged.
Thermal error−Secondary thermistor range error.
The secondary circuit thermistor is unplugged.
Contact Miller Electric Mfg. LLC service department
The secondary circuit thermistor is reading too high
or too low for a valid temperature.
The control board is damaged.
Thermal error−Magnetic thermistor range error.
The magnetic circuit thermistor is unplugged.
Contact Miller Electric Mfg. LLC service department
The magnetic circuit thermistor is reading too high
or too low for a valid temperature.
The primary control board is damaged.
Boost error−Cycle power to clear
error.
The primary boost has not successfully been
established.
Cycle power to clear error. If this error persists after
a power cycle, contact Miller Electric Mfg. LLC service department.
Over voltage−Cycle power to
clear error.
Primary voltage is above 310 volts.
Reduce primary voltage below 310 volts.
Under voltage−Cycle power to
clear error.
The primary voltage is below 90 volts.
Increase primary voltage above 90 volts.
Network error−Communication
between micros has been lost.
The two microcontrollers on the control board are
no longer communicating.
Cycle power to clear error. If this error persists after
a power cycle, contact Miller Electric Mfg. LLC service department.
Network error−Communication
between boards has been lost.
The wiring harness between the control board and
interface board is damaged.
Cycle power to clear error. If this error persists after
a power cycle, contact Miller Electric Mfg. LLC service department.
The primary control board is damaged.
The interface board is damaged.
Secondary Current FB error−
Check Weld Current FB device.
The wiring harness between the control board and
weld current sensor is damaged.
Cycle power to clear error. If this error persists after
a power cycle, contact Miller Electric Mfg. LLC service department.
The weld current sensor is damaged.
Weld over voltage error - Cycle
power to clear error.
The secondary control board is damaged.
Cycle power to clear error. If this error persists after
a power cycle, contact Miller Electric Mfg. LLC service department.
Clamp error - Cycle power to
clear error.
The secondary control board is damaged.
Cycle power to clear error. If this error persists after
a power cycle, contact Miller Electric Mfg. LLC service department.
OM-281426 Page 47
. A complete Parts List is available at www.MillerWelds.com
7-5. Troubleshooting
Trouble
No weld output; unit completely
inoperative.
Remedy
Place line disconnect switch in On position.
Check and replace line fuse(s), if necessary, or reset supplementary protector.
Be sure power cord is plugged in and that receptacle is receiving input power.
No weld output; unit is on.
Check and secure loose weld cable(s) into receptacle(s).
Check and correct poor connection of work clamp to workpiece.
Erratic or improper welding arc or
output.
Use proper size and type of weld cable (see your Distributor).
Clean and tighten weld connections.
Verify electrode polarity; check and correct poor connections to workpiece.
Fan not operating.
Unit not warmed up enough to require fan cooling.
Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor and control circuitry.
Stick welding problems: Hard starts; Use proper type and size of electrode.
poor welding characteristics; unusual
Verify electrode polarity; check and correct poor connections.
spattering.
Make sure a remote control is not connected.
TIG welding problems: Wandering arc; Use proper type and size of tungsten.
hard starts; poor welding characterisUse properly prepared tungsten.
tics; spattering problems.
Verify electrode polarity.
TIG welding problems: Tungsten
Shield weld zone from drafts.
electrode oxidizing and not remaining
Check for correct type shielding gas.
bright after welding.
Check and tighten gas fittings.
Verify electrode polarity.
OM-281426 Page 48
. A complete Parts List is available at www.MillerWelds.com
Notes
OM-281426 Page 49
SECTION 8 − ELECTRICAL DIAGRAM
Figure 8-1. Circuit Diagram
OM-281426 Page 50
281418-A
OM-281426 Page 51
SECTION 9 − HIGH FREQUENCY
9-1. Welding Processes Requiring High Frequency
1
High-Frequency Voltage
TIG − helps arc jump air gap
between torch and workpiece and/
or stabilize the arc.
