OM-279299F

2021-12

Processes

MIG (GMAW) Welding

Pulsed MIG (GMAW-P) Welding

Description

Arc Welding Power Source And Wire

Feeder

Millermatic

®

255

For product information,

Owner’s Manual translations, and more, visit

www.MillerWelds.com

OWNER’S MANUAL

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 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.

Miller is backed by the most hassle-free warranty in the business.

Miller is the first welding equipment manufacturer in the

U. S. A. to be registered to the

ISO 9001 Quality System

Standard.

Mil_Thank1 2019 01

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1 Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-2

1-3

1-4

1-5

1-6

Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Additional Hazards For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Principal Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2-1

2-2

2-3

Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . . . . . . . . . . . . . . . . . 7

2-4

2-5

2-6

Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 3 – DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3-1 Additional Safety Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3-2 Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 4 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4-1

4-2

Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4-3

4-4

4-5

Information About Default Weld Parameters And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Unit Specifications For MIG (GMAW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4-6

4-7

4-8

Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Static Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SECTION 5 – INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5-1 Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5-2 Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5-3

5-4

Connecting 1-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Wiring Optional 240 Volt Plug (119172) For Connection To Miller Welder/Generator With Split-Phase 240 Volt Auxiliary

Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5-5

5-6

5-7

5-8

Generator Or Inverter Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Selecting Cable Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Process/Polarity Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5-9 MIG Welding Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5-10 MIG Gun Connection Inside Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5-11 Connecting Shielding Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5-12 Installing Wire Spool And Adjusting Hub Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5-13 Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5-14 Connecting Spoolmatic ® 15A Or 30A Or Spoolmate 200 Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5-15 Connecting XR-Aluma-Pro Or XR-Aluma-Pro-Lite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

5-16 Threading Welding Wire For XR-Aluma-Pro Or XR-Aluma-Pro Lite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5-17 Threading Welding Wire For Spoolmate 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5-18 Threading Welding Wire For Spoolmatic 15/30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5-19 Calibrating Spoolgun. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

SECTION 6 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6-1

6-2

Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6-3

6-4

6-5

Using Auto-Set ™ Elite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Using Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6-6

6-7

6-8

Manual MIG Set-Up Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Setting Crater Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Manual Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Using Optional MDX-250 EZ-Select ™ Gun In Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6-9 Pulsed MIG Auto-Set ™ Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6-10 Pulsed MIG Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6-11 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6-12 Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6-13 MIG Welding Parameter Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

SECTION 7 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

TABLE OF CONTENTS

7-1

7-2

7-3

7-4

Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Changing Drive Roll Or Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Aligning Drive Rolls and Wire Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

7-5

7-6

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

SECTION 8 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

8-1

8-2

MDX-250 MIG Gun Consumables And Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Drive Roll And Wire Guide Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

SECTION 9 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

SECTION 10 – GMAW WELDING (MIG) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

10-1 Typical GMAW (MIG) Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

10-2 Typical GMAW (MIG) Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

10-3 Holding And Positioning Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

10-8 Troubleshooting – Excessive Spatter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

10-11 Troubleshooting – Lack Of Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING

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.

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 Principal 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 the ability to solve or resolve problems relating to the subject matter, the work, or the project and has received safety training to recognize and avoid the hazards involved.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on.

The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

� Do not touch live electrical parts.

� Wear dry, hole-free insulating gloves and body protection.

� Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground.

� Do not use AC weld output in damp, wet, or confined spaces, or if there is a danger of falling.

� Use AC output ONLY if required for the welding process.

� If AC output is required, use remote output control if present on unit.

� Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant voltage (wire) welder, 2) a DC manual

(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!

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 these hazards.

� Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to

OSHA 29 CFR 1910.147 (see Safety Standards).

� Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes.

� Always verify the supply ground — check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.

� When making input connections, attach proper grounding conductor first — double-check connections.

� Keep cords dry, free of oil and grease, and protected from hot metal and sparks.

� Frequently inspect input power cord and ground conductor for damage or bare wiring — replace immediately if damaged — bare wiring can kill.

� Turn off all equipment when not in use.

� Do not use worn, damaged, undersized, or repaired cables.

� Do not drape cables over your body.

� If earth grounding of the workpiece is required, ground it directly with a separate cable.

� Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.

� Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.

� Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be present.

� Wear a safety harness if working above floor level.

� Keep all panels and covers securely in place.

� Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.

� Insulate work clamp when not connected to workpiece to prevent contact with any metal object.

� Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process not in use.

� Use GFCI protection when operating auxiliary equipment in damp or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter power sources

AFTER removal of input power.

� Turn off unit, disconnect input power, and discharge input capacitors according to instructions in Manual before touching any parts.

OM-279299 Page 1

HOT PARTS can burn.

� Do not touch hot parts bare handed.

� Allow cooling period before working on equipment.

� To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

FLYING METAL OR DIRT can injure eyes.

� Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.

� Wear approved safety glasses with side shields even under your welding helmet.

FUMES AND GASES can be hazardous.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

� Keep your head out of the fumes. Do not breathe the fumes.

� Ventilate the work area and/or use local forced ventilation at the arc to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed.

� If ventilation is poor, wear an approved air-supplied respirator.

� Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

� Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe.

� Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

� Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

BUILDUP OF GAS can injure or kill.

� Shut off compressed gas supply when not in use.

� Always ventilate confined spaces or use approved air-supplied respirator.

ARC RAYS can burn eyes and skin.

Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld.

� Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in

Safety Standards).

� Wear approved safety glasses with side shields under your helmet.

� Use protective screens or barriers to protect others from flash, glare, and sparks; warn others not to watch the arc.

� Wear body protection made from durable, flame-resistant material

(leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

OM-279299 Page 2

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up.

Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns.

Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.

� Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

� Do not weld where flying sparks can strike flammable material.

� Protect yourself and others from flying sparks and hot metal.

� Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

� Watch for fire, and keep a fire extinguisher nearby.

� Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

� Do not cut or weld on tire rims or wheels. Tires can explode if heated. Repaired rims and wheels can fail. See OSHA 29 CFR

1910.177 listed in Safety Standards.

� Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless they are properly prepared according to AWS F4.1 and AWS A6.0 (see

Safety Standards).

� Do not weld where the atmosphere can contain flammable dust, gas, or liquid vapors (such as gasoline).

� Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards.

� Do not use welder to thaw frozen pipes.

� Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

� Wear body protection made from durable, flame-resistant material

(leather, heavy cotton, wool). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

� Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.

� After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.

� Use only correct fuses or circuit breakers. Do not oversize or bypass them.

� Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby.

� Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.

NOISE can damage hearing.

Noise from some processes or equipment can damage hearing.

� Wear approved ear protection if noise level is high.

ELECTRIC AND MAGNETIC FIELDS

(EMF) can affect Implanted Medical

Devices.

� Wearers of Pacemakers and other Implanted Medical Devices should keep away.

� Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations.

CYLINDERS can explode if damaged.

Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode.

Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

� Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.

� Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.

� Keep cylinders away from any welding or other electrical circuits.

� Never drape a welding torch over a gas cylinder.

� Never allow a welding electrode to touch any cylinder.

� Never weld on a pressurized cylinder — explosion will result.

� Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

� Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when opening the valve.

� Keep protective cap in place over valve except when cylinder is in use or connected for use.

� Use the proper equipment, correct procedures, and sufficient number of persons to lift, move, and transport cylinders.

� Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.

1-3.

Additional Hazards For Installation, Operation, And Maintenance

MOVING PARTS can injure.

� Keep away from moving parts.

� Keep away from pinch points such as drive rolls.

FIRE OR EXPLOSION hazard.

� Do not install or place unit on, over, or near combustible surfaces.

� Do not install unit near flammables.

� Do not overload building wiring - be sure power supply system is properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

� Use lifting eye to lift unit and properly installed accessories only, NOT gas cylinders. Do not exceed maximum lift eye weight rating (see

Specifications).

� Use correct procedures and equipment of adequate capacity to lift and support unit.

� If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

� Keep equipment (cables and cords) away from moving vehicles when working from an aerial location.

� Follow the guidelines in the Applications Manual for the Revised

NIOSH Lifting Equation (Publication No. 94-110) when manually lifting heavy parts or equipment.

OVERUSE can cause

OVERHEATING.

� Allow cooling period; follow rated duty cycle.

� Reduce current or reduce duty cycle before starting to weld again.

� Do not block or filter airflow to unit.

FLYING SPARKS can injure.

� Wear a face shield to protect eyes and face.

� Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

� Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

� Put on grounded wrist strap BEFORE handling boards or parts.

� Use proper static-proof bags and boxes to store, move, or ship PC boards.

WELDING WIRE can injure.

� Do not press gun trigger until instructed to do so.

� Do not point gun toward any part of the body, other people, or any metal when threading welding wire.

BATTERY EXPLOSION can injure.

� Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.

MOVING PARTS can injure.

� Keep away from moving parts such as fans.

� Keep all doors, panels, covers, and guards closed and securely in place.

� Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary.

� Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.

READ INSTRUCTIONS.

� Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.

� Use only genuine replacement parts from the manufacturer.

� Perform installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and local codes.

H.F. RADIATION can cause interference.

� High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.

� Have only qualified persons familiar with electronic equipment perform this installation.

� The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.

� If notified by the FCC about interference, stop using the equipment at once.

OM-279299 Page 3

� 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.

as robots.

ARC WELDING can cause interference.

� Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors, computers, and computer-driven equipment such

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.

1-5.

Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, American Welding

Society standard ANSI Standard Z49.1. Website: http://www.aws.org

.

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute. Website: www.ansi.org

.

Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1 from

Global Engineering Documents. 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. Website: www.global.ihs.com

.

National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org

and www.sparky.org

.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-

1 from Compressed Gas Association. Website: www.cganet.com

.

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.

� 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.

For more information, go to www.P65Warnings.ca.gov

.

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2 from Canadian Standards Association. Website: www.

csagroup.org

.

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B from National Fire Protection Association.

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. Website: www.osha.gov

.

OSHA Important Note Regarding the ACGIH TLV, Policy Statement on the Uses of TLVs and BEIs.

Website: www.osha.gov

.

Applications Manual for the Revised NIOSH Lifting Equation from the

National Institute for Occupational Safety and Health (NIOSH). Website: www.cdc.gov/NIOSH .

SOM 2020–02

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.

OM-279299 Page 4

SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT

UTILISATION

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.

2-2.

Dangers relatifs au soudage à l’arc

Les symboles présentés ci-après sont utilisés tout au long du présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez vigilant et suivez les directives mentionnées afin d’éviter tout danger. Les consignes de sécurité présentées ciaprès ne font que résumer les informations contenues dans les principales normes de sécurité énumérées à la section

2-5. Veuillez lire et respecter toutes ces 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.

