Miller | LE230842 | Owner Manual | Miller OPTIMA User manual

Miller OPTIMA User manual
OM-2805
182 111D
June 2004
Processes
Pulsed MIG (GMAW-P)
Description
Synergic Control
Optima

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From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual catalog sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
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Mil_Thank 7/03
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 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Connecting To Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Welding Power Source Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Overview And Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Initial Display, Manual MIG Pulser Mode, And CV Mig Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Setup Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Choosing Pulse Programs And Setting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. How Manual Pulsed MIG Waveform Components Affect Arc and Burn-off Rate . . . . . . . . . . . . . . . . . .
SECTION 3 − PROGRAMS FOR 304 MODEL WELDING POWER SOURCES . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Overview Of Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Programs For 304 Model Welding Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − PROGRAMS FOR 350 MODEL WELDING POWER SOURCES . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Overview Of Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Programs For 350 Model Welding Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − PROGRAMS FOR 456 MODEL WELDING POWER SOURCES . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Overview Of Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Programs For 456 Model Welding Power Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _8/03
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.
. Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
Y 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.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Y Only qualified persons should install, operate, maintain, and
repair this unit.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
Y During operation, keep everybody, especially children, away.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
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 electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
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.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
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 output in damp areas, if movement is confined, 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 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 and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Keep your head out of the fumes. Do not breathe the fumes.
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 Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
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 drape cables over your body.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D If inside, ventilate the area and/or use exhaust at the arc to remove
welding fumes and gases.
D If ventilation is poor, use an approved air-supplied respirator.
D Read the Material Safety Data Sheets (MSDSs) and the
manufacturer’s instructions for metals, consumables, coatings,
cleaners, and degreasers.
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 on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and if necessary, while wearing an
air-supplied respirator. The coatings and any metals containing
these elements can give off toxic fumes if welded.
OM-2805 Page 1
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 a welding helmet fitted with a proper shade of filter to protect
your face and eyes 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 and
glare; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot protection.
BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
MAGNETIC FIELDS can affect pacemakers.
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 Protect yourself and others from flying sparks and hot metal.
D Do not weld where flying sparks can strike flammable material.
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 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.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
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 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 oil-free protective garments 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.
FLYING METAL 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.
OM-2805 Page 2
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding 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.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, 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 shielding 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.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and CGA publication P-1 listed in Safety
Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
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.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING UNIT can cause injury.
H.F. RADIATION can cause interference.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use 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
OVERUSE can cause OVERHEATING
D
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.
D
D
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.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
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.
ARC WELDING can cause interference.
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
D
WELDING WIRE can cause injury.
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.
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D 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
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-2805 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(phone: 305-443-9353, website: www.aws.org).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).
Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 (phone: 305-443-9353, website: www.aws.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org and www.
sparky.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), 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 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-2805 Page 4
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
SECTION 2 − INSTALLATION
2-1. Connecting To Welding Power Source
1
2
3
304 Model Welding Power
Sources
456 Model Welding Power
Sources
XMT 350 Model Welding
Power Sources
4
Remote 14 Cord On Control
Unit
5
14-Pin Extension Cord
(Customer-Supplied)
Use one of these MILLER extension cords:
043 690 − 25 ft (7.6 m)
1
043 691 − 50 ft (15.2 m)
Or
. Make
sure total cord length
does not exceed 200 ft (61 m).
2
6
Wire Feeder
Connect control as shown if you
want control to be close to feeder.
If you want control to be close to
welding power source, connect
control to welding power source,
and connect extension cord between control cord and feeder.
4
5
Set applicable welding power
source controls as explained in
Section 2-2.
6
3
ST-801 316-A / Ref. ST-801 192 / ST-801 718 / Ref. 803 691-A
2-2. Welding Power Source Settings
Welding Power Source
Model
Mode Switch Setting
Voltage/Amperage Control
Switch Setting
Inductance/Dig or
Inductance Control Setting
XMT 304 CC/CV
Pulsed MIG
Remote
This control is not functional with
welding power source in Pulsed
MIG mode. Adjust as normal
when welding power source is
used in MIG mode.
Invision 304P
No Mode switch - setting automatically done by control unit.
No V/A Control switch - setting
automatically done by control unit.
Same as above
XMT 456 CC/CV
Pulsed MIG
Remote
Same as above
Phoenix 456 CC/CV
Pulsed MIG
Remote
Same as above
Invision 456P
No Mode switch - setting automatically done by control unit.
No V/A Control switch - setting
automatically done by control unit.
Same as above
XMT 350 CC/CV
Pulsed MIG
No V/A Control switch - setting
automatically done by control unit.
Same as above
OM-2805 Page 5
2-3. Overview And Controls
Overview
The control unit provides three
modes of operation:
CV Mig − control functions as a remote voltage control.
1
Manual MIG Pulser − control functions as a discrete pulsed MIG CC
control.
2
Synergic Pulser − programs that
use factory-entered values are
used to control process.
Setup screens (see Section 2-5) allow the type of welding power
source in use to be defined, programs or modes to be made inaccessible (locked out) to the operator, and the language used in the
displays (English, French, etc.) to
be defined.
3
Controls
1
Display
2
Parameter Select Push Button
Press button to move > on display.
The parameter indicated by > is
selected.
3
Example
To select Program 3, set to Non Adaptive, and set Arc Length to 36, proceed as follows:
When top line of display is selected,
turning knob accesses pre-written
pulse programs, Manual MIG Pulser mode, or CV MIG mode.
304 model power source shown.
Select top line by pressing
push button until > is on top
line, and turn knob until
Program 3 appears.
> P r g
0 3 5 A l
5 3 5 6
A r
See example at left.
A d a p t i v e
5 0
Press push button to select
second line, and turn knob so
Non Adaptive appears.
3
Parameter Adjust Knob
Turn knob to change selected parameter. Knob turns in either
direction.
P r g
> N o n
5 0
Select third line, and turn
knob to set arc length to 36.
>
A r c
3
L e n g t h
0 3 5 A l
A r
A d a p t i v e
A r c
L e n g t h
P r g
3
N o n
A d a p t i v e
3 6
5 3 5 6
0 3 5 A l
A r c
5 3 5 6
A r
L e n g t h
ST-801 315-A
OM-2805 Page 6
2-4. Initial Display, Manual MIG Pulser Mode, And CV Mig Mode
1
2
304 model power source shown.