1
TIG
high_freq 2018-01
9-2. Installation Showing Possible Sources Of HF Interference
Weld Zone
11, 12
50 ft
(15 m)
10
14
9
8
7
3
2
13
1
4
5
6
Best Practices
Not Followed
Sources of Direct High-Frequency
Radiation
1 High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table
OM-281426 Page 52
Sources of Conduction of High
Frequency
7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring
Sources of Reradiation of High
Frequency
10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines
S-0694
9-3. Recommended Installation To Reduce HF Interference
7
Weld Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
8
4
8
Ground all metal objects and all wiring in
welding zone using
#12 AWG wire.
Nonmetal
Building
Ground
workpiece if
required by
codes.
9
Best Practices Followed
Metal Building
8
8
11
10
Ref. S-0695
1
High-Frequency Source (welding
power source with built-in HF or
separate HF unit)
Ground metal machine case (clean paint
from around hole in case, and use case
screw), work output terminal, line disconnect device, input supply, and worktable.
2 Center Point of Welding Zone
Midpoint between high-frequency source
and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
4 Weld Output Cables
Keep cables short and close together.
5
Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections
using copper straps or braided wire.
Ground conduit every 50 ft (15 m).
6
Water Pipes and Fixtures
Ground water pipes every 50 ft (15 m).
7
External Power or Telephone Lines
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
8
Grounding Rod
Consult the National Electrical Code for
specifications.
Metal Building Requirements
9
Metal Building Panel Bonding
Methods
Bolt or weld building panels together, install
copper straps or braided wire across
seams, and ground frame.
10 Windows and Doorways
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
11 Overhead Door Track
Ground the track.
OM-281426 Page 53
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-281426 Page 54
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.
4
1
Wrong Tungsten
Preparation
Straight Ground
Grind lengthwise, not radial.
Ideal Tungsten Preparation − Stable Arc
Notes
OM-281426 Page 55
SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW)
Ref. gtaw_Phase_2018−01
11-1. Positioning The Torch
!
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 cerium or
lanthanum based tungsten
instead of thoriated. Thorium dust 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
Workpiece
3
2
4
90°
1
Make sure workpiece is clean
before welding.
2
Work Clamp
Place as close to the weld as
possible.
10−15°
4
5
6
10−25°
3
4
5
6
Torch
Filler Rod (If Applicable)
Gas Cup
Tungsten Electrode
Select and prepare tungsten
according to Section 10-2.
Guidelines:
5
6
1/16 in
3/16 in
Bottom View Of Gas Cup
The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate shielding gas coverage. (For
example, if tungsten is 1/16 in
diameter, gas cup should be a
minimum of 3/16 in diameter.
Tungsten extension is the distance
the tungsten extends out gas cup of
torch.
The tungsten extension should be
no greater than the inside diameter
of the gas cup.
Arc length is the distance from the
tungsten to the workpiece.
Ref.161892
-
OM-281426 Page 56
11-2. Torch Movement During Welding
Tungsten Without Filler Rod
75°
Welding direction
Form pool
Tilt torch
Move torch to front
of pool. Repeat process.
Tungsten With Filler Rod
75°
Welding direction
Form pool
15°
Tilt torch
Remove rod
Add filler metal
Move torch to front
of pool. Repeat process.
162002-B
11-3. Positioning Torch Tungsten For Various Weld Joints
“T” Joint
Butt Weld And Stringer Bead
20°
90°
70°
75°
20°
10°
15°
Corner Joint
Lap Joint
20-40°
90°
75°
75°
15°
30°
15°
162003 / 0792
OM-281426 Page 57
SECTION 12 − GMAW WELDING (MIG) GUIDELINES
12-1. Typical GMAW (MIG) Process Connections
!
Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
Regulator/
Flowmeter
Wire Feeder/
Welding Power Source
Gun
Shielding Gas
Gas
Workpiece
Work Clamp
GMAW1 2018−12 (GMAW Only) − Ref. 801909-A
12-2. 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-281426 Page 58
ipm = inches per minute; mpm = meters per minute
12-3. 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
12-4. 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-281426 Page 59
12-5. 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
12-6. Poor Weld Bead Characteristics
1
2
3
1
2
3
4
5
Large Spatter Deposits
Rough, Uneven Bead
Slight Crater During Welding
Bad Overlap
Poor Penetration
4
S-0053-A
5
12-7. Good Weld Bead Characteristics
1
2
3
Weld a new bead or layer for each
1/8 in. (3.2 mm) thickness in metals
being welded.
1
4
5
2
3
No Overlap
Good Penetration into Base
Metal
4
5
OM-281426 Page 60
Fine Spatter
Uniform Bead
Moderate Crater During
Welding
S-0052-B
12-8. Troubleshooting − Excessive Spatter
Excessive Spatter − scattering of molten metal particles that
cool to solid form near weld bead.
S-0636
Possible Causes
Corrective Actions
Wire feed speed too high.
Select lower wire feed speed.
Voltage too high.
Select lower voltage range.
Electrode extension (stickout) too long.
Use shorter electrode extension (stickout).
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Insufficient shielding gas at welding arc.
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
Incorrect polarity.
Check polarity required by welding wire, and change to correct polarity at welding power source.
12-9. Troubleshooting − Porosity
Porosity − small cavities or holes resulting from gas pockets
in weld metal.
S-0635
Possible Causes
Insufficient shielding gas at welding arc.
Corrective Actions
Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in. (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas.
Use welding grade shielding gas; change to different gas.
Dirty welding wire.
Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty.
Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of nozzle.
Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.
12-10. Troubleshooting − Excessive Penetration
Excessive Penetration − weld metal melting through base metal
and hanging underneath weld.
Excessive Penetration Good Penetration
S-0639
Possible Causes
Excessive heat input.
Corrective Actions
Select lower voltage range and reduce wire feed speed.
Increase travel speed.
OM-281426 Page 61
12-11. 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.
12-12. 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.
12-13. 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-281426 Page 62
12-14. 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.
12-15. Troubleshooting − Distortion
Distortion − contraction of weld metal during welding that forces
base metal to move.
Base metal moves
in the direction of
the weld bead.
S-0642
Possible Causes
Excessive heat input.
Corrective Actions
Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
Notes
OM-281426 Page 63
12-16. Common GMAW (MIG) Shielding Gases
This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed
over the years. The most commonly used shielding gases are listed in the following table.
Application
Gas
Spray Arc
Steel
Short
Circuiting
Steel
Spray Arc
Stainless
Steel
Short
Circuiting
Stainless
Steel
GMAW-P
Stainless
Steel
All
Positions
Argon
Argon + 1% O2
Flat &
Horizontal
Fillet
All
Positions
Flat &
Horizontal
Fillet
Argon + 2% O2
Flat &
Horizontal
Fillet
All
Positions
Flat &
Horizontal
Fillet
Argon + 5%
CO2
Flat &
Horizontal
Fillet
All
Positions
Argon + 10%
CO2
Flat &
Horizontal
Fillet
All
Positions
Argon + 25%
CO2
All
Positions
Argon + 50%
CO2
All
Positions
CO2
All
Positions
Spray Arc
Aluminum
Short
Circuiting
Aluminum
GMAW-P
Aluminum
All
Positions
All
Positions
All
Positions
All
Positions
Helium
All
Positions1
Argon +
Helium
All
Positions1
90% HE +
7-1/2% AR +
2-1/2% CO2
65% AR + 33%
HE + 2% CO2
1
GMAW-P
Steel
Heavy Thicknesses
OM-281426 Page 64
All
Positions
All
Positions
12-17.
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-281426 Page 65
SECTION 13 − GUIDELINES FOR STICK WELDING (SMAW)
13-1. 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
13-2).