Au cours de l’utilisation, tenir toute personne à l’écart et plus particulièrement les enfants.

UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort.

Le contact d’organes électriques sous tension peut provoquer des accidents mortels ou des brûlures graves. Le circuit de l’électrode et de la pièce est sous tension lorsque le courant est délivré à la sortie. Le circuit d’alimentation et les circuits internes de la machine sont également sous tension lorsque l’alimentation est sur Marche. Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de commande du rouleau et toutes les parties métalliques en contact avec le fil sont sous tension électrique. Un

équipement installé ou mis à la terre de manière incorrecte ou impropre constitue un danger.

� Ne pas toucher aux pièces électriques sous tension.

� Porter des gants isolants et des vêtements de protection secs et sans trous.

� S’isoler de la pièce à couper et du sol en utilisant des housses ou des tapis assez grands afin d’éviter tout contact physique avec la pièce à couper ou le sol.

� Ne pas utiliser de sortie de soudage CA dans des zones humides ou confinées ou s’il y a un risque de chute.

� Se servir d’une source électrique à courant électrique UNIQUE-

MENT si le procédé de soudage le demande.

� Si l’utilisation d’une source électrique à courant électrique s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.

Ce groupe de symboles veut dire Avertissement! Attention! DAN-

GER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIE-

CES CHAUDES. Reportez-vous aux symboles et aux directives cidessous afin de connaître les mesures à prendre pour éviter tout danger.

� D’autres consignes de sécurité sont nécessaires dans les conditions suivantes : risques électriques dans un environnement humide ou si l’on porte des vêtements mouillés ; sur des structures métalliques telles que sols, grilles ou échafaudages ; en position coincée comme assise, à genoux ou couchée ; ou s’il y a un risque

élevé de contact inévitable ou accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC à tension constante

(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste

à souder AC à tension à vide réduite. Dans la plupart des situations, l’utilisation d’un poste à souder DC à fil à tension constante est recommandée. En outre, ne pas travailler seul !

� Couper l’alimentation ou arrêter le moteur avant de procéder

à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller l’alimentation selon la norme OSHA 29 CFR 1910.147

(voir normes de sécurité).

� Installez, mettez à la terre et utilisez correctement cet équipement conformément à son Manuel d’Utilisation et aux réglementations nationales, gouvernementales et locales.

� Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer que le fil de terre du cordon d’alimentation est bien raccordé

à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

� En effectuant les raccordements d’entrée, fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.

� Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez-les contre les étincelles et les pièces métalliques chaudes.

� Vérifier fréquemment le cordon d’alimentation et le conducteur de mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé -, le remplacer immédiatement s’il l’est -. Un fil dénudé peut entraîner la mort.

� L’équipement doit être hors tension lorsqu’il n’est pas utilisé.

� Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.

� Ne pas enrouler les câbles autour du corps.

� Si la pièce soudée doit être mise à la terre, le faire directement avec un câble distinct.

� Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre ou une électrode provenant d’une autre machine.

� Ne pas toucher des porte électrodes connectés à deux machines en même temps à cause de la présence d’une tension à vide doublée.

� N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les pièces endommagées. Entretenir l’appareil conformément à ce manuel.

OM-279299 Page 5

� Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.

� S’assurer que tous les panneaux et couvercles sont correctement en place.

� Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.

� Isoler la pince de masse quand pas mis à la pièce pour éviter le contact avec tout objet métallique.

� Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à une même borne de sortie de soudage. Débrancher le câble pour le procédé non utilisé.

� Utiliser une protection différentielle lors de l’utilisation d’un équipement auxiliaire dans des endroits humides ou mouillés.

Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée.

� Éteignez l’unité, débranchez le courant électrique, et déchargez les condensateurs d’alimentation selon les instructions indiquées dans le manuel avant de toucher les pièces.

LES PIÈCES CHAUDES peuvent provoquer des brûlures.

� Ne pas toucher à mains nues les parties chaudes.

� Prévoir une période de refroidissement avant de travailler à l’équipement.

� Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour

éviter les brûlures.

DES PIECES DE METAL ou DES

SALETES peuvent provoquer des blessures dans les yeux.

� Le soudage, l’écaillement, le passage de la pièce

à la brosse en fil de fer, et le meulage génèrent des étincelles et des particules métalliques volantes. Pendant la période de refroidissement des soudures, elles risquent de projeter du laitier.

� Porter des lunettes de sécurité avec écrans latéraux ou un écran facial.

LES FUMÉES ET LES GAZ peuvent

être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation peut être dangereux pour votre santé.

� Eloigner votre tête des fumées. Ne pas respirer les fumées.

� À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de l’arc pour l’évacuation des fumées et des gaz de soudage. Pour déterminer la bonne ventilation, il est recommandé de procéder à un prélèvement pour la composition et la quantité de fumées et de gaz auxquelles est exposé le personnel.

� Si la ventilation est médiocre, porter un respirateur anti-vapeurs approuvé.

� Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.

� Travailler dans un espace fermé seulement s’il est bien ventilé ou en portant un respirateur à alimentation d’air. Demander toujours

à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provoquant des blessures ou des accidents mortels.

S’assurer que l’air de respiration ne présente aucun danger.

� Ne pas souder dans des endroits situés à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.

OM-279299 Page 6

� 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 ACCUMULATIONS DE GAZ risquent de provoquer des blessures ou même la mort.

� Fermer l’alimentation du gaz comprimé en cas de non utilisation.

� Veiller toujours à bien aérer les espaces confinés ou se servir d’un respirateur d’adduction d’air homologué.

LES 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 et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.

� Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pour protéger votre visage et vos yeux pendant le soudage ou pour regarder (voir ANSI

Z49.1 et Z87.1 énuméré dans les normes de sécurité).

� Porter des lunettes de sécurité avec écrans latéraux même sous votre casque.

� Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc.

� Porter un équipement de protection pour le corps fait d’un matériau résistant et ignifuge (cuir, coton robuste, laine). La protection du corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.

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.

� Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir soigneusement avec des protections homologués.

� Ne pas souder dans un endroit là où des étincelles peuvent tomber sur des substances inflammables.

� Se protéger et d’autres personnes de la projection d’étincelles et de métal chaud.

� Des étincelles et des matériaux chauds du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures.

� Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.

� Le soudage effectué sur un plafond, plancher, paroi ou séparation peut déclencher un incendie de l’autre côté.

� Ne pas couper ou souder des jantes ou des roues. Les pneus peuvent exploser s’ils sont chauffés. Les jantes et les roues réparées peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans les normes de sécurité.

� Ne pas effectuer le soudage sur des conteneurs fermés tels que des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été préparés correctement conformément à AWS F4.1 et AWS A6.0

(voir les Normes de Sécurité).

� Ne pas souder là où l’air ambiant pourrait contenir des poussières, gaz ou émanations inflammables (vapeur d’essence, par exemple).

� Brancher le câble de masse sur la pièce le plus près possible de la zone de soudage pour éviter le transport du courant sur une longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.

� Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.

� En cas de non utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

� Porter un équipement de protection pour le corps fait d’un matériau résistant et ignifuge (cuir, coton robuste, laine). La protection du corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.

� Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.

� Une fois le travail achevé, assurez-vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.

� Utiliser exclusivement des fusibles ou coupe-circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

� Suivre les recommandations dans OSHA 1910.252 (a) (2) (iv) et

NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité.

� Lire et comprendre les fiches de données de sécurité et les instructions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.

LE BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peut affecter l’ouïe.

� Porter des protections approuvées pour les oreilles si le niveau sonore est trop élevé.

Les CHAMPS

ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les implants médicaux.

� Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance.

� Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approcher de la zone où se déroule du soudage à l’arc, du soudage par points, du gougeage, de la découpe plasma ou une opération de chauffage par induction.

LES BOUTEILLES peuvent exploser si elles sont endommagées.

Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.

� Protéger les bouteilles de gaz comprimé d’une chaleur excessive, des chocs mécaniques, des dommages physiques, du laitier, des flammes ouvertes, des étincelles et des arcs.

� Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou de se renverser.

� Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.

� Ne jamais placer une torche de soudage sur une bouteille à gaz.

� Une électrode de soudage ne doit jamais entrer en contact avec une bouteille.

� Ne jamais souder une bouteille pressurisée - risque d’explosion.

� Utiliser seulement des bouteilles de gaz comprimé, régulateurs, tuyaux et raccords convenables pour cette application spécifique; les maintenir ainsi que les éléments associés en bon état.

� Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors de l’ouverture de la vanne.

� Le couvercle du détendeur doit toujours être en place, sauf lorsque la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.

� Utilisez les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever, déplacer et transporter les bouteilles.

� Lire et suivre les instructions sur les bouteilles de gaz comprimé, l’équipement connexe et le dépliant P-1 de la CGA (Compressed

Gas Association) mentionné dans les principales normes de sécurité.

2-3.

Symboles de dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU

D’EXPLOSION.

� Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables.

� Ne pas installer l’appareil à proximité de produits inflammables.

� Ne pas surcharger l’installation électrique - s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures.

� Utiliser l’anneau de levage uniquement pour soulever l’appareil, NON PAS les chariots, les bouteilles de gaz ou tout autre accessoire.

� Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter l’appareil.

� En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

� Tenir l’équipement (câbles et cordons) à distance des véhicules mobiles lors de toute opération en hauteur.

OM-279299 Page 7

� Suivre les consignes du Manuel des applications pour l’équation de levage NIOSH révisée (Publication Nº94– 110) lors du levage manuelle de pièces ou équipements lourds.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

� Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.

� Réduire le courant ou le facteur de marche avant de poursuivre le soudage.

� Ne pas obstruer les passages d’air du poste.

LES ÉTINCELLES PROJETÉES peuvent provoquer des blessures.

� Porter un écran facial pour protéger le visage et les yeux.

� Affûter l'électrode au tungstène uniquement à la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l'on porte l'équipement homologué de protection du visage, des mains et du corps.

� Les étincelles risquent de causer un incendie - éloigner toute substance inflammable.

LES CHARGES

ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.

� Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces.

� Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprimes.

Les PIÈCES MOBILES peuvent causer des blessures.

� Ne pas s’approcher des organes mobiles.

� Ne pas s’approcher des points de coincement tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent provoquer des blessures.

� Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction.

� Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.

L’EXPLOSION DE LA BATTERIE peut provoquer des blessures.

� Ne pas utiliser l’appareil de soudage pour charger des batteries ou faire démarrer des véhicules à l’aide de câbles de démarrage, sauf si l’appareil dispose d’une fonctionnalité de charge de batterie destinée à cet usage.

Les PIÈCES MOBILES peuvent causer des blessures.

� S’abstenir de toucher des organes mobiles tels que des ventilateurs.

� Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.

� Lorsque cela est nécessaire pour des travaux d’entretien et de dépannage, faire retirer les portes, panneaux, recouvrements ou dispositifs de protection uniquement par du personnel qualifié.

� Remettre les portes, panneaux, recouvrements ou dispositifs de protection quand l’entretien est terminé et avant de rebrancher l’alimentation électrique.

LIRE LES INSTRUCTIONS.

� Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section.

� N’utiliser que les pièces de rechange recommandées par le constructeur.

� Effectuer l’installation, l’entretien et toute intervention selon les manuels d’utilisateurs, les normes nationales, provinciales et de l’industrie, ainsi que les codes municipaux.

LE RAYONNEMENT HAUTE

FRÉQUENCE (H.F.) risque de provoquer des interférences.

� Le rayonnement haute fréquence (H. F.) peut provoquer des interférences avec les équipements de radio-navigation et de communication, les services de sécurité et les ordinateurs.

� Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.

� L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation.

� Si le FCC signale des interférences, arrêter immédiatement l’appareil.

� Effectuer régulièrement le contrôle et l’entretien de l’installation.

� Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les interférences éventuelles.

LE SOUDAGE À L’ARC risque de provoquer des interférences.

� 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.

� Veiller à ce que tout l’équipement de la zone de soudage soit compatible électromagnétiquement.

� Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas que possible (ex. par terre).

� Veiller à souder à une distance de 100 mètres de tout équipement

électronique sensible.

� Veiller à ce que ce poste de soudage soit posé et mis à la terre conformément à ce mode d’emploi.

� En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.

OM-279299 Page 8

2-4.

Proposition californienne 65 Avertissements

Pour plus d’informations, consulter www.P65Warnings.ca.gov

.

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.

2-5.

Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, American Welding

Society standard ANSI Standard Z49.1. Website: http://www.aws.org

.

Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute. Website: www.ansi.org

.

Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1 from

Global Engineering Documents. 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. Website: www.global.ihs.com

.

National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org

and www.sparky.org

.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-

1 from Compressed Gas Association. Website: www.cganet.com

.

Safety in Welding, Cutting, and Allied Processes, CSA Standard

W117.2 from Canadian Standards Association. Website: www.

csagroup.org

.

Standard for Fire Prevention During Welding, Cutting, and Other Hot

Work, NFPA Standard 51B from National Fire Protection Association.

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. Website: www.osha.gov

.

OSHA Important Note Regarding the ACGIH TLV, Policy Statement on the Uses of TLVs and BEIs.

Website: www.osha.gov

.

Applications Manual for the Revised NIOSH Lifting Equation from the

National Institute for Occupational Safety and Health (NIOSH). Website: www.cdc.gov/NIOSH .

SOM_fre 2020–02

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: par exemple, des restrictions d’accès pour les passants ou une évaluation individuelle des risques 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 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.

OM-279299 Page 9

Do not work on unit if engine is running. Stop engine first.

Safe21 2017 04

Do not smoke while fueling or if near fuel.

Safe22 2017 04

Stop engine before fueling.

Safe23 2017 04

�

Complete Parts List is available at www.MillerWelds.com

SECTION 3 – DEFINITIONS

Do not fuel a hot engine.

3-1.

Additional Safety Symbol Definitions

Safe75 2017 04

Safe24 2017 04

Warning! Watch Out! There are possible hazards as shown by the symbols.

Safe82 2012 07

Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift eye ing voltage during operation - keep hands and metal objects away.

When power is applied failed parts can explode or cause other parts to explode.

to explode.

Safe7 2017 04

Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.

Safe40 2012 05

Hazardous voltage remains on input capacitors after power is turned

Hazardous voltage remains on input capacitors after power is turned

Always wear long sleeves and button your collar when servicing unit.

power is turned off before working on unit, AND check input capacitor voltage, and be sure it is near 0 before touching any parts.

3-2.

Miscellaneous Symbols And Definitions

After taking proper precautions as shown, connect power to unit.

Amperage voltage, and be sure it is near 0 before touching any parts.

Input Power Or

Input Voltage

Positive

=< 60

°

Voltage

Disconnect input plug or power before working on machine.

Negative

A complete Parts List is available at www.MillerWelds.com

Rated No-Load

Voltage

Input Protection

SECTION 3 DEFINITIONS

Duty Cycle

Direct Current

(DC)

Single Phase Line Connection

3-1.

Miscellaneous Symbols And Definitions

A

V

%

Suitable for Welding in an Environment

Percent

of Electric Shock

Voltage

Rated Supply

Voltage

Negative

Wire Diameter

Foot Control

Safe46 2012 05

Safe55 2012 05

Increase

On

Read Owner’s Manual. Read labels on unit.

Output

Conventional Load

Off

Single Phase

Hertz

Safe47 2012 05

Positive

Current

Voltage Input

inside label. Double-check all connections, jumper link positions, and

Welding

Become trained and read the instructions before working on the machine or welding.

Lift-Arc Operation

(GTAW)

OM-279299 Page 10

Line Connection

Plugged filter or hoses can cause overheating to the power source and torch.

Notes

Induction heating can cause injury or burns from hot items such as rings, watches, or parts.

Safe50 2012 05

Safe74 2012 07

Every 100 hours, check and clean filter and check condition of hoses.

Safe51 2012 05

OM-

Use coolant suggested by the manufacturer.

Safe52 2012 05

°

Falling unit can cause injury. Do not move or operate unit where it could tip.

Safe53 2017 04

OM-

Safe27 2012 05

Safe28 2012 05

Safe29 2012 05

Safe30 2012 05

OM-

OM-

OM-285986 Page 9

Wire Type

�

Complete Parts List is available at www.MillerWelds.com

Self Shielded Flux

Cored Arc Welding

(FCAW)

Wire Feed Spool

Gun

Gas Metal Arc

Welding (GMAW)

Gas Metal Arc

Welding (GMAW)

MIG/Gun Control

Gas Postflow

Gas Preflow

Cold Jog (Inch) Toward Workpiecel

Pulse

OM-279299 Page 11

�

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.

Software Licensing Agreement

The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at https://www.millerwelds.com/eula and are incorporated by reference herein.

4-3.

Information About Default Weld Parameters And Settings

NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only; and final weld results can be affected by other variables and application-specific circumstances. The appropriateness of all parameters and settings should be evaluated and modified by the end user as necessary based upon application-specific requirements. The end user is solely responsible for selection and coordination of appropriate equipment, adoption or adjustment of default weld parameters and settings, and ultimate quality and durability of all resultant welds. Miller Electric expressly disclaims any and all implied warranties including any implied warranty of fitness for a particular purpose.

4-4.

Unit Specifications For MIG (GMAW)

�

Do not use information in unit specifications table to determine electrical service requirements. See Section , 5-3, for information on con-

necting input power.

Rated Welding Output Amperage Range

Maximum Open-Circuit

Voltage DC

Amperes Input at Rated Load Output, 50/60 Hz, Single-Phase

208 VAC 240 VAC

260 A at 27 Volts DC,

40% Duty Cycle

230 A at 25.5 Volts DC,

60% Duty Cycle

20–350

20–350

87

87

47.8

40.6

41.1

35

Solid Steel .

.024 - .045 in.

(0.6 - 1.2 mm)

Wire Type And Diameter

Flux Cored

.035 - .045 in.

(0.9 - 1.2 mm)

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.

B. Temperature Specifications

Operating Temperature Range *

-22 to 122°F (-30 to 50°C)

*Output is derated at temperatures above 104°F (40°C).

Aluminum

.035 - .047 in.

(0.9 - 1.3 mm)

Dual Shield

.045 in. (1.2 mm)

Wire Weed Speed

Range

50 - 800 IPM

(1.2 - 17.8 m/min)

Storage/Transportation Temperature Range

-40 to 149°F (-40 to 65°C)

OM-279299 Page 12

�

Complete Parts List is available at www.MillerWelds.com

4-6.

Dimensions And Weight

Weight

84 lb (38.1 kg)

13.75 in.

(349 mm)

19.25 in.

(489 mm)

26.25 in.

(667 mm)

OM-279299 Page 13

�

Complete Parts List is available at www.MillerWelds.com

4-7.

Duty Cycle And Overheating

Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.

If unit overheats, output stops. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before starting to weld again.

NOTICE – Exceeding duty cycle can damage unit and void warranty.

60% Duty Cycle At 230A

6 Minutes Welding

40% Duty Cycle At 260A

4 Minutes Resting

4 Minutes Welding

Overheating

6 Minutes Resting

0 A or V

15

OR

Reduce Duty Cycle

Minutes

4-8.

Static Characteristics

The static (output) characteristics of the welding power source can be described as flat during the GMAW process and drooping during the

SMAW and GTAW processes. Static characteristics are also affected by control settings (including software), electrode, shielding gas, weldment material, and other factors. Contact the factory for specific information on the static characteristics of the welding power source.

OM-279299 Page 14

�

Complete Parts List is available at www.MillerWelds.com

SECTION 5 – INSTALLATION

5-1.

Selecting A Location

Movement

1

A complete Parts List is available at www.MillerWelds.com

Do not move or operate unit where it could tip.

Special installation may be required where gasoline or volatile liquids are present - see NEC Article 511 or CEC Section 20.

1 Lifting Handles

Use handles to lift unit.

2 Line Disconnect Device

Locate unit near correct input power supply.

A complete Parts List is available at www.MillerWelds.com

Location And Airflow

2

18 in.

(460 mm)

18 in.

(460 mm) loc_smallmig2 2018-09 161-122 loc_smallmig2 2018-09 161-122

OM-279299 Page 3

OM-279299 Page 3

OM-279299 Page 15

�

Complete Parts List is available at www.MillerWelds.com

5-2.

Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations are for an individual branch circuit sized for the rated output and duty cycle of one welding power source. In individual branch 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.

NOTICE – Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input voltage is outside this range, output may not be available.

Rated Supply Voltage (V)

Rated Maximum Supply Current I

1max

(A)

Rated Effective Supply Current I

1eff

(A)

Maximum Recommended Standard Fuse Rating In Amperes 1

Time Delay Fuses 2

Normal Operating Fuses 3

Maximum Recommended Supply Conductor Length In Feet (Meters) 4

Raceway Installation

Minimum Supply Conductor Size In AWG (mm 2 ) 5

Minimum Grounding Conductor Size In AWG (mm 2 ) 5

Reference: 2020 National Electrical Code (NEC) (including article 630)

50/60 Hz 1-Phase

208

86.9

34.1

90

100

54 (17)

8 (10)

8 (10)

50/60 Hz 1-Phase

240

74.6

30.8

80

90

73 (22)

8 (10)

8 (10)

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 Maximum total length of copper input conductors in entire installation, raceway and/or flexible cord.