2
1
X X X X X X
3 0 4
C O P Y R I GH T
M I L L E R
M f g .
MOD E L S
( C )
2 0 0 4
E l e c t r i c
If welding power source type does
not match welding power source in
use, change according to Section
2-5.
3
Manual MIG Pulser Mode
The control unit functions as a discrete pulsed MIG CC control in this
mode.
Select Amps Peak line, and use
knob to set peak amperage from
100−400 amps, but always at least
1 amp more than background amperage. (100 - 425 amps for 350
models). (100 - 600 amps for 456
models).
> M a n u a l
M i g
P u l s e r
3 4 6
A m p s
P e a k
7 8
A m p s
B a c k g r o u n d
1 2 7
P P S
7 8
A m p s
1 2 7
Display scrolls to
show lines 5 and 6.
When power is applied, initial display with software number and
welding power source type appears
momentarily, and then last program
to be viewed before control was
shut down appears.
Select top line of display, and turn
knob until Manual MIG Pulser is displayed.
C o .
3
With > on top line, turn
knob until Manual Mig
Pulser appears.
Software Number
Defined Welding Power
Source Type
P P S
1 . 7 3
> 4 0 0
m s
A m p s
F r e q u e n c y
B a c k g r o u n d
F r e q u e n c y
P u l s e
S t a r t
W i d t h
Select Amps Background line, and
use knob to set background amperage (min: 10 amps; max: 300 amps,
but always at least 1 amp less than
peak setting).
Select PPS Frequency line, and
use knob to set pulse frequency (20
- 300 pulses per second, but max
setting may be less depending on
Pulse Width setting).
Select ms Pulse Width line, and use
knob to set pulse width (1 - 5 ms, but
max setting may be less depending
on Frequency setting).
Select Amps Start line, and use
knob to set starting amperage from
(150 - 530 amps). (150 - 563 amps
for 350 models). (150 - 800 amps for
456 models). This amperage value
is used at the start of the weld or
when an arc is restarted.
4
CV Mig Mode
The control unit functions as a remote voltage control in this mode.
The welding power source Inductance/Dig control is active in this
mode (see Section 2-2).
4
With > on top line, turn
knob until CV MIG
appears.
> C V
M I G
2 0 . 0
V o l t s
Select top line of display, and turn
knob until CV MIG is displayed. Select Volts line, and use knob to set
arc voltage from min to max of welding power source voltage. (10 - 35
volts for 304 and 350 models). (10
- 38 volts for 456 models).
OM-2805 Page 7
2-5. Setup Screens
To access Setup screens: turn
welding power source Off, press
and hold Select push button, turn
unit On, and hold push button down
until initial screen leaves.
To exit Setup screens, turn welding
power source Off and then On
again. Parameters that are displayed when the Setup screens are
exited are active.
1
1
S e t u p
P o w e r
> 3 0 4
S o u r c e
MOD E L S
Welding Power Source
Screen
. Unit originally shipped with 304
models selected.
Select third line of display, and turn
knob until desired welding power
source type is displayed.
Choices are:
- 304 Models
- 350 Models
- 456 Models
2
2
S e t u p
3 0 4
MOD E L S
A c c e s s i b l e
P r o g r a m s
M a n u a l
P u l s e r
M i g
> O f f
Accessible Programs Screen
Select second line of display, and
turn knob until Accessible Programs is displayed. Select third line
of display and turn knob to access
each program and the CV MIG
mode and the Manual MIG Pulser
mode as desired. Select the fourth
line and turn knob to define each option On (accessible) or Off (not accessible).
Programs and modes that are defined Off are not shown when the
operator scrolls through the displays in normal operation.
3
3
S e t u p
L a n g u a g e
> E n g l i s h
OM-2805 Page 8
Language Screen
Select second line of display, and
turn knob until Language is displayed. Select third line of display
and turn knob until desired language is shown. The choices are
English, French, Italian, and
Spanish.
2-6. Choosing Pulse Programs And Setting Parameters
Choosing Pulse Program:
Pulse programs are pre-written and cannot be
changed by the user. See Sections 3 and 5 for
program parameters.
Choose program depending on the type and size of
wire, and type of shielding gas used. For example,
the program shown below is for .045 steel wire using
95Ar − 5CO2 gas.
304 model power source shown.
> P r g
7
0 4 5 S t
A r 5 C O 2
A d a p t i v e
5 0
A r c
L e n g t h
Choosing Adaptive Or Non Adaptive:
Setting Arc Length:
Adaptive: Pulse frequency is automatically regulated
to maintain a constant arc length, regardless of
changes in wire stickout.
Each pulsed weld program contains a different range of
arc length values. Numbers (0 − 100) are for reference
only.
Non Adaptive: Constant pulse frequency is maintained, regardless of the arc length.
Adjustment normally needed if wire feed speed or type of
weld joint is changed.
Choose mode which best applies to your
application.
Set arc length that best applies to your application.
OM-2805 Page 9
2-7. How Manual Pulsed MIG Waveform Components Affect Arc and Burn-off Rate
Changes to Arc
A
Comments
A Electrode extension (stickout)
B Arc length
Reference Waveform
T
A
T
Increase Peak Amperage Only
A
C Contact tube-to-work distance should be 3/8 in to
3/4 in. Recommended gun angle is 10 to 20 degrees from vertical.
Increasing peak amperage only:
Increases burn-off rate, which directly affects
arc length
Increases average amperage slightly
Increase heat input slightly
Note: A good fine tuning parameter for arc length.
Assuming a constant pulse width (peak time), peak amperage should be high enough to achieve a spray transfer. Too low of a peak current often results in a globular
transfer. High peak amperages result in smaller droplets, and a more forceful or driving arc.
T
Decrease Peak Amperage Only
A
T
Increasing background amperage only:
Increases arc length
Increases average amperage
Increases heat input and penetration
Increases puddle fluidity
Increase Background Amperage Only
A
T
Decrease Background Amperage Only
A
T
Note: This current level is largely responsible for arc
stabilization, and must be high enough to maintain the
arc between peak current pulses.