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-281426 Page 66
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
AMPERAGE
RANGE
250
200
150
PENETRATION
6013
POSITION
6010
&
6011
100
50
DIAMETER
ELECTRODE
13-2. Electrode And Amperage Selection Chart
MIN. PREP, ROUGH
HIGH SPATTER
*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)
Ref. S-087 985-A
13-3. 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-281426 Page 67
13-4. 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
13-5. 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
13-6. 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-281426 Page 68
13-7. 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
13-8. 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
13-9. 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-281426 Page 69
13-10. 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
2
1/16 in.
(1.6 mm)
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
Square Groove Weld
3
S-0062
13-11. 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
13-8. Remove slag before making
another weld pass.
3
S-0060 / S-0058-A / S-0061
OM-281426 Page 70
13-12. 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
1
2 To 3 in.
(51-76 mm)
2
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
13-13. Troubleshooting
Porosity − small cavities or holes resulting from gas pockets in weld metal.
Possible Causes
Remedy
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
Remedy
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
Remedy
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-281426 Page 71
Lack Of Penetration − shallow fusion between weld metal and base metal.
Lack of Penetration
Good Penetration
Possible Causes
Remedy
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
Remedy
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
Remedy
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
Remedy
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
Remedy
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-281426 Page 72
SECTION 14 − PARTS LIST
14-1. Recommended MIG Spare Parts
Part
No.
Description
Quantity
. . . . . . . . . . 261157 . . . . . . . . . . . . . . Roll, Drive .024, .030-.035V Wire, .035VK Wire . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . ♦202926 . . . . . . . . . . . . . Roll, Drive VK .030-.035/.045 Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 271493 . . . . . . . . . . . . . . Lens Cover, Replaceable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦OPTIONAL
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.
. See OM-282976 (shipped with this product) for replacement consumables for MDX welding gun.
14-2. Recommended TIG Spare Parts
Part
No.
Description
Quantity
. . . . . . WP1712RDI25 . . . . . . . . . . . Tig Torch, A-150 12.5FT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 194744 . . . . . . . . . . . . . . Foot Control, RFCS-14HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . AK2C . . . . . . . . . . . . . . . Accessory Kit, Ceriated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . AK-150MFC . . . . . . . . . . . . Accessory Kit, FX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
. A complete Parts List is available online at www.MillerWelds.com
OM-281426 Page 73
SECTION 15 − SOFTWARE LICENSE AGREEMENT
The accompanying software (“Software”) is provided by Miller Electric Mfg. LLC (“Miller”), 1635 W. Spencer St., P.O. Box 1079, Appleton, WI
54912, to qualified purchasers for use in conjunction with Miller welding equipment only.
IMPORTANT−READ CAREFULLY: This Software License Agreement (”Agreement”) is a legal agreement between You (either an individual or
a single entity) and Miller Electric Mfg. LLC (“Miller”). BY OPENING THE SEALED SOFTWARE PACKET(S) AND/OR USING THE SOFTWARE, YOU ARE AGREEING TO BE BOUND BY THE TERMS OF THIS AGREEMENT. If You do not agree to the terms of this Agreement,
promptly return the unopened Software packet(s) and the accompanying items, including any Miller hardware, written materials, and binders or
other containers, to the place you obtained them for a full refund.
SOFTWARE LICENSE.
The Software is protected by copyright laws and international copyright treaties, as well as other intellectual property laws and treaties. The
Software is licensed, not sold.
1.
GRANT OF LICENSE. This Agreement grants you the limited, non−exclusive right to use one copy of the Software on a single Miller
Welding system at a time. No concurrent usage of this Software is permitted, except in the case where the intention of the Software is to
modify the Miller Welding system, such as a Software update or to enable a software feature.
2.
DESCRIPTION OF OTHER RIGHTS AND LIMITATIONS.
S
Limitations on Reverse Engineering, Decompilation, and Disassembly. You may not reverse engineer, decompile, or disassemble the
Software, except and only to the extent such activity is expressly permitted by applicable law notwithstanding this limitation.