5 Raceway 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 75°C (167°F) with not more than three single current-carrying conductors in a raceway.

OM-279299 Page 16

allen_wrench allen_set

�

Complete Parts List is available at www.MillerWelds.com

5-3.

Connecting 1-Phase Input Power

L2 flathead

240 VAC, 1

NGO’s tools/

L1

3

6

1

1

2

8

9

7

=GND/PE Earth Ground

4

L1

L2

5

Installation must meet all National and Local Codes—have only qualified persons make this installation.

Disconnect and lockout/tagout input power before connecting input conductors from unit. Follow established procedures regarding the installation and removal of lockout/tagout devices.

Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal.

See rating label on unit and check input voltage available at site.

1 Input Power Cord

2 Disconnect Device (switch shown in the

OFF position)

3 Disconnect Device Grounding Terminal

4 Disconnect Device Line Terminals

5 Black And White Input Conductor (L1

And L2)

6 Green Or Green/Yellow Grounding

Conductor

Connect green or green/yellow grounding conductor to disconnect device grounding terminal first.

Connect input conductors L1 and L2 to disconnect device line terminals.

7 Over-Current Protection

Select type and size of over-current protection using Electrical Service Guide (fused disconnect switch shown).

8 Receptacle (NEMA 6– 50R) Customer

Supplied

9 Plug and Power Cord (NEMA Type 6–

50P Plug Shown)

Close and secure door on disconnect device.

Follow established lockout/tagout procedures to put unit in service.

Ref. Input13 2015−08 philips head wrench crescent wrench pliers needlenose knife steelbrush nutdriver chippinghammer solderiron stripcrimp heavy-duty workclamp light-duty workclamp wirecutter frontcutter

OM-279299 Page 17 torque screwdriver torque wrench socket wrench drill strapwrench airgun hammer handream awl greasegun file filterwrench paintbrush qtip (swab) vicegrip crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench

OM-222 Page 1

�

Complete Parts List is available at www.MillerWelds.com

5-4.

Wiring Optional 240 Volt Plug (119172) For Connection To Miller Welder/Generator

With Split-Phase 240 Volt Auxiliary Power

3 (Not Used)

4

5

6

Plug Front

View

7

4

3

2

240V

8

6

5

1 Input And Grounding Conductors

2 Plug wired for 240 Volt, 2–wire Load

3 Neutral (Brass) Terminal and Prong (Not

Used)

4 Load 1 (Brass) Terminal and Prong

5 Load 2 (Brass) Terminal and Prong

6 Ground (Brass) Terminal and Prong

7 Black and White Input Conductors

8 Green

Conductor or Green/Yellow Ground

Always connect green or green/ yellow wire to ground terminal, never to a load terminal. Connect black (L1) and white (L2) wires to load terminals.

allen_wrench allen_set

1

NGO’s

7 tools/

8

Green Or

Green/Yelflathead philips head wrench crescent wrench allen_wrench allen_set pliers

NGO’s tools/ needlenose knife steelbrush

Ref. 120 813-D / 907734 nutdriver chippinghammer wirecutter frontcutter pliers needlenose solderiron stripcrimp knife nutdriver torque wrench

OM-279299 Page 18 socket wrench drill chippinghammer heavy-duty workclamp light-duty workclamp wirecutter greasegun filterwrench strapwrench hammer awl airgun torque screwdriver torque wrench socket wrench drill qtip (swab) handream vicegrip greasegun crimper filterwrench feelergauge flashlight file paintbrush ruler strapwrench airgun qtip (swab) vicegrip hammer toothbrush awl punch file solvent paintbrush pinextractor eprompuller pipewrench

OM-222 Page 1 crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench

OM-222 Page 1

�

Complete Parts List is available at www.MillerWelds.com

5-5.

Generator Or Inverter Requirements

1 2

Set Engine Control Switch to Run position, not Run/Idle.

Set generator Voltage/Amperage

Control to 10 (or max) for maximum auxiliary power.

For maximum output, Miller recommends a

12 kW or greater generator.

Generator Settings, if applicable.

1 Engine Control Switch Setting

2 Generator Amperage/Voltage Control

Setting

5-6.

Selecting Cable Sizes

NOTICE – The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

Welding

Amperes

100

150

200

250

300

350

400

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding***

100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m)

350 ft

(105 m)

10 - 60%

Duty Cycle

AWG (mm 2 )

60 - 100%

Duty Cycle

AWG (mm 2 )

10 - 100% Duty Cycle AWG (mm 2 )

4 (20)

3 (30)

3 (30)

2 (35)

1 (50)

1/0 (60)

1/0 (60)

4 (20)

3 (30)

2 (35)

1 (50)

1/0 (60)

2/0 (70)

2/0 (70)

4 (20)

2 (35)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

3/0 (95)

3 (30)

1 (50)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

4/0 (120)

2 (35)

1/0 (60)

2/0 (70)

3/0 (95)

4/0 (120)

2x2/0 (2x70)

2x2/0 (2x70)

1 (50)

2/0 (70)

2x3/0 (2x95)

2x3/0 (2x95)

1/0 (60)

3/0 (95)

2x3/0 (2x95)

2x4/0

(2x120)

400 ft

(120 m)

1/0 (60)

3/0 (95)

3/0 (95)

4/0 (120)

4/0 (120)

2x2/0 (2x70)

4/0 (120)

2x2/0 (2x70)

2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)

2x4/0

(2x120)

2x4/0

(2x120)

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

( ) = mm 2 for metric use.

***For distances longer than those shown in this guide, see AWS Fact Sheet No. 39, Welding Cables, available from the American Welding

Society at http://www.aws.org

.

OM-279299 Page 19

OM-253555 Page 1

�

Complete Parts List is available at www.MillerWelds.com

5-7.

Weld Output Terminals

Turn off unit and disconnect input power before making connections.

Do not use worn, damaged, undersized, or repaired cables.

1 Positive (+) Weld Output Terminal

2 Negative (-) Weld Output Terminal

See Section 5-9 for information on connect-

ing to weld output terminals and standard connection diagrams.

2

1 output term1 2015−02

5-8.

Process/Polarity Table

Polarity Process

GMAW — Solid wire with shielding gas

FCAW—S — Selfshielding wire-no shielding gas

FCAW—G — Fluxcored wire with shielding gas

DCEP — Reverse Polarity

DCEN — Straight Polarity

DCEP — Reverse Polarity

Cable Connections

Wire Drive Assembly Cable

Connect to positive (+) output receptacle

Work Cable

Connect to negative (-) output receptacle

Connect to negative (-) output receptacle

Connect to positive (+) output receptacle

Connect to positive (+) output receptacle

Connect to negative (-) output receptacle

OM-279299 Page 20

�

Complete Parts List is available at www.MillerWelds.com

5-9.

MIG Welding Connections

4

3

2

1

MIG/FCAW-G − DCEP

(Direct Current Electrode Positive)

4

3 2

1

FCAW-S − DCEN

(Direct Current Electrode Negative)

8

5

7

6

280401B / Ref. 275167A / 282987A

Turn off unit and disconnect input power before making connections.

Do not use worn, damaged, undersized, or repaired cables.

1 Positive Weld Output Receptacle

2 Negative Weld Output Receptacle

3 Wire Drive Assembly Cable

4 Work Clamp And Cable

Ensure all connections are tight.

5 Gun End

Connect gun end to drive assembly (see

Section 5-10).

Connect plug on end of cable to four pin receptacle inside unit.

8 MIG Shielding Gas Connection

6 Trigger Control Cable

7 Four Pin Trigger Control Cable

Receptacle

Connect supplied gas hose between regulator/flowmeter gas hose connection and fitting on rear panel of power source (see

Section ).

Route trigger control cable through MIG gun hole.

OM-279299 Page 21

�

Complete Parts List is available at www.MillerWelds.com

5-10. MIG Gun Connection Inside Unit

3

4

1 Gun Securing Knob

2 Gun Block

3 Gun Outlet Wire Guide

4 Gun End

Loosen knob. Insert end of gun through opening in front panel until gun end bottoms against gun block.Tighten knob.

�

Be sure that gun end is tight against drive assembly.

Correct

1 2

4

Incorrect

4

OM-279299 Page 22

282950A

allen_wrench

�

Complete Parts List is available at www.MillerWelds.com

5-11. Connecting Shielding Gas Supply

1

2

4

2

3

1 allen_set

11

10

6

9

7

NGO’s tools/

8 flathead

1

2

5

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.

3 Mixed Gas Cylinder

4 CO

2

Gas Cylinder

5 Argon Gas Cylinder

6 Regulator/Flowmeter

Install so face is vertical.

7 Regulator/Flowmeter

Connection

Gas

8 Welding Power Source CO

2

Gas Hose Connection

Hose

And Mixed

Connect gas hose between regulator/flowmeter gas hose connection, and the appropriate fitting for the gas type on rear of welding power source.

9 Flow Adjust

Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. Typical flow rate for CO

2

. shielding gas and MIG

(GMAW) welding is 15 to 30 CFH (cubic feet per hour) and mixed gas is 25 to 45 CFH.

10 CO

2

Adapter (Customer Supplied)

11 O-Ring (Customer Supplied)

Install adapter with O-ring between regulator/flowmeter and CO

2 cylinder.

philips head wrench crescent wrench pliers needlenose knife steelbrush nutdriver

Ref. 804 654-A / 282987A chippinghammer solderiron stripcrimp heavy-duty workclamp light-duty workclamp wirecutter frontcutter torque screwdriver torque wrench socket wrench drill strapwrench airgun hammer handream awl greasegun file filterwrench paintbrush

OM-279299 Page 23 qtip (swab) vicegrip crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench

OM-222 Page 1

�

Complete Parts List is available at www.MillerWelds.com

5-12. Installing Wire Spool And Adjusting Hub Tension

Installing 8 in. (203 mm) Wire Spool

Hand tighten knob clockwise. When a slight force is needed to turn spool, tension is set

Removing 8 in. (203 mm) Spool Hub And Spool Nut

1

2

1 Spindle

2 Spool Hub And Nut — For 8 in. (203 mm)

Spool Only

3 Spindle Hardware

Remove spindle hardware and retain. Remove spool hub and spool nut and retain for future use.

Installing 4 in. (102 mm) Wire Spool

4

5

6

3

7

4 Spindle

5 Washer, Flat

Order two additional flat washers (Part

No. 605941).

6 Spring, Compression

Order one additional spring (Part No.

186437).

7 Spindle Hardware

Install Spindle hardware on spindle in exact order as shown and tighten slightly.