Increasing pulse width (time) only:
Increases arc length
Increases heat input and penetration
Increases arc cone width
Increase average amperage
Increase Pulse Width (TIme) Only
A
T
Decrease Pulse Width (Time) Only
A
Increasing pulses per second only:
Increase arc length
Increases average amperage
Increases heat input
T
Increase Pulses Per Second Only
A
T
Decrease Pulses Per Second Only
OM-2805 Page 10
Note: A good fine tuning parameter for arc length.
Typically this variable is adjusted to control the Burn off
rate of the wire as it is fed into the arc.
SECTION 3 − PROGRAMS FOR 304 MODEL WELDING
POWER SOURCES
NOTE
Section 3-1 provides basic information on each of the programs in the unit’s
memory for the 304 Model welding power sources. See Section 3-2 for more
detailed information on each of the programs.
NOTE
Synergic Information: The manufacturer makes no warranties, express or implied,
that welds made using the synergic parameters of this equipment will meet the
requirements of the application.
The synergic parameters contained in this equipment are intended only to be a
general guideline. The choice and use of any synergic setting must be tested as to
its suitability for the application.
3-1. Overview Of Programs
Program #
Wire Type
Wire Size
Shielding Gas
IPM: Min
IPM: Max
1
Nickel
.035 in
75Ar/25He
80
780
2
5356AL
.047 in
Argon
165
730
3
5356AL
.035 in
Argon
200
875
4
4043AL
.047 in
Argon
110
730
5
4043AL
.035 in
Argon
160
875
6
Steel
.045 in
98Ar/2CO2
80
550
7
Steel
.045 in
95Ar/5CO2
80
550
8
Steel
.035 in
98Ar/2CO2
100
780
9
Steel
.035 in
95Ar/5CO2
100
780
10
Stainless
.045 in
98Ar/2CO2
90
620
11
Stainless
.045 in
95Ar/5CO2
100
600
12
Stainless
.035 in
98Ar/2CO2
100
780
13
Stainless
.035 in
95Ar/5CO2
100
780
14
Silicon Bronze
.035 in
Argon
120
780
15
Metal Core
.052 in
Argon/CO2
60
450
16
Metal Core
.045 in
Argon/CO2
100
550
Manual MIG Pulser
CV MIG
3-2. Programs For 304 Model Welding Power Sources
Program 1 −− .035 Nickel −− 75 Argon / 25 Helium (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
80
0
221
14
40
1.90
458
141
10
268
36
60
2.10
505
212
20
294
58
84
2.40
529
283
30
327
73
96
2.50
529
354
40
337
89
114
2.65
529
425
50
346
105
124
2.72
529
496
60
368
111
139
2.84
529
567
70
382
122
149
2.90
529
638
80
395
138
170
3.00
529
709
90
400
152
182
3.16
529
780
100
400
169
167
3.55
529
OM-2805 Page 11
Program 2 −− .047 Aluminum 5356 −− Argon (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
165
0
294
42
59
1.40
529
222
10
304
61
69
1.50
529
279
20
320
81
75
1.65
529
336
30
335
89
96
1.80
529
393
40
348
100
107
2.00
529
450
50
362
120
116
2.20
529
507
60
374
134
129
2.30
529
564
70
384
155
140
2.45
529
621
80
393
167
156
2.60
529
678
90
400
189
166
2.70
529
730
100
400
230
222
2.93
529
Program 3 −− .035 Aluminum 5356 −− Argon (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
200
0
272
31
51
1.30
484
268
10
272
43
71
1.30
510
336
20
277
54
90
1.35
529
404
30
288
67
99
1.41
529
472
40
298
78
104
1.53
529
540
50
313
86
106
1.66
529
608
60
323
103
111
1.75
529
676
70
330
117
121
1.85
529
744
80
354
134
139
2.00
529
812
90
374
149
150
2.20
529
875
100
389
144
150
2.26
529
Program 4 −− .047 Aluminum 4043 −− Argon (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
110
0
268
31
50
1.35
529
172
10
298
56
75
1.45
529
234
20
309
86
82
1.59
529
296
30
329
109
97
1.75
529
358
40
348
134
126
1.90
529
420
50
356
152
135
2.14
529
482
60
373
163
148
2.31
529
544
70
387
174
171
2.50
529
606
80
400
199
195
2.74
529
668
90
400
257
212
3.11
529
730
100
400
257
227
3.70
529
OM-2805 Page 12
Program 5 −− .035 Aluminum 4043 −− Argon (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
160
0
236
31
50
1.20
470
231
10
252
45
76
1.25
501
302
20
277
58
98
1.30
529
373
30
288
78
109
1.40
529
444
40
302
101
114
1.56
529
515
50
329
125
125
1.74
529
586
60
346
134
130
1.90
529
657
70
362
144
145
2.14
529
728
80
373
152
153
2.23
529
799
90
395
166
183
2.54
529
875
100
400
181
210
2.80
529
Program 6 −− .045 ER70S−3 Mild Steel −− 98 Argon / 2 CO2 (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
80
0
323
48
57
2.20
498
127
10
345
65
89
2.30
529
174
20
370
90
105
2.45
529
221
30
390
92
138
2.60
529
268
40
390
108
155
2.70
529
315
50
400
119
175
2.80
529
362
60
400
144
185
2.90
529
409
70
400
155
200
2.96
529
456
80
400
181
215
3.05
529
503
90
400
221
230
3.12
529
550
100
400
277
250
3.27
529
Program 7 −− .045 ER70S−3 Mild Steel −− 95 Argon / 5 CO2 (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
80
0
323
48
55
2.20
498
127
10
338
56
92
2.25
529
174
20
370
78
110
2.30
529
221
30
385
97
130
2.45
529
268
40
390
108
155
2.60
529
315
50
400