S
Termination. Without prejudice to any other rights, Miller may terminate this Agreement if you fail to comply with the terms and conditions of this Agreement. Upon termination of this Agreement for any reason, you must destroy all copies of the Software and all of its
component parts.
S
Transfer. You may permanently transfer the Software, together with all of your rights under this Agreement, to another end user, provided you transfer all of the Software (including any component parts, media and printed materials, any upgrades and this Agreement)
and you retain no copies. In addition the end user receiving the transferred Software must agree to all terms of this Agreement.
3.
INTELLECTUAL PROPERTY RIGHTS. All title and intellectual property rights in and to the Software, and any copies You are permitted to
make herein are owned by Miller. All rights not expressly granted are reserved by Miller.
4.
U.S. GOVERNMENT RESTRICTED RIGHTS. All Software provided to the U.S. Government pursuant to solicitations issued on or after
December 1, 1995 is provided with the commercial license rights and restrictions described elsewhere herein. All Software provided to the
U.S. Government pursuant to solicitations issued prior to December 1, 1995 is provided with ”Restricted Rights” as provided for in FAR,
48 CFR 52.227−14 (JUNE 1987) or DFAR, 48 CFR 252.227−7013 (OCT 1988), as applicable.
5.
EXPORT RESTRICTIONS. You acknowledge that the Software is subject to U.S. export jurisdiction. You agree to comply with all applicable international and national laws that apply to the Software, including the U.S. Export Administration Regulations, as well as end−user,
end−use and country destination restrictions issued by U.S. and other governments.
MISCELLANEOUS. If you acquired this Software in the United States, this Agreement is governed by the laws of the State of Wisconsin. If this
Software was acquired outside the United States, then local law may apply.
DISCLAIMER OF WARRANTIES. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, MILLER PROVIDES TO YOU THE
SOFTWARE, AND ANY (IF ANY) SUPPORT SERVICES RELATED TO THE SOFTWARE (”SUPPORT SERVICES”) AS IS AND WITH ALL
FAULTS; AND MILLER HEREBY DISCLAIMS WITH RESPECT TO THE SOFTWARE AND SUPPORT SERVICES ALL WARRANTIES AND
CONDITIONS, WHETHER EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT LIMITED TO, ANY (IF ANY) WARRANTIES OR
CONDITIONS OF OR RELATED TO: MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, LACK OF VIRUSES, ACCURACY
OR COMPLETENESS OF RESPONSES, RESULTS, WORKMANLIKE EFFORT AND LACK OF NEGLIGENCE. ALSO THERE IS NO WARRANTY, DUTY OR CONDITION OF TITLE, QUIET ENJOYMENT, QUIET POSSESSION, OR CORRESPONDENCE TO DOCUMENTATION
PROVIDED OR NONINFRINGEMENT. THE ENTIRE RISK ARISING OUT OF USE OR PERFORMANCE OF THE SOFTWARE AND ANY
SUPPORT SERVICES REMAINS WITH YOU.
EXCLUSION OF INCIDENTAL, CONSEQUENTIAL AND CERTAIN OTHER DAMAGES. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, IN NO EVENT SHALL MILLER OR ITS SUPPLIERS BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT, OR CONSEQUENTIAL DAMAGES WHATSOEVER (INCLUDING, BUT NOT LIMITED TO, DAMAGES FOR LOSS OF PROFITS OR CONFIDENTIAL
OR OTHER INFORMATION, FOR BUSINESS INTERRUPTION, FOR PERSONAL INJURY, FOR LOSS OF PRIVACY, FOR FAILURE TO
MEET ANY DUTY INCLUDING OF GOOD FAITH OR OF REASONABLE CARE, FOR NEGLIGENCE, AND FOR ANY OTHER PECUNIARY
OR OTHER LOSS WHATSOEVER) ARISING OUT OF OR IN ANY WAY RELATED TO THE USE OF OR INABILITY TO USE THE SOFTWARE, THE PROVISION OF OR FAILURE TO PROVIDE SUPPORT SERVICES, OR OTHERWISE UNDER OR IN CONNECTION WITH
ANY PROVISION OF THIS AGREEMENT, EVEN IN THE EVENT OF THE FAULT, TORT (INCLUDING NEGLIGENCE), STRICT LIABILITY,
BREACH OF CONTRACT OR BREACH OF WARRANTY OF MILLER OR ANY SUPPLIER, AND EVEN IF MILLER OR ANY SUPPLIER HAS
BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.