OM-279299 Page 24

�

Complete Parts List is available at www.MillerWelds.com

5-13. Threading Welding Wire

4

7

1

1

2

2 3 5

6 in.

(150 mm)

6

3 allen_wrench allen_set

NGO’s tools/ flathead

4 philips head wrench crescent wrench

3

4

1

2

5 6

8

9 pliers needlenose knife steelbrush nutdriver

7 chippinghammer

1

2

3

4

WOOD solderiron torque screwdriver torque wrench stripcrimp socket wrench heavy-duty workclamp drill light-duty workclamp 1 wirecutter

2 Welding Wire

3 Inlet Wire Guide frontcutter

4 Pressure Adjustment Knob

5 Drive Roll

6 Outlet Wire Guide

7 Gun Conduit Cable

Lay gun cable out straight.

Step 1.

Open pressure assembly.

Step 2.

Pull and hold wire; cut off end.

greasegun filterwrench

�

Hold wire tightly to keep it from unraveling.

Step 3.

Push wire through guides into gun; continue to hold wire.

Step 4.

Close and tighten pressure assembly, and let go of wire.

�

Use pressure indicator scale to set a desired drive roll pressure. Begin with a setting of 2. If necessary, make additional adjustments after trying this initial setting.

Step 5.

Remove gun nozzle and contact tip.

Step 6.

Turn On.

Step 7.

Press gun trigger until wire comes out of gun. Reinstall contact tip and nozzle.

Step 8.

Feed wire to check drive roll pressure. Tighten knob enough to prevent slipping.

Step 9.

Cut off wire. Close and latch door.

OM-279299 Page 25 handream strapwrench airgun hammer awl file paintbrush qtip (swab) vicegrip crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench

OM-222 Page 1

�

Complete Parts List is available at www.MillerWelds.com

5-14. Connecting Spoolmatic

®

15A Or 30A Or Spoolmate 200 Gun

2

7

6

5

2 allen_wrench pliers allen_set needlenose knife

NGO’s tools/ flathead philips head wrench crescent wrench 9

8 3

4

1 steelbrush nutdriver chippinghammer

282999 3 solderiron torque screwdriver torque wrench stripcrimp socket wrench heavy-duty workclamp drill light-duty workclamp

1 wirecutter frontcutter

Insert plug into receptacle, and tighten threaded collar.

2 Weld Cable

3 Shielding Gas Hose

Route weld cable and gas hose through opening in panel.

4 Drive Casting greasegun filterwrench

Remove the 3/4 in. bolt from the drive casting. Use bolt to connect spoolgun weld cable to drive casting.

5 1/2-13 x 3/4 in. Bolt (282942)

6 Lock Washer (602216)

7 Washer (602247)

8 Gas Hose Routing Hole

To route gas hose through rear panel, drill 1 in. hole through bottom of rear plastic bezel.

Align drill with pilot dimple in plastic bezel visible from inside wire drive compartment.

9 Gas Hose Fitting

Route shielding gas hose through wire drive compartment, out opening in rear panel, and up to regulator/flowmeter. Connect gas hose fitting to regulator/flowmeter.

handream strapwrench airgun hammer awl

OM-279299 Page 26 file paintbrush qtip (swab) vicegrip crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench

OM-222 Page 1

�

Complete Parts List is available at www.MillerWelds.com

5-15. Connecting XR-Aluma-Pro Or XR-Aluma-Pro-Lite

allen_wrench allen_set

3/32 in.

(2.4 mm)

NGO’s tools/ flathead philips head wrench

2

3 crescent wrench

1 pliers needlenose knife steelbrush nutdriver chippinghammer

5

4

803463 / 282952A solderiron stripcrimp torque screwdriver torque wrench socket wrench heavy-duty workclamp light-duty workclamp

1 wirecutter frontcutter

2 Gun Liner

3 Wire Outlet Guide

Trim excess liner from end of gun so no more than 3/32 in. (2.4 mm) of liner extends past wire outlet guide

4 Gun Securing Knob

Loosen securing knob. Insert gun end through opening until it bottoms against drive assembly (make sure gun end does not touch drive rolls). Tighten knob.

Be sure to change drive rolls to the proper size and type.

5 Gun Trigger Plug

Insert plug into receptacle, and tighten threaded collar.

drill greasegun filterwrench handream strapwrench airgun hammer awl file paintbrush

OM-279299 Page 27 qtip (swab) vicegrip crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench

OM-222 Page 1

�

Complete Parts List is available at www.MillerWelds.com

5-16. Threading Welding Wire For XR-Aluma-Pro Or XR-Aluma-Pro Lite

1

2

6 in.

(150 mm)

4

1

2

3

4

3 allen_wrench allen_set

NGO’s tools/ flathead philips head wrench crescent wrench

5

6 pliers needlenose knife steelbrush nutdriver chippinghammer

NGO’s tools/ solderiron torque screwdriver torque wrench stripcrimp socket wrench heavy-duty workclamp allen_wrench pliers drill light-duty workclamp allen_set needlenose wirecutter frontcutter knife flathead philips head

Step 1.

Open pressure assembly.

Step 2.

Pull and hold wire; cut off end.

wrench crescent wrench

�

Use pressure indicator scale to set a desired drive roll pressure. Begin with a setting of 2. If necessary, make addi-

�

Hold wire tightly to keep it from unraveling.

tional adjustments after trying this initial setting.

Step 4.

steelbrush bly, and let go of wire.

Step 5.

Turn on power switch.

Step 3.

Push wire through guides into gun; continue to hold wire.

Step 6.

Open top cover and open pressure roll assembly.

nutdriver greasegun filterwrench

OM-279299 Page 28

Press gun trigger until about 4 in. (102 mm) of wire is sticking out front of gun. Install nozzle and contact tip.

Close top cover on gun. Press trigger switch until about 6 in. (152 mm) of wire is sticking out end of contact tip. Cut off wire.

�

XR-Aluma-Pro and XR-Aluma-Pro Lite gun drive roll pressure should be set to match the alloy being used.

solderiron handream stripcrimp heavy-duty workclamp light-duty workclamp wirecutter frontcutter strapwrench qtip (swab) airgun vicegrip hammer awl torque screwdriver torque wrench crimper socket wrench feelergauge drill flashlight file paintbrush ruler handream greasegun filterwrench toothbrush punch pinextractor airgun eprompuller hammer pipewrench awl

OM-222 Page 1 file paintbrush qtip (swab) vicegrip crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench

OM-222 Page 1

allen_wrench allen_set

�

Complete Parts List is available at www.MillerWelds.com

5-17. Threading Welding Wire For Spoolmate 200

7

6

5

3

1 NGO’s tools/ flathead philips head wrench crescent wrench

2

9

4 pliers needlenose knife steelbrush nutdriver chippinghammer

8

Ref. 243 740-C solderiron torque screwdriver torque wrench stripcrimp socket wrench heavy-duty workclamp drill light-duty workclamp

1 wirecutter frontcutter

2 Canister

3 Thumbscrew (Cover)

Loosen thumbscrew, and rotate cover open.

4 Wire Spool

Loosen wire from spool, cut off bent wire, and pull 6 in (150 mm) of wire off spool.

5 Pressure Roll Assembly

Press arm inward to open pressure roll assembly.

6 Wire Inlet Guide

7 Drive Roll Groove

8 Contact Tip

Thread wire through wire inlet guide, along drive roll groove, and out contact tip.

Install spool so wire feeds off top.

9 Spool Brake Thumbnut

If necessary, turn thumbnut counterclockwise slightly to install spool.

Close cover and secure with thumbscrew.

greasegun filterwrench handream strapwrench airgun hammer awl file paintbrush

OM-279299 Page 29 qtip (swab) vicegrip crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench

OM-222 Page 1

�

Complete Parts List is available at www.MillerWelds.com

5-18. Threading Welding Wire For Spoolmatic 15/30A

6

8 7 allen_wrench allen_set

NGO’s tools/ flathead philips head wrench crescent wrench

1

11

2

10

3 pliers needlenose knife steelbrush nutdriver chippinghammer

9

5

150 436-F

4 solderiron torque screwdriver torque wrench stripcrimp socket wrench heavy-duty workclamp drill light-duty workclamp

1 wirecutter frontcutter

2 Canister

3 Canister Cover

4 Thumbscrew (Canister Cover)

Loosen thumbscrew, and remove cover.

5 Wire Spool

Loosen wire from spool, cut off bent wire, and pull 6 in (150 mm) of wire off spool.

greasegun filterwrench

6 Pressure Roll Assembly

Lift arm and open pressure roll assembly.

7 Canister Inlet Guide

8 Drive Roll Groove

For wire sizes .035 in. (0.9 mm) and smaller use small groove, and .047 in.

(1.2 mm) and 1/16 in (1.6 mm) use large groove.

9 Contact Tip

Install spool so wire feeds off bottom.

10 Spool Brake Thumbnut

If necessary, turn thumbnut counterclockwise slightly to install spool.

11 Thumbscrew (Canister Rotation)

Thread wire through canister inlet guide, along drive roll groove, and out contact tip.

Loosen thumbscrew to rotate canister.

Close and secure pressure roll assembly

Reinstall top cover and canister cover.

handream strapwrench airgun hammer qtip (swab) vicegrip awl file paintbrush crimper

OM-279299 Page 30 feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench

OM-222 Page 1

�

Complete Parts List is available at www.MillerWelds.com

5-19. Calibrating Spoolgun

2

4

1

5

3

6

7

�

Spoolmatic 15/30A and Spoolmate

200 motors are unique to this welding power source. Motor calibration is necessary any time a different Spoolmatic

15/30A or Spoolmate 200 is connected to the Multimatic 255.

1 Settings Menu

2 Slow Speed Calibration Menu

3 Fast Speed Calibration Menu

4 Home

5 Spg Cal (Spoolgun Cal)

6 Right Knob

7 Gun Type

8 Next

9 Save

8

Connect spoolgun to unit. Cut wire flush at nozzle

Follow instructions in Section 6-5 to enter

the setup menu.

�

SPG CAL will only be displayed as the fifth tab when a spoolgun is connected.

Press SPG CAL to access slow speed calibration menu.

Press Gun Type to select the spoolgun being used.

To begin the slow speed calibration, pull the spoolgun trigger. The wire will feed and automatically stop.

Cut wire flush at nozzle and measure runout. If wire length is not 24 in., use right knob to enter the amount that the wire was short/ long.

297061-D

9

Pull spoolgun trigger again to verify the adjustment. Repeat these steps until satisfied with accuracy.

Press Next to access fast speed calibration.

To begin the fast speed calibration, pull the spoolgun trigger. The wire will feed wire and automatically stop.