119
175
2.65
529
362
60
400
133
180
2.75
529
409
70
400
149
200
2.76
529
456
80
400
174
215
2.80
529
503
90
400
216
230
2.85
529
550
100
400
277
250
2.93
529
OM-2805 Page 13
Program 8 −− .035 ER70S−3 Mild Steel −− 98 Argon / 2 CO2 (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
293
42
51
1.60
451
168
10
309
56
91
1.66
491
236
20
332
72
110
1.80
501
304
30
359
81
120
1.99
529
372
40
370
86
150
2.15
529
440
50
390
92
170
2.25
529
508
60
400
108
180
2.35
529
576
70
400
112
195
2.45
529
644
80
400
123
200
2.60
529
712
90
400
133
220
2.70
529
780
100
400
144
240
2.85
529
Program 9 −− .035 ER70S−3 Mild Steel −− 95 Argon / 5 CO2 (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
282
43
46
1.50
451
168
10
298
51
95
1.55
491
236
20
332
62
110
1.66
501
304
30
346
78
127
1.73
529
372
40
349
81
160
1.76
529
440
50
359
84
190
1.85
529
508
60
370
87
210
1.90
529
576
70
379
89
220
1.97
529
644
80
389
94
230
2.00
529
712
90
395
95
260
2.05
529
780
100
400
97
280
2.10
529
Program 10 −− .045 309L Stainless Steel −− 98 Argon / 2 CO2 (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
90
0
288
31
90
1.80
442
143
10
318
54
105
2.00
475
196
20
351
75
125
2.00
505
249
30
359
97
143
2.20
529
302
40
379
100
160
2.40
529
355
50
390
109
175
2.50
529
408
60
400
117
185
2.50
529
461
70
400
133
200
2.65
529
514
80
400
149
220
2.70
529
567
90
400
167
240
2.85
529
620
100
400
175
260
2.80
529
OM-2805 Page 14
Program 11 −− .045 309L Stainless Steel −− 95 Argon / 5 CO2 (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
302
39
90
1.80
454
150
10
318
54
105
2.00
487
200
20
351
75
125
2.00
510
250
30
359
97
143
2.20
529
300
40
379
100
160
2.40
529
350
50
390
109
175
2.50
529
400
60
400
117
185
2.50
529
450
70
400
133
200
2.65
529
500
80
400
149
220
2.70
529
550
90
400
164
240
2.80
529
600
100
400
175
260
2.80
529
Program 12 −− .035 309L Stainless Steel −− 98 Argon / 2 CO2 (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
257
26
55
1.63
400
168
10
266
42
80
1.75
430
236
20
282
67
90
1.85
451
304
30
298
81
105
1.95
472
372
40
313
86
121
1.98
494
440
50
327
92
135
2.00
510
508
60
348
108
147
2.12
529
576
70
362
112
171
2.20
529
644
80
379
117
180
2.25
529
712
90
400
120
182
2.30
529
780
100
400
123
190
2.43
529
Program 13 −− .035 309L Stainless Steel −− 95 Argon / 5 CO2 (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
257
26
58
1.60
400
168
10
266
45
83
1.75
430
236
20
282
72
92
1.85
461
304
30
298
87
107
1.99
491
372
40
316
92
125
2.05
512
440
50
329
98
135
2.15
529
508
60
349
106
140
2.25
529
576
70
362
112
170
2.30
529
644
80
373
119
180
2.35
529
712
90
389
123
183
2.35
529
780
100
400
123
190
2.43
529
OM-2805 Page 15
Program 14 −− .035 Silicon Bronze −− Argon (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
120
0
238
21
61
1.20
503
186
10
272
43
71
1.30
529
252
20
282
61
95
1.43
529
318
30
301
78
110
1.51
529
384
40
324
95
129
1.50
529
450
50
341
106
136
1.70
529
516
60
363
114
138
1.82
529
582
70
378
128
143
1.88
529
648
80
387
134
148
1.96
529
714
90
400
144
160
2.10
529
780
100
400
144
194
2.16
529
Program 15 −− .052 Metal Core −− Recommended Gases: Argon/CO2
Gas: Argon/CO2 mixes up to 20% CO2 (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
60
0
360
36
40
2.00
529
99
10
365
70
50
2.10
529
138
20
370
94
73
2.20
529
177
30
374
116
94
2.35
529
216
40
379
133
112
2.50
529
255
50
384
147
129
2.65
529
294
60
387
160
144
2.85
529
333
70
390
174
159
3.00
529
372
80
393
186
174
3.15
529
411
90
396
199
189
3.35
529
450
100
400
210
204
3.50
529
Program 16 −− .045 Metal Core −− Recommended Gases: Argon/CO2
Gas: Argon/CO2 mixes up to 20% CO2 (For 304 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
310
45
50
2.30
529
145
10
330
62
65
2.45
529
190
20
354
70
90
2.55
529
235
30
365
78
110
2.65
529
280
40
370
89
130
2.75
529
325
50
376
100
150
2.85
529
370
60
381
111
165
3.00
529
415
70
385
122
180
3.15
529
460
80
390
138
190
3.25
529
505
90
395
155
200
3.35
529
550
100
400
175
205
3.45
529
OM-2805 Page 16
SECTION 4 − PROGRAMS FOR 350 MODEL WELDING
POWER SOURCES
NOTE
Section 4-1 provides basic information on each of the programs in the unit’s
memory for the 350 Model welding power sources. See Section 4-2 for more
detailed information on each of the programs.
NOTE
Synergic Information: The manufacturer makes no warranties, express or implied,
that welds made using the synergic parameters of this equipment will meet the
requirements of the application.
The synergic parameters contained in this equipment are intended only to be a
general guideline. The choice and use of any synergic setting must be tested as to
its suitability for the application.