LIMITATION OF LIABILITY AND REMEDIES. MILLER SHALL NOT BE LIABLE FOR ANY DAMAGES OF ANY KIND WHATSOEVER ARISING OUT OF YOUR RELIANCE ON THE SOFTWARE OR YOUR USE OR THE USE BY YOUR EMPLOYEES OR AUTHORIZED INDEPENDENT CONTRACTORS OF ANY WELDING PRODUCT IN CONNECTION WITH OR IN CONJUNCTION WITH THE SOFTWARE. NOTWITHSTANDING ANY DAMAGES THAT YOU MIGHT INCUR FOR ANY REASON WHATSOEVER (INCLUDING, WITHOUT LIMITATION,
ALL DAMAGES REFERENCED ABOVE AND ALL DIRECT OR GENERAL DAMAGES), THE ENTIRE LIABILITY OF MILLER AND ANY OF
ITS SUPPLIERS UNDER ANY PROVISION OF THIS AGREEMENT AND YOUR EXCLUSIVE REMEDY FOR ALL OF THE FOREGOING
SHALL BE LIMITED TO THE GREATER OF THE AMOUNT ACTUALLY PAID BY YOU FOR THE SOFTWARE OR U.S. $5.00. THE FOREGOING LIMITATIONS, EXCLUSIONS AND DISCLAIMERS SHALL APPLY TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW,
EVEN IF ANY REMEDY FAILS ITS ESSENTIAL PURPOSE.
242053-B
OM-281426 Page 74
Effective January 1, 2019
(Equipment with a serial number preface of MK or newer)
Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
* Subarc Wire Drive Assemblies
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to
* TIG Torches (No Labor)
authorized distributors that new Miller equipment sold after the
* Tregaskiss Guns (No Labor)
effective date of this limited warranty is free of defects in material
* Water Cooling Systems
and workmanship at the time it is shipped by Miller. THIS
* Wireless Remote Foot/Hand Controls and Receivers
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Work Stations/Weld Tables (No Labor)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
5. 6 Months — Parts
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Batteries
Within the warranty periods listed below, Miller will repair or replace 6. 90 Days — Parts
any warranted parts or components that fail due to such defects in
* Accessories (Kits)
material or workmanship. Miller must be notified in writing within
* Canvas Covers
thirty (30) days of such defect or failure, at which time Miller will
* Induction Heating Coils and Blankets, Cables, and
provide instructions on the warranty claim procedures to be
Non-Electronic Controls
followed. Notifications submitted as online warranty claims must
* M-Guns
provide detailed descriptions of the fault and troubleshooting steps
* MIG Guns, Subarc (SAW) Torches, and External
taken to diagnose failed parts. Warranty claims that lack the
Cladding Heads
required information as defined in the Miller Service Operation
* Remote Controls and RFCS-RJ45
Guide (SOG) may be denied by Miller.
* Replacement Parts (No labor)
Miller shall honor warranty claims on warranted equipment listed
* Spoolmate Spoolguns
below in the event of a defect within the warranty coverage time
periods listed below. Warranty time periods start on the delivery Miller’s True Blue® Limited Warranty shall not apply to:
date of the equipment to the end-user purchaser, or 12 months 1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, relays, work
after the equipment is shipped to a North American distributor, or
station table tops and welding curtains, or parts that
18 months after the equipment is shipped to an international
fail due to normal wear. (Exception: brushes and
distributor, whichever occurs first.
relays are covered on all engine-driven products.)