Cut wire flush at nozzle and measure runout. If wire length is not 24 in., use right knob to enter the amount that the wire was short/ long.

Pull spoolgun trigger again to verify the adjustment. Repeat these steps until satisfied with accuracy.

Press Save to complete the calibration procedure and be returned back to the settings menu.

Press Home to return to weld mode.

OM-279299 Page 31

6-1.

Controls

�

Complete Parts List is available at www.MillerWelds.com

SECTION 6 – OPERATION

1 2

3

4

6 5

7

297061-D

8

1 Auto-Set Button

Press to turn Auto-Set On or Off.

2 Pulse Button

Press to turn Pulse On or Off in the MIG process.

3 USB Port

Use for software upgrade and collecting error codes.

4 Power Switch

Use switch to turn unit On or Off.

The USB port can be used to charge cell phones and similar devices.

5 Color LCD Display

6 Left Knob

Use left knob to adjust voltage in MIG mode,

Arc length in Pulsed MIG mode, or change parameter values in Set-up mode.

7 Right Knob

Use right knob to adjust wire feed speed or change parameter values in Set-up mode.

8 Soft Keys

Multiple functions depending on which screen is being displayed.

OM-279299 Page 32

�

Complete Parts List is available at www.MillerWelds.com

6-2.

Special Features

MIG Mode

Jog Mode

In MIG mode, the left knob is used to adjust welding voltage within a range of 12 to 32 volts. The right knob is used to adjust wire feed speed within a range of 50 to 800 IPM. Refer to weld chart inside the wire drive compartment for proper parameter settings according to wire type, shielding gas, and material type and thickness.

If gun trigger is pressed and held for more than 3 seconds without striking an arc, unit will automatically shut off weld power and shielding gas. Trigger error will be displayed after preset length of wire is fed, dependent on MIG gun selected.

Weld Status When trigger is released on a MIG gun, spool gun, or push-pull gun, the last actual amperage and voltage are shown on the display for 5 seconds. If a programmed value requires adjustment after the arc is extinguished and during the 5-second display of actual values, turning either knob will cause actual values in the displays to be replaced by programmed values for adjustment purposes.

MIG Gun-On-Demand MIG guns, spool guns, and push-pull guns can be used with this unit. To switch from one gun to another, momentarily press the trigger on the desired unused gun to make it the active gun. Once the trigger is pressed, the unit will recall stored data and both displays will show the last programmed values for that particular gun. If the unit is powered down and back on again, the gun last used will become the current active gun.

Pulsed MIG Mode Voltage Adjustment

In Pulsed MIG mode there is no manual voltage adjustment; instead, voltage is synergically aligned with the proper wire feed speed. Arc Length adjustment is used to adjust actual arc length, which automatically adjusts the voltage.

See weld chart in front compartment for proper wire feed speed adjustment according to wire size and type.

OM-279299 Page 33

6-3.

Using Auto-Set

™

�

Complete Parts List is available at www.MillerWelds.com

Elite

1 2

12

10

11

8

9

297061-D

1 Auto-Set Button

Press to turn Auto-Set On or Off.

2 Pulse Button

Press to turn Pulse On or Off..

3 Material/Gas Left Button

4 Material/Gas Right Button

Press to select material and gas. Left button moves cursor to the left, right button moves cursor to the right.

5 Diameter Button

Selects the size of the wire.

3 4 5 6

6 Material Thickness Left Button

7 Material Thickness Right Button

Use to select material thickness. Left button moves cursor to the left, right button moves cursor to the right.

8 Left Knob

Use left knob to fine tune voltage in MIG mode or arc length in Pulsed MIG mode

9 Right Knob

Use right knob to fine tune wire feed speed.

7

�

When using a spoolgun or push-pull gun in Auto-Set, the potentiometer on the gun is deactivated. Wire feed speed is controlled on the front panel.

10 Welding Output Icon

When visible, indicates weld output is on.

11 Improper Weld Polarity Icon

When visible, indicates electrode and work cables need to be switched.

12 Bullseye Indicator

Represents factory default settings.

OM-279299 Page 34

6-4.

Using Manual Mode

�

Complete Parts List is available at www.MillerWelds.com

1 2

7

5 6

8

297061-D

3 4

1 Auto-Set Button

Press to turn Auto-Set On or Off.

2 Pulse Button

Press to turn Pulse On or Off..

3 Set-Up Button

Press Setup to optimize arc performance or to add timers to weld sequence.

4 Program Button

Press Program to save favorite weld programs, up to four programs per weld process. See Section 6–7.

5 Jog Button

Feed wire without turning on weld output and energizing gas solenoid.

6 Purge Button

Energizes gas solenoid without turning on weld output or feeding wire.

7 Left Knob

Use left knob to adjust voltage in MIG mode or arc length in Pulsed MIG mode.

8 Right Knob

Use right knob to adjust wire feed speed

�

When using a spoolgun or push-pull gun, wire feed speed is controlled at the gun and the right knob is deactivated.

OM-279299 Page 35

�

Complete Parts List is available at www.MillerWelds.com

6-5.

Manual MIG Set-Up Mode

1

2 3

4

297061-D

1

2

3

Set—Up Button

Left Knob

Right Knob

4 Home Button

To enter the Setup menu from the Manual

Mode home screen, press Setup

Once in the Setup menu, rotate the left knob to find a particular item, and rotate the right knob to change setting or status.

Press Home to save settings and return to welding mode.

Items that can be adjusted from this menu are:

Wire and Gas Type : Optimize arc starts and weld performance by selecting the wire type and gas being used.

Wire Diameter : Optimize arc starts and weld performance by selecting the wire diameter that matches the wire being used.

Inductance : Changes the fluidity of the weld puddle. Increasing inductance produces a more fluid, softer arc. Decreasing inductance produces a stiffer arc. Inductance settings range from 0 to 99. The default setting is 50.

Preflow : The amount of time that the shielding gas will flow after the trigger is depressed and before the welding arc can start. Preflow settings range from Disabled to 5 seconds.

Postflow : The amount of time that the shielding gas will flow after the arc has been shut off. Postflow settings range from Disabled to 5 seconds.

Run-In : The speed of the wire prior to the welding arc being struck. Auto is the default setting. The other options are Disabled or

Manual. Manual settings range from 5 to

150% of the welding wire feed speed.

FasTackt : Enabling FasTack reduces arc start time by automatically increasing the run-in speed when doing repetitive arc starts. FasTack automatically uses a slower wire feed speed when the wire is cool and a faster wire feed speed when the wire is hot.

Default setting is Disabled.

Crater : The amount of time the welding arc stays on after the welding gun trigger is released. This feature is used to fill the void or crater at the end of the weld. Crater settings range from 0.1 to 5 seconds

Spot Timer : The amount of time that the arc can be active before it shuts off automatically. Spot timer setting range is from Disabled to 120 seconds. Spot timer is reset upon release of welding gun trigger.

Stitch Timer : Used in conjunction with the spot timer and while the trigger is continuously depressed. Controls the amount of time that the arc will be inactive after the spot timer times out. Stitch time setting range is from 1 to 120 seconds.

Set Up Push Motor Torque (SUP): This feature is only displayed when an AlumaPro

Lite gun is connected to the welding power source. The SUP setting adjusts the over torque limit of the push motor inside the welding power source. The range is 0 to

250, and the default value is 130. The AlumaPro Lite SUP value can be found on the back end of the gun. Set the SUP value on the machine to match the value on the gun.

OM-279299 Page 36

6-6.

Setting Crater Time

�

Complete Parts List is available at www.MillerWelds.com

1

3

2

297061-D

1

2

Left Knob

Right Knob

3 Home Button

The crater setting is the amount of time the welding arc stays on after the welding gun trigger is released. This feature is used to fill the void or "crater" at the end of the weld.

In the Setup menu, rotate the left knob to highlight Crater , and rotate the right knob to select Manual .

The following Crater variables can be adjusted:

Crater Time : Time range is 0.1 to 5 seconds.

Crater Voltage (MIG settings) or Arc

Length (Pulse settings): Voltage range is 10 to 32 volts. Arc length range is 0 to 99.

Crater Wire Feed Speed : Wire feed speed range is 50 to 800 ipm.

Crater Delay : This setting is for spot or stitch welding without crater fill if the arc time is less than the set time. Time range is 0 to 5 seconds. (If crater delay is set for 2 seconds, weld operation will not go into crater if gun trigger is released before 2 seconds.)

OM-279299 Page 37

�

Complete Parts List is available at www.MillerWelds.com

6-7.

Manual Program Mode

1

3

5

4

297061-D

1 Program Button

2 Program Soft Keys

3 Left Knob

4 Right Knob

5 Home Button

The unit can store four programs. The programs have default setting saved when the machines come from the factory.

Saving Programs In Manual Mode

To enter the Program menu from the Manual

Mode home screen, press the Program button.

White Program tabs will appear above four of the soft keys.

2

Determine where you would like to save the settings. Push and hold that Program soft key for two seconds. The display will show

"Saved" when the program has been successfully saved.

Saving Programs From Auto-Set Mode

Program mode cannot be accessed from

Auto-Set mode. To save settings, note the weld parameters and return to Manual mode to access Program mode.

Recalling Programs

Push the Program button to select desired program. The selected Program tab will turn blue and the proper setting will be displayed.

Weld parameters may be changed while using the program with the left and right knobs.

If the settings are changed, the program tab will turn white and the lettering will turn black. To save the new settings, press and hold the Program button again for two seconds.

If you change the setting but do not wish to save it, press the Program button again to recall the original settings.

Exiting Program Mode

Press the Home button to exit Program mode and return to Manual mode.

�

To use optional MDX-250 EZ-Select

MIG gun with Program mode, see

Section 6-8.

OM-279299 Page 38

�

Complete Parts List is available at www.MillerWelds.com

6-8.

Using Optional MDX-250 EZ-Select

™

Gun In Program Mode

2

1

Ref. 800797-A

1 Trigger Switch

2 Program LEDS

The optional MDX-250 EZ-Select gun gives the operator the ability to change weld programs at the gun. When the MDX-250 is connected, "EZ Select" is displayed in the last tab. Push the soft key below the EZ Select tab to enable.

When this feature is enabled, the 4 LEDs on the MDX-250 gun handle indicate which program is active. Tap the gun trigger to select the program. The number of lit LEDs on the gun indicates the selected program and allows the operator to know which program is being used without going back to or seeing the machine.

Tap the trigger once. LED 1 on the gun illuminates. Program 1 is selected.

Tap the trigger twice. LEDs 1 and 2 on the gun illuminate. Program 2 is selected.

Tap the trigger three times. LEDs 1, 2, and 3 on the gun illuminate. Program 3 is selected.