4-1. Overview Of Programs
Program #
Wire Type
Wire Size
Shielding Gas
IPM: Min
IPM: Max
1
Nickel
.035 in
75Ar/25He
80
780
2
5356AL
.047 in
Argon
165
730
3
5356AL
.035 in
Argon
200
875
4
4043AL
.047 in
Argon
110
730
5
4043AL
.035 in
Argon
160
875
6
Steel
.045 in
98Ar/2CO2
80
550
7
Steel
.045 in
95Ar/5CO2
80
550
8
Steel
.035 in
98Ar/2CO2
100
780
9
Steel
.035 in
95Ar/5CO2
100
780
10
Stainless
.045 in
98Ar/2CO2
90
620
11
Stainless
.045 in
95Ar/5CO2
100
600
12
Stainless
.035 in
98Ar/2CO2
100
780
13
Stainless
.035 in
95Ar/5CO2
100
780
14
Silicon Bronze
.035 in
Argon
120
780
15
Metal Core
.052 in
Argon/CO2
60
450
16
Metal Core
.045 in
Argon/CO2
100
550
Manual MIG Pulser
CV MIG
4-2. Programs For 350 Model Welding Power Sources
Program 1 −− .035 Nickel −− 75 Argon / 25 Helium (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
80
0
221
14
40
1.90
458
141
10
268
36
60
2.10
505
212
20
294
58
84
2.40
529
283
30
327
73
96
2.50
563
354
40
337
89
114
2.65
563
425
50
346
105
124
2.72
563
496
60
368
111
139
2.84
563
567
70
382
122
149
2.90
563
638
80
395
138
170
3.00
563
709
90
400
152
182
3.16
563
780
100
400
169
167
3.55
563
OM-2805 Page 17
Program 2 −− .047 Aluminum 5356 −− Argon (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
165
0
294
42
59
1.40
529
222
10
304
61
69
1.50
563
279
20
320
81
75
1.65
563
336
30
335
89
96
1.80
563
393
40
348
100
107
2.00
563
450
50
362
120
116
2.20
563
507
60
374
134
129
2.30
563
564
70
384
155
140
2.45
563
621
80
393
167
156
2.60
563
678
90
400
189
166
2.70
563
730
100
400
230
222
2.93
563
Program 3 −− .035 Aluminum 5356 −− Argon (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
200
0
272
31
51
1.30
484
268
10
272
43
71
1.30
510
336
20
277
54
90
1.35
529
404
30
288
67
99
1.41
563
472
40
298
78
104
1.53
563
540
50
313
86
106
1.66
563
608
60
323
103
111
1.75
563
676
70
330
117
121
1.85
563
744
80
354
134
139
2.00
563
812
90
374
149
150
2.20
563
875
100
389
144
150
2.26
563
Program 4 −− .047 Aluminum 4043 −− Argon (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
110
0
268
31
50
1.35
529
172
10
298
56
75
1.45
563
234
20
309
86
82
1.59
563
296
30
329
109
97
1.75
563
358
40
348
134
126
1.90
563
420
50
356
152
135
2.14
563
482
60
373
163
148
2.31
563
544
70
387
174
171
2.50
563
606
80
400
199
195
2.74
563
668
90
400
257
212
3.11
563
730
100
400
257
227
3.70
563
OM-2805 Page 18
Program 5 −− .035 Aluminum 4043 −− Argon (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
160
0
236
31
50
1.20
470
231
10
252
45
76
1.25
501
302
20
277
58
98
1.30
529
373
30
288
78
109
1.40
563
444
40
302
101
114
1.56
563
515
50
329
125
125
1.74
563
586
60
346
134
130
1.90
563
657
70
362
144
145
2.14
563
728
80
373
152
153
2.23
563
799
90
395
166
183
2.54
563
875
100
400
181
210
2.80
563
Program 6 −− .045 ER70S−3 Mild Steel −− 98 Argon / 2 CO2 (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
80
0
323
48
57
2.20
498
127
10
345
65
89
2.30
529
174
20
370
90
105
2.45
563
221
30
390
92
138
2.60
563
268
40
390
108
155
2.70
563
315
50
400
119
175
2.80
563
362
60
400
144
185
2.90
563
409
70
400
155
200
2.96
563
456
80
400
181
215
3.05
563
503
90
400
221
230
3.12
563
550
100
400
277
250
3.27
563
Program 7 −− .045 ER70S−3 Mild Steel −− 95 Argon / 5 CO2 (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
80
0
323
48
55
2.20
498
127
10
338
56
92
2.25
529
174
20
370
78
110
2.30
563
221
30
385
97
130
2.45
563
268
40
390
108
155
2.60
563
315
50
400
119
175
2.65
563
362
60
400
133
180
2.75
563
409
70
400
149
200
2.76
563
456
80
400
174
215
2.80
563
503
90
400
216
230
2.85
563
550
100
400
277
250
2.93
563
OM-2805 Page 19
Program 8 −− .035 ER70S−3 Mild Steel −− 98 Argon / 2 CO2 (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
293
42
51
1.60
451
168
10
309
56
91
1.66
491
236
20
332
72
110
1.80
501
304
30
359
81
120
1.99
529
372
40
370
86
150
2.15
563
440
50
390
92
170
2.25
563
508
60
400
108
180
2.35
563
576
70
400
112
195
2.45
563
644
80
400
123
200
2.60
563
712
90
400
133
220
2.70
563
780
100
400
144
240
2.85
563
Program 9 −− .035 ER70S−3 Mild Steel −− 95 Argon / 5 CO2 (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
282
43
46
1.50
451
168
10
298
51
95
1.55
491
236
20
332
62
110
1.66
501
304
30
346
78
127
1.73
529
372
40
349
81
160
1.76
563
440
50
359
84
190
1.85
563
508
60
370
87
210
1.90
563
576
70
379
89
220
1.97
563
644
80
389
94
230
2.00
563
712
90
395
95
260
2.05
563
780
100
400
97
280
2.10
563
Program 10 −− .045 309L Stainless Steel −− 98 Argon / 2 CO2 (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
90
0
288
31
90
1.80
442
143
10
318
54
105
2.00
475
196
20
351
75
125
2.00
505
249
30
359
97
143
2.20
529
302
40
379
100
160
2.40
563
355
50
390
109
175
2.50
563
408
60
400
117
185
2.50
563
461
70
400
133
200
2.65
563
514
80
400
149
220
2.70
563
567
90
400
167
240
2.85
563
620
100
400
175
260
2.80
563
OM-2805 Page 20
Program 11 −− .045 309L Stainless Steel −− 95 Argon / 5 CO2 (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
302
39
90
1.80
454
150
10
318
54
105
2.00
487
200
20
351
75
125
2.00
510
250
30
359
97
143
2.20
529
300
40
379
100
160
2.40
563
350
50
390
109
175
2.50
563
400
60
400
117
185
2.50
563
450
70
400
133
200
2.65
563
500
80
400
149
220
2.70
563
550
90
400
164
240
2.80
563
600
100
400
175
260
2.80
563
Program 12 −− .035 309L Stainless Steel −− 98 Argon / 2 CO2 (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