1. 5 Years Parts — 3 Years Labor
* Original Main Power Rectifiers Only to Include SCRs, 2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
Diodes, and Discrete Rectifier Modules
covered by the manufacturer’s warranty, if any.
2. 3 Years — Parts and Labor Unless Specified
* Auto-Darkening Helmet Lenses (No Labor) (See 3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
Classic Series Exception Below)
improperly operated or misused based upon industry
* Engine Driven Welder/Generators
standards, or equipment which has not had reasonable
(NOTE: Engines are Warranted Separately by the
and necessary maintenance, or equipment which has
Engine Manufacturer.)
been used for operation outside of the specifications for
* Insight Welding Intelligence Products
the equipment.
* Inverter Power Sources
4. Defects caused by accident, unauthorized repair, or
* Plasma Arc Cutting Power Sources
improper testing.
* Process Controllers
MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL
* Semi-Automatic and Automatic Wire Feeders
AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN
* Transformer/Rectifier Power Sources
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
3. 2 Years — Parts and Labor
The exclusive remedies for warranty claims are, at Miller’s
* Auto-Darkening Helmet Lenses − Classic Series Only option, either: (1) repair; or (2) replacement; or, if approved in
(No Labor)
writing by Miller, (3) the pre-approved cost of repair or
* Auto-Darkening Weld Masks (No Labor)
replacement at an authorized Miller service station; or (4)
* Fume Extractors − Capture 5, Filtair 400 and Industrial payment of or credit for the purchase price (less reasonable
Collector Series
depreciation based upon use). Products may not be returned
4. 1 Year — Parts and Labor Unless Specified
without Miller’s written approval. Return shipment shall be at
* AugmentedArc and LiveArc Welding Systems
customer’s risk and expense.
* Automatic Motion Devices
The above remedies are F.O.B. Appleton, WI, or Miller’s
* Bernard BTB Air-Cooled MIG Guns (No Labor)
authorized service facility. Transportation and freight are the
* CoolBelt and CoolBand Blower Unit (No Labor)
customer’s responsibility. TO THE EXTENT PERMITTED BY
LAW, THE REMEDIES HEREIN ARE THE SOLE AND
* Desiccant Air Dryer System
EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL
* Field Options
(NOTE: Field options are covered for the remaining THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR
SPECIAL,
INCIDENTAL OR
warranty period of the product they are installed in, DIRECT, INDIRECT,
or for a minimum of one year — whichever is CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY
greater.)
WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
* RFCS Foot Controls (Except RFCS-RJ45)
WARRANTY, GUARANTY, OR REPRESENTATION,
* Fume Extractors − Filtair 130, MWX and SWX Series
INCLUDING
ANY
IMPLIED
WARRANTY
OF
* HF Units
MERCHANTABILITY OR FITNESS FOR PARTICULAR
* ICE/XT Plasma Cutting Torches (No Labor)
PURPOSE, ARE EXCLUDED AND DISCLAIMED BY
* Induction Heating Power Sources, Coolers
MILLER.
(NOTE: Digital Recorders are Warranted
Some US states do not allow limiting the duration of an implied
Separately by the Manufacturer.)
warranty or the exclusion of certain damages, so the above
* Load Banks
limitations may not apply to you. This warranty provides
* Motor-Driven Guns (except Spoolmate Spoolguns)
specific legal rights, and other rights may be available
* PAPR Blower Unit (No Labor)
depending on your state. In Canada, some provinces provide
* Positioners and Controllers
additional warranties or remedies, and to the extent the law
* Racks (For Housing Multiple Power Sources)
prohibits their waiver, the limitations set out above may not
* Running Gear/Trailers
apply. This Limited Warranty provides specific legal rights, and
* Spot Welders
other rights may be available, but may vary by province.
mil dom warr 2019-01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
City
State
Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
© 2019 Miller Electric Mfg. LLC
2019−01