Tap the trigger 4 times. LEDs 1, 2, 3, and 4 on the gun illuminate. Program 4 is selected

When the EZ-Select feature is disabled on the welder, LEDs 1 and 4 on the gun are illuminated.

OM-279299 Page 39

�

Complete Parts List is available at www.MillerWelds.com

6-9.

Pulsed MIG Auto-Set

™

Mode

1 2

7

6

297061-D

3

4

5

1 Auto-Set Button

2 Pulse Button

Press Auto-Set and Pulse buttons.

3 Wire and Gas Buttons

Use soft keys to select wire and gas for

Pulsed MIG.

4 Wire Diameter

Use soft key to select wire diameter.

5 Material Thickness

Use soft keys to move cursor to left or right to select material thickness.

6 Left Knob

Use left knob to fine tune arc length. Arc length defaults to 50.

7 Right Knob

Use right knob to fine tune wire feed speed.

Arc Length

Arc length can be adjusted from 0-99. All

Pulse MIG programs are set with a value of

50. Adjusting the Arc Length will vary the length of the welding arc cone.

(0 Setting)

Low Setting

(99 Setting)

High Setting

If a gas is used other than what is listed on the Pulse MIG welding program chart, the

Arc Length can be adjusted to help customize your arc to the gas being used.

OM-279299 Page 40

�

Complete Parts List is available at www.MillerWelds.com

6-10. Pulsed MIG Manual Mode

1

4

3

297061-D

2, 5

1 Pulse Button

2 Set-Up Button

3 Left Knob

4 Right Knob

5 Home Button

Press Pulse and Set Up buttons

In the Setup menu, rotate left knob to highlight material and gas. Rotate right knob to select material and gas being used.

Rotate left knob to highlight wire diameter.

Rotate right knob to select wire diameter being used.

Press Home to return to welding mode.

Operation

Adjust right knob for proper wire feed speed and adjust left knob to change arc length if required. Arc length will default to 50. Refer to Pulse MIG welding chart for proper Wire

Speed setting for metal and metal thickness being welded. All Pulse MIG programs are set up with the gases listed in the Pulse MIG welding chart. If alternate gases are used, adjust arc length and/or arc control to adjust arc characteristics.

Arc Length

Arc length can be adjusted from 0-99. All

Pulse MIG programs are set with a value of

50. Adjusting the arc length will vary the length of the welding arc cone.

Arc Length can be adjusted to help customize your arc to the gas being used.

Arc Control

Press Setup button to enter Setup menu.

Rotate left knob to select Arc Control. The setting can be adjusted from 0 to 50. All

Pulse MIG welding programs are designed with a setting of 25. Using the right knob to adjust the Arc Control setting will vary the width of the welding arc cone.

(0 Setting)

(50 Setting)

(0 Setting)

(99 Setting)

Low Setting High Setting

Low Setting High Setting

If a gas is used other than what is listed on the Pulse MIG welding program chart, the

If a gas is used other than what is listed on the Pulse MIG welding program chart, the

Arc Control can be adjusted to help customize your arc to the gas being used.

OM-279299 Page 41

6-11. System

�

Complete Parts List is available at www.MillerWelds.com

297061-D

1 2 3 4 5

From the System Setting screen, the operator can monitor how the unit is being used, view system software information, restore the unit to factory default settings, and select optional welding guns.

Access the System information screen from the manual MIG home screen by pressing

Setup, then System

System Screen

The System screen displays four or five tabs above the soft keys, depending on which welding gun is connected.

1 Back

Press soft key to return to Setup screen.

2 Counters

Press soft key to access timer logs with a

USB thumb drive. In the counters menu, there are two options:

Reset Log : Press soft key to reset all system timers.

Save Log : Insert USB thumb drive into USB port on front of welder. Press soft key to download all system timers to the drive. This system information can then be loaded into an Excel spreadsheet.

3 Software

Press soft key to display the system software versions. This information is used by factory authorized service agents.

License : Press soft key to display Miller Licensing Agreement.

4 Reset

Press soft key to reset unit to original factory settings

5 EZ-Select ™

This tab is only present when using the optional EZ Select MIG gun or an AlumaPro or

AlumaPro Lite push pull gun.

EZ Selectt : The system detects that the optional EZ Select MIG gun is connected to the system. Press soft key to enable or disable the trigger tap program select feature of the EZ Select gun.

PPG: Press soft key to match the push-pull gun being used. The selected gun, AlumaPro or AlumaPro Lite, appears above the blue tab.

OM-279299 Page 42

6-12. Support

�

Complete Parts List is available at www.MillerWelds.com

The support screen allows the operator to quickly access the Miller website and phone number to obtain more product information or get service support.

Access the Support screen from the manual

MIG screen by pressing Set-up, then Sup-

port. See section 6-5.

OM-279299 Page 43

�

Complete Parts List is available at www.MillerWelds.com

6-13. MIG Welding Parameter Chart

OM-279299 Page 44

�

Complete Parts List is available at www.MillerWelds.com

A complete Parts List is available at www.MillerWelds.com

SECTION 7 – MAINTENANCE AND TROUBLESHOOTING

SECTION 17 MAINTENANCE & TROUBLESHOOTING

7-1.

Routine Maintenance

17-1. Routine Maintenance

Disconnect power before maintaining.

�

Maintain more often during severe conditions.

� = Check ◇ = Change

Every 3

Months

1/2 in.

(13 mm)

Every

3

Months

� Damaged Or Unreadable

Labels

Every 6

Months

FUEL

� Repair Or Replace Cracked Weld Cables

SLUDGE

� Inside Unit � Clean Drive Rolls

7-2.

Changing Drive Roll Or Wire Inlet Guide

� = Clean � = Replace

Replace Cracked

Torch Body

Repair Or Replace

Cracked Cables And

Cords

Clean

And

Tighten Weld

Connections

2

1

4

1 Securing Screw

2 Inlet Wire Guide

Loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw.

3 Drive Roll

The drive roll consists of two different sized grooves. The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll. The groove closest to the motor shaft is the proper groove to thread.

4 Drive Roll Securing Nut

Turn nut one click to secure drive roll..

3

OM-249336 Page 1

7/16 in.

7-3.

Overheating

Thermistors RT1, RT2, and the thermistors contained within the inverter module PM1 protect the unit from damage due to overheating. If the output diode heat sink, output inductor L2, and/or inverter module PM1 gets too hot, they command the weld controller to disable the output. The fan keeps running to cool the unit. Wait several minutes before trying to weld.

OM-279299 Page 45

OM-231242 Page 29

OM-278215 Page 33

�

Complete Parts List is available at www.MillerWelds.com

7-4.

Aligning Drive Rolls and Wire Guide

Correct

Incorrect

1

2

3 allen_wrench

4 allen_set

5

NGO’s tools/

Turn Off power.

View is from top of drive rolls looking down with pressure assembly open.

1 Drive Roll Securing Nut

2 Drive Roll

3 Wire Guide

4 Welding Wire

5 Drive Gear

Insert screwdriver, and turn screw in or out until drive roll groove lines up with wire guide.

Close pressure roll assembly.

flathead philips head wrench crescent wrench

Ref. 800412-A pliers

7-5.

Error Messages

needlenose knife steelbrush nutdriver chippinghammer

Overtemp-Please wait while the welder cools down.

stripcrimp light-duty workclamp

Internal temperature of welder has exceeded the maximum limit.

Wait for unit to cool down. If the fan is not running, contact Miller Electric authorized service location.

frontcutter

Inverter Module * Output Rectifier *

Secondary Magnetics

Trigger error-Release MIG gun trigger to clear error.

torque screwdriver

MIG gun or spool gun trigger is engaged on power up.

MIG gun trigger is held during jog for more than

17 feet of wire.

Release 4-pin trigger to clear error.

torque wrench

Spool gun trigger is held during jog for more than

10 seconds.

socket wrench 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.

greasegun filterwrench 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.

strapwrench awl file paintbrush

Trigger Error-Release Spool Gun trigger/Release Push-Pull trigger to clear error.

The 10-pin trigger is engaged on power up.

Trigger held too long during jog mode. Spool gun for more than 10 seconds. Push-pull gun for more than 37 feet of wire.

Release the 10-pin trigger.

OM-279299 Page 46 qtip (swab) vicegrip crimper feelergauge flashlight ruler toothbrush punch solvent pinextractor eprompuller pipewrench

OM-222 Page 1

Message

Gun Error XR-A Python S XR Edge S

XR A S XR-A AlumaPro Plus

Shorted output-First remove short, then pull trigger to clear error.

Motor error-Motor has drawn too much current.

* Internal motor has stalled * Internal motor has drawn too much current *

Remote motor has stalled * Motor tach is running too slow or is damaged.

Fan error-Either the top fan or the bottom fan is running too slow or is damaged.

Thermal error-Inverter module thermistor is shorted.

Thermal error-Inverter module thermistor open.

Thermal error-Secondary magnetics thermistor is shorted.

Thermal error-Secondary magnetics thermistor is open.

Thermal error-Output rectifier thermistor is shorted.

Thermal error-Output rectifier thermistor is open.

Cycle power to clear error +15V or –

15V * Primary Error

Over voltage-Cycle power to clear error.

Under voltage-Cycle power to clear error.

�

Complete Parts List is available at www.MillerWelds.com

Error

Trigger is engaged for more than 1 second after the arc is broken.

After an overtemp error, the trigger is held after the welder has completed cooling.

Trigger is engaged while another process is selected.

The trigger leads re shorted.

System parameters do not support this equipment.

The welding wire came into contact with the workpiece while jogging wire.

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.

The control board is damaged.

Too much pressure on pressure adjust knob.

The gun liner is obstructed.

The gun contact tip is obstructed.

The welding wire is entangled.

The control board is damaged.

Remedy

Replace with compatible MIG gun.

Remove short and pull trigger, or wait 30 seconds to clear error.

Contact Miller Electric authorized service location.

Reduce pressure on the pressure adjust knob.

Clear obstruction or replace gun liner.

Clear obstruction or replace contact tip.

Untangle welding wire.

Contact Miller Electric authorized service location.

Clear obstruction from fan.

Contact Miller Electric authorized service location.

The fan blades are obstructed.

The fan wiring harness is disconnected.

The fan is damaged.

The control board is damaged.

The inverter module thermistor is reading too high for a valid temperature.

The control board is damaged.

Ambient temperature is too cold for valid reading.

The inverter module thermistor is reading too low for a valid temperature.

The control board is damaged.

The secondary magnetics thermistor is reading too high for a valid temperature.

The control board is damaged.

Ambient temperature is too cold for valid reading.

The secondary magnetics thermistor is reading too low for a valid temperature.