257
26
55
1.63
400
168
10
266
42
80
1.75
430
236
20
282
67
90
1.85
451
304
30
298
81
105
1.95
472
372
40
313
86
121
1.98
494
440
50
327
92
135
2.00
510
508
60
348
108
147
2.12
529
576
70
362
112
171
2.20
563
644
80
379
117
180
2.25
563
712
90
400
120
182
2.30
563
780
100
400
123
190
2.43
563
Program 13 −− .035 309L Stainless Steel −− 95 Argon / 5 CO2 (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
257
26
58
1.60
400
168
10
266
45
83
1.75
430
236
20
282
72
92
1.85
461
304
30
298
87
107
1.99
491
372
40
316
92
125
2.05
512
440
50
329
98
135
2.15
529
508
60
349
106
140
2.25
563
576
70
362
112
170
2.30
563
644
80
373
119
180
2.35
563
712
90
389
123
183
2.35
563
780
100
400
123
190
2.43
563
OM-2805 Page 21
Program 14 −− .035 Silicon Bronze −− Argon (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
120
0
238
21
61
1.20
503
186
10
272
43
71
1.30
529
252
20
282
61
95
1.43
563
318
30
301
78
110
1.51
563
384
40
324
95
129
1.50
563
450
50
341
106
136
1.70
563
516
60
363
114
138
1.82
563
582
70
378
128
143
1.88
563
648
80
387
134
148
1.96
563
714
90
400
144
160
2.10
563
780
100
400
144
194
2.16
563
Program 15 −− .052 Metal Core −− Recommended Gases: Argon/CO2
Gas: Argon/CO2 mixes up to 20% CO2 (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
60
0
360
36
40
2.00
563
99
10
365
70
50
2.10
563
138
20
370
94
73
2.20
563
177
30
374
116
94
2.35
563
216
40
379
133
112
2.50
563
255
50
384
147
129
2.65
563
294
60
387
160
144
2.85
563
333
70
390
174
159
3.00
563
372
80
393
186
174
3.15
563
411
90
396
199
189
3.35
563
450
100
400
210
204
3.50
563
Program 16 −− .045 Metal Core −− Recommended Gases: Argon/CO2
Gas: Argon/CO2 mixes up to 20% CO2 (For 350 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
310
45
50
2.30
563
145
10
330
62
65
2.45
563
190
20
354
70
90
2.55
563
235
30
365
78
110
2.65
563
280
40
370
89
130
2.75
563
325
50
376
100
150
2.85
563
370
60
381
111
165
3.00
563
415
70
385
122
180
3.15
563
460
80
390
138
190
3.25
563
505
90
395
155
200
3.35
563
550
100
400
175
205
3.45
563
OM-2805 Page 22
SECTION 5 − PROGRAMS FOR 456 MODEL WELDING
POWER SOURCES
NOTE
Section 5-1 provides basic information on each of the programs in the unit’s
memory for the 456 Model welding power sources. See Section 5-2 for more
detailed information on each of the programs.
NOTE
Synergic Information: The manufacturer makes no warranties, express or implied,
that welds made using the synergic parameters of this equipment will meet the
requirements of the application.
The synergic parameters contained in this equipment are intended only to be a
general guideline. The choice and use of any synergic setting must be tested as to
its suitability for the application.
5-1. Overview Of Programs
Program #
Wire Type
Wire Size
Shielding Gas
IPM: Min
IPM: Max
1
Nickel
.035 in
75Ar/25He
120
670
2
Nickel
.045 in
75Ar/25He
100
600
3
5356AL
.062 in
Argon
180
580
4
5356AL
.047 in
Argon
200
750
5
5356AL
.035 in
Argon
350
850
6
4043AL
.062 in
Argon
120
520
7
4043AL
.047 in
Argon
150
750
8
4043AL
.035 in
Argon
240
840
9
Steel
.062 in
95Ar/5CO2
60
400
10
Steel
.052 in
95Ar/5CO2
70
750
11
Steel
.045 in
95Ar/5CO2
80
750
12
Steel
.035 in
95Ar/5CO2
80
750
13
Stainless
.045 in
98Ar/2CO2
90
750
14
Stainless
.035 in
98Ar/2CO2
100
750
15
Silicon Bronze
.035 in
Argon
120
750
16
Metal Core
.062 in
Ar/CO2
50
500
17
Metal Core
.052 in
Ar/CO2
50
750
18
Metal Core
.045 in
Ar/CO2
100
750
Manual MIG Pulser
CV MIG
OM-2805 Page 23
5-2. Programs For 456 Model Welding Power Sources
Program 1 −− .035 Nickel −− 75 Argon / 25 Helium (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
120
0
254
37
40
2.85
501
175
10
287
49
54
2.96
501
230
20
312
61
68
3.08
511
285
30
331
72
77
3.20
522
340
40
348
84
89
3.32
532
395
50
360
91
99
3.40
543
450
60
374
98
108
3.48
554
505
70
390
105
117
3.55
564
560
80
404
112
126
3.62
575
615
90
418
120
135
3.69
585
670
100
432
127
144
3.76
596
Program 2 −− .045 Nickel −− 75 Argon / 25 Helium (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
289
56
56
3.00
600
150
10
315
75
76
3.22
600
200
20
345
89
100
3.34
600
250
30
364
103
116
3.50
628
300
40
385
117
129
3.62
645
350
50
404
134
142
3.72
660
400
60
423
150
155
3.82
670
450
70
440
164
168
3.92
677
500
80
458
176
180
4.02
688
550
90
475
188
192
4.12
702
600
100
491
197
204
4.20
712
Program 3 −− .062 Aluminum 5356 −− Argon (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
180
0
291
82
50
2.25
652
220
10
312
98
62
2.38
663
260
20
338
120
77
2.55
705
300
30
362
136
90
2.69
723
340
40
383
148
100
2.80
748
380
50
404
160
110
2.91
772
420
60
428
176
122
3.04
783
460
70
451
192
134
3.19
794
500
80
484
207
146
3.34
801
540
90
501
216
156
3.42
801
580
100
517
225
165
3.50
801
OM-2805 Page 24
Program 4 −− .047 Aluminum 5356 −− Argon (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
200
0
240
47
55
2.10
501
255
10
270
58
80
2.20
600
310
20
301
65
98
2.30
600
365
30
320
72
110
2.40
652
420
40
341
80
120
2.50
652
475
50
350
91
130
2.60
652
530
60
388
101
140
2.70
652
585
70
411
110
153
2.80
702
640
80
421
120
163
2.90
702
695
90
440
131
168
2.95
702
750
100
461
141
170
3.00
702
Program 5 −− .035 Aluminum 5356 −− Argon (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
350
0
200
65
54
1.90
451
400
10
216
72
66
1.95
451
450
20
230
80
78
2.00
451
500
30
242
87
88
2.05
501
550
40
251
94
96
2.10
501
600
50
261
101
104