The control board is damaged.

The output rectifier thermistor is reading too high for a valid temperature.

The control board is damaged.

Ambient temperature is too cold for valid reading.

The output rectifier thermistor is reading too low for a valid temperature.

The control board is damaged.

The primary boost has not successfully been established.

Primary voltage is above 288 volts.

Contact Miller Electric authorized service location

Place unit in environment warmer than –30°F (–

22°C).

Contact Miller Electric authorized service location.

Contact Miller Electric authorized service location

Place unit in environment warmer than –30°F (–

22°C).

Contact Miller Electric authorized service location.

Contact Miller Electric authorized service location

Place unit in environment warmer than –30°F (–

22°C).

Contact Miller Electric authorized service location.

Cycle power to clear error. If this error persists after a power cycle, contact Miller Electric Mfg.

authorized service location.

Reduce primary voltage below 288 volts.

The primary voltage is below 150 volts.

Increase primary voltage above 150 volts.

OM-279299 Page 47

Message

Network error-Inverter Communication is down.

Network error-Primary Communication is down.

�

Complete Parts List is available at www.MillerWelds.com

Error

The two microcontrollers on the control board are no longer communicating.

Remedy

Cycle power to clear error. If this error persists after a power cycle, contact Miller Electric Mfg.

authorized service location.

Network error-Communication between UI and control boards is down.

Contact Miller Electric Mfg. authorized service locatuin.

Cable error — Connect wire feed housing cable to clear error.

The wiring harness between the control board and interface board is damaged.

The primary control board is damaged.

The interface board is damaged.

The wire feed housing cable is not attached to either the positive stud or negative stud of the power source.

The control board is damaged.

Connect wire drive assembly cable to either the positive or negative stud.

Transformer Saturation error — Release trigger to clear OR cycle power to clear.

Main transformer has detected an overcurrent condition.

Missing UI Membrane Switch Overlay.

UI is not detected as being plugged in.

UI Membrane Switch Overlay doesn’t match arc controller program

CAN Data Version Incompatible

Detected UI membrane is not detected as matching the type reported by the main control board.

The UI and the Control are not compatible, perhaps due to a partial firmware upgrade.

Contact Miller Electric authorized service location

Cycle power to clear error. If this problem persists, contact Miller Electric Mfg. authorized service location.

Contact Miller Electric Mfg. authorized service location.

Contact Miller Electric Mfg. authorized service location.

Restart the Firmware upgrade process.

Contact Miller Electric Mfg. authorized service location.

7-6.

Troubleshooting

Trouble

No weld output; unit completely inoperative.

No weld output; unit is on.

Erratic or improper welding arc or output.

Fan not operating.

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.

Check and secure loose weld cable(s) into receptacle(s).

Check and correct poor connection of work clamp to workpiece.

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.

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.

OM-279299 Page 48

�

Complete Parts List is available at www.MillerWelds.com

SECTION 8 – PARTS LIST

8-1.

MDX-250 MIG Gun Consumables And Recommended Spare Parts

See OM-282976 (shipped with this product) for information on replacement consumables for the MDX welding gun.

8-2.

Drive Roll And Wire Guide Kits

1 V-Grooved rolls for hard wire.

2 U-Grooved rolls for soft and soft shelled cored wires.

3 U-Cogged rolls for extremely soft shelled wires(usually hard surfacing types).

4 V-Knurled rolls for hard shelled cored wires.

5 Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination with U-Grooved)

Drive Roll

Fraction

0.023/0.025 in.

0.030/0.035 in.

0.030 in.

0.035 in.

0.045 in.

Wire Diameter

Decimal

0.023/0.025 in.

0.030/0.035 in.

0.030 in.

0.035 in.

0.045 in.

Metric

0.6 mm

0.8/0.9 mm

0.8 mm

0.9 mm

1.2 mm

Kit No.

087131

204579

079594

079595

079596

Part No.

087130

203526

053695

053700

053697

Type

V-Grooved

V-Grooved

V-Grooved

V-Grooved

V-Grooved

Inlet Wire Guide

056192

056192

056192

056192

056193

OM-279299 Page 49

SECTION 9 – ELECTRICAL DIAGRAMS

OM-279299 Page 50

Figure 9-1. Circuit Diagram

279043-E

OM-279299 Page 51

SECTION 10 – GMAW WELDING (MIG) GUIDELINES

10-1. Typical GMAW (MIG) Process Connections

1

7

2

1

7

5

6

Weld current can damage electronic battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.

6

1

1 Wire Feeder/Welding Power Source

2 Gun

3 Workpiece

4 Work Clamp

(0.0625 in.)

4

3

2

5 Gas

6 4

3

7 Regulator/Flowmeter

3

3

2

1

2

1/16 in.

(0.0625 in.)

4

4

�

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 Material Thickness

Material thickness parameters.

determines weld

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 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.

OM-279299 Page 52

OM-

OM-

SECTION 1 GMAW WELDING (MIG) GUIDELINES WHEN

USING A VOLTAGE-SENSING FEEDER

1

3

2

4 8

5

6

7

Wire Size

0.023 in. (0.58 mm)

0.030 in. (0.76 mm)

0.035 in. (0.89 mm)

Amperage Range

30-90 A

40-145 A

50-180 A

*62.5 A based on 1/16 in. (1.6 mm) material thickness.

Recommended Wire Feed Speed

3.5 in. (89 mm) per amp

2 in. (51 mm) per amp

1.6 in. (41 mm) per amp

Wire Feed Speed *

3.5 x 62.5 A = 219 ipm (5.56 mpm)

2 x 62.5 A = 125 ipm (3.19 mpm)

1.6 x 62.5 A = 100 ipm (2.56 mpm) ipm = inches per minute; mpm = meters per minute

1-1.

Holding And Positioning Welding Gun

90

°

1

3

2

5

4

6

Groove Welds

0

°

-15

°

90

°

90

°

6

90

°

7

0

°

-15

°

45

°

7

45

°

6

45

°

�

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 Hold Gun and Control Gun Trigger

2 Workpiece

3 Work Clamp

4 Electrode Extension (Stickout)

Solid Wire – 3/8 to 1/2 in. (9 to 13 mm)

0

°

-15

°

5 Cradle Gun and Rest Hand on

Workpiece

7

6 End View Of Work Angle

45

°

7 Side View Of Gun Angle

6

0

°

-15

°

7

90

°

6

90

°

0

°

-15

°

7

Fillet Welds

45

°

45

°

6

0

°

-15

°

7

OM-4419 Page 1

OM-279299 Page 53

10-4. Conditions That Affect Weld Bead Shape

10

°

10

°

Gun Angles and Weld Bead Profiles

10

°

10

°

1

1

2

2

1

1

10

°

10

°

10

°

3

10

°

3

2

2

3

3

Electrode Extensions (Stickout)

4 5

4 5

4 5

4 5

Fillet Weld Electrode Extensions (Stickout)

6

6

6

6

4

4

4

7

7

7

7

5

5

5

5

8

8

8

8

6

6

6

6

9

9

9

9

�

Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage.

1 Push

2 Perpendicular

3 Drag

4 Short

5 Normal

6 Long

7 Slow

8 Normal

9 Fast

OM-279299 Page 54

10-5. Gun Movement During Welding

1

1

1

3

3

3

2

2

2

�

Normally, 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.

1 Stringer Bead - Steady Movement Along

Seam

2 Weave Bead - Side To Side Movement

Along Seam

3 Weave Patterns

Use weave patterns to cover a wide area in one pass of the electrode.

10-6. Poor Weld Bead Characteristics

1

1

1

2

2 3 4

4

3 4

5

5

5

1 Large Spatter Deposits

2 Rough, Uneven Bead

3 Slight Crater During Welding

4 Bad Overlap

5 Poor Penetration

10-7. Good Weld Bead Characteristics

1

1

1

2

2

2

3

3

4

3

4

4

5

5

5

1 Fine Spatter

2 Uniform Bead

3 Moderate Crater During Welding

Weld a new bead or layer for each 1/8 in.

(3.2 mm) thickness in metals being welded.

4 No Overlap

5 Good Penetration into Base Metal

OM-279299 Page 55

OM-4419 Page 1

10-8. Troubleshooting – Excessive Spatter

Excessive Spatter - scattering of molten metal particles that cool to solid form near weld bead.

Possible Causes

Wire feed speed too high.

Voltage too high.

Electrode extension (stickout) too long.

Workpiece dirty.

Insufficient shielding gas at welding arc.

Dirty welding wire.

Incorrect polarity.

Corrective Actions

Select lower wire feed speed.

Select lower voltage range.

Use shorter electrode extension (stickout).

Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.

Use clean, dry welding wire.

Eliminate pickup of oil or lubricant on welding wire from feeder or liner.

Check polarity required by welding wire, and change to correct polarity at welding power source.

10-9. Troubleshooting – Porosity

Porosity - small cavities or holes resulting from gas pockets in weld metal.

Possible Causes

Insufficient shielding gas at welding arc.

Wrong gas.

Dirty welding wire.

Workpiece dirty.

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.

Use welding grade shielding gas; change to different gas.

Use clean, dry welding wire.

Eliminate pick up of oil or lubricant on welding wire from feeder or liner.

Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.

Use a more highly deoxidizing welding wire (contact supplier).

Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

Welding wire extends too far out of nozzle.

10-10. Troubleshooting – Excessive Penetration

Possible Causes

Excessive heat input.

Excessive Penetration - weld metal melting through base metal and hanging underneath weld.

Corrective Actions

Select lower voltage range and reduce wire feed speed.

Increase travel speed.

OM-279299 Page 56

10-11. Troubleshooting – Lack Of Penetration

Lack Of Penetration - shallow fusion between weld metal and base metal.

Possible Causes

Improper joint preparation.

Improper weld technique.

Insufficient heat input.

Incorrect polarity.

Corrective Actions

Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics.

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.

Select higher wire feed speed and/or select higher voltage range.

Reduce travel speed.

Check polarity required by welding wire, and change to correct polarity at welding power source.

10-12. Troubleshooting – Incomplete Fusion

Incomplete Fusion - failure of weld metal to fuse completely with base metal or a preceeding weld bead.

Possible Causes

Workpiece dirty.

Insufficient heat input.

Improper welding technique.

Corrective Actions

Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.

Select higher voltage range and/or adjust wire feed speed.

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.

10-13. Troubleshooting – Burn-Through

Burn-Through - weld metal melting completely through base metal resulting in holes where no metal remains.

Possible Causes

Excessive heat input.

Corrective Actions

Select lower voltage range and reduce wire feed speed.

Increase and/or maintain steady travel speed.

10-14. Troubleshooting – Waviness Of Bead