2.17
501
650
60
272
108
112
2.24
501
700
70
284
117
121
2.32
501
750
80
296
127
130
2.40
550
800
90
301
131
137
2.45
550
850
100
303
134
140
2.48
550
Program 6 −− .062 Aluminum 4043 −− Argon (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
120
0
258
56
40
2.15
550
160
10
270
89
60
2.40
649
200
20
298
115
80
2.60
649
240
30
336
134
106
2.89
702
280
40
367
148
122
3.15
720
320
50
400
157
134
3.35
737
360
60
421
169
144
3.55
748
400
70
440
181
154
3.70
758
440
80
461
192
164
3.90
772
480
90
480
204
174
4.05
787
520
100
498
216
180
4.18
801
OM-2805 Page 25
Program 7 −− .047 Aluminum 4043 −− Argon (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
150
0
200
40
54
2.00
501
210
10
218
68
80
2.16
600
270
20
270
82
96
2.42
600
330
30
320
94
110
2.55
600
390
40
360
112
120
2.68
600
450
50
385
127
131
2.81
652
510
60
407
138
141
2.92
652
570
70
428
148
151
3.02
702
630
80
451
160
160
3.12
702
690
90
470
171
170
3.26
751
750
100
491
181
180
3.38
751
Program 8 −− .035 Aluminum 4043 −− Argon (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
240
0
157
42
35
2.05
402
300
10
160
61
40
2.10
451
360
20
181
80
60
2.17
451
420
30
218
101
75
2.30
451
480
40
244
112
90
2.40
501
540
50
256
120
104
2.50
501
600
60
268
131
117
2.60
501
660
70
280
141
127
2.70
550
720
80
291
152
138
2.80
550
780
90
301
162
148
2.90
550
840
100
312
174
158
3.00
550
Program 9 −− .062 ER70S−3 Mild Steel −− 95 Argon / 5 CO2 (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
60
0
458
51
60
2.42
674
94
10
489
82
81
2.62
688
128
20
512
110
102
2.80
702
162
30
527
134
120
2.92
716
196
40
541
155
138
3.04
730
230
50
557
176
156
3.17
748
264
60
569
197
174
3.30
762
298
70
581
218
192
3.43
776
332
80
590
240
210
3.56
790
366
90
600
251
220
3.62
801
400
100
600
261
228
3.68
801
OM-2805 Page 26
Program 10 −− .052 ER70S−3 Mild Steel −− 95 Argon / 5 CO2 (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
70
0
369
44
57
2.30
600
138
10
449
68
94
2.43
600
206
20
484
89
125
2.58
624
274
30
512
117
150
2.70
652
342
40
538
138
170
2.80
674
410
50
562
162
191
2.90
698
478
60
574
174
212
3.00
727
546
70
585
185
235
3.10
755
614
80
595
195
248
3.15
780
682
90
600
200
253
3.18
801
750
100
600
204
256
3.20
801
Program 11 −− .045 ER70S−3 Mild Steel −− 95 Argon / 5 CO2 (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
80
0
381
37
50
2.00
550
147
10
404
56
80
2.20
600
214
20
435
70
110
2.35
652
281
30
461
84
130
2.50
698
348
40
487
91
145
2.70
698
415
50
498
98
155
2.80
698
482
60
512
105
165
2.90
698
549
70
522
110
175
3.00
698
616
80
534
115
185
3.10
698
683
90
545
120
195
3.20
698
750
100
555
124
205
3.30
698
Program 12 −− .035 ER70S−3 Mild Steel −− 95 Argon / 5 CO2 (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
80
0
291
37
33
1.48
398
147
10
315
65
59
1.62
480
214
20
345
82
85
1.75
508
281
30
385
96
100
1.87
522
348
40
421
101
110
1.95
536
415
50
442
110
120
1.98
547
482
60
458
120
130
2.10
561
549
70
472
124
140
2.20
571
616
80
487
129
150
2.26
582
683
90
501
134
160
2.32
592
750
100
510
138
165
2.37
600
OM-2805 Page 27
Program 13 −− .045 309L Stainless Steel −− 98 Argon / 2 CO2 (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
90
0
320
47
60
1.50
441
156
10
345
70
90
1.65
472
222
20
371
89
120
1.75
511
288
30
402
103
145
1.85
550
354
40
430
117
155
1.97
589
420
50
454
129
165
2.09
631
486
60
470
138
175
2.20
663
552
70
484
145
185
2.30
695
618
80
498
152
195
2.40
727
684
90
512
157
210
2.50
762
750
100
527
162
225
2.60
801
Program 14 −− .035 309L Stainless Steel −− 98 Argon / 2 CO2 (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
272
40
44
1.52
402
165
10
298
49
77
1.67
420
230
20
310
72
88
1.79
441
295
30
322
96
100
1.91
458
360
40
334
108
112
2.03
480
425
50
348
115
125
2.14
494
490
60
362
122
138
2.22
501
555
70
374
129
151
2.29
508
620
80
388
136
164
2.35
515
685
90
400
143
177
2.40
522
750
100
411
150
190
2.45
529
Program 15 −− .035 Silicon Bronze −− Argon (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
120
0
280
37
42
1.30
501
183
10
331
54
57
1.40
540
246
20
371
68
72
1.50
582
309
30
402
77
93
1.60
610
372
40
421
87
108
1.70
642
435
50
442
96
119
1.80
663
498
60
463
108
130
1.90
684
561
70
482
115
140
2.00
705
624
80
496
122
150
2.10
720
687
90
508
127
160
2.20
730
750
100
520
131
170
2.30
737
OM-2805 Page 28
Program 16 −− .062 Metal Core −− Recommended Gases: Argon/CO2
Gases: Argon/CO2 mixes up to 20% CO2 (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
50
0
451
37
38
2.10
674
95
10
498
70
68
2.30
705
140
20
515
91
90
2.40
741
185
30
527
120
112
2.50
772
230
40
541
150
132
2.60
800
275
50
552
171
150
2.75
800
320
60
562
190
168
2.90
800
365
70
571
209
185
3.05
800
410
80
581
225
202
3.20
800
455
90
590
244
220
3.35
800
500
100
600
261
238
3.50
800
Program 17 −− .052 Metal Core −− Recommended Gases: Argon/CO2
Gases: Argon/CO2 mixes up to 20% CO2 (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
50
0
360
30
35
1.90
600
120
10
421
54
75
2.00
649
190
20
461
72
105
2.10
698
260
30
491
91
125
2.25
751
330
40
512
105
145
2.40
800
400
50
531
120
165
2.50
800
470
60
545
127
180
2.60
800
540
70
564
138
190
2.70
800
610
80
576
143
202
2.80
800
680
90
588
148
214
2.90
800
750
100
600
150
225
3.00
800
Program 18 −− .045 Metal Core −− Recommended Gases: Argon/CO2
Gases: Argon/CO2 mixes up to 20% CO2 (For 456 Models)
IPM
Trim
Peak Amp
Background Amp
Freq.
Pulse Width
Starting Amps
100
0
376
42
60
1.70
476
165
10
409
51
95
1.80
511
230
20
440
65
115
1.90
540
295
30
465
75
140
1.95
568
360
40
480
82
155
2.00
582
425
50
496
89
170
2.10
596
490
60
512
96
185
2.20
614
555
70
527
101
195
2.25
628
620
80
543
105
205
2.30
645
685
90
560
112
217
2.40
660
750
100
576
120
230
2.50
677
OM-2805 Page 29
SECTION 6 − TROUBLESHOOTING
6-1. Error Codes
1
2
Program CRC Error
Program Range Error
If either error code appears, reset
the display to factory settings as follows:
Press Parameter Select push button or turn welding power source
Off and back On. Change settings
and continue.
1
E R R OR
P r o g r a m
M e m o r y
P r e s s
C R C
W i l l
P a r m .
B e
R e s e t
S e l e c t
2
E R R OR
P r o g r a m
M e m o r y
P r e s s
OM-2805 Page 30
R a n g e
W i l l
P a r m .
B e
R e s e t
S e l e c t
6-2. Troubleshooting
Trouble
No weld output.
Remedy
Be sure welding power source Power switch is On.
Check welding gun and/or wire feeder if applicable.
No control of weld output.
Check welding power source control settings.
Tighten all interconnecting cord connections.
Check pendant cord and replace if needed.
Erratic weld; incorrect weld
characteristics.
Check to make sure correct program is selected for welding wire and shielding gas used.
Check wire feeder and welding power source settings.
182 109-B
Figure 6-1. Circuit Diagram
OM-2805 Page 31
SECTION 7 − PARTS LIST
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-1. Main Assembly
. . . 1 . . . . . . . . . . 174 960 . . PANEL, rear & sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 126 873 . . BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 3 . . . . . . . . . . 174 715 . . KNOB, round 1.250dia x .250 ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 167 633 . . WASHER, shoulder .612 ID x 1.060 ID nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 010 291 . . WASHER, flat .625 ID x .250 OX nylafil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 159 264 . . RING, rtng ext . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PC1 . . 220 925 . . CIRCUIT CARD ASSEMBLY, remote pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 144 844 . . STAND-OFF, 6-32 x .875 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . . . . . . 181 757 . . CABLE, extension 25ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 134 900 . . . STRAIN RELIEF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 183 091 . . . CABLE, shld 18ga 7/c nprn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25ft
. . . 6 . . . RC3 . . 152 369 . . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 143 922 . . . CONNECTOR, circ cpc clamp str rlf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . 097 426 . . . CABLE, shld No. 18ga 10/c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1ft
. . . 9 . . PLG4 . 141 162 . . . CONNECTOR & PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 079 739 . . . CONNECTOR, circ CPC clamp str . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 174 959 . . CASE SECTION, front & ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 153 169 . . ACTUATOR, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 174 446 . . GASKET, meter lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 155 024 . . LENS, clear antiglare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG1 . 153 501 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG2 . 164 900 . . CONNECTOR & SOCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1
. Hardware is common and
not available unless listed.
15
2
14
3
13
10
12
9
11
4
8
5
7
6
ST-801 315-A
Figure 7-1. Main Assembly
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-2805 Page 32
Notes
Start Your Professional
Welding Career Now!
400 Trade Square East, Troy, Ohio 45373
1-800-332-9448 www.welding.org
Over 80,000 trained
since 1930!
Notes
Effective January 1, 2004
(Equipment with a serial number preface of “LE” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
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.
*
LIMITED WARRANTY − Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Induction Heating Coils and Blankets
*
APT & SAF Model Plasma Cutting Torches
*
Remote Controls
*
Accessory Kits
*
Replacement Parts (No labor)
*
Spoolmate Spoolguns
*
Canvas Covers
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller’s True Blue Limited Warranty shall not apply to:
1.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that the
equipment was delivered to the original retail purchaser, or one
year after the equipment is sent to a North American distributor
or eighteen months after the equipment is sent to an
International distributor.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)
2.
Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for the
equipment.
1.
5 Years Parts — 3 Years Labor
*
*
2.
3 Years — Parts and Labor
*
*
*
*
3.
Original main power rectifiers
Inverters (input and output rectifiers only)
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
*
Water Coolant Systems (Integrated)
*
*
*
Intellitig
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DS-2 Wire Feeder
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources and Coolers
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Maxstar 85, 140
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True
Blue for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)
4.
6 Months — Batteries
5.
90 Days — Parts
*
MIG Guns/TIG Torches
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary
from state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may be
available, but may vary from province to province.
miller_warr 6/04
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
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate 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. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Replacement Parts
Training (Schools, Videos, Books)
International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
Welding Process Handbooks
www.MillerWelds.com
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.
PRINTED IN USA
 2004 Miller Electric Mfg. Co.
1/04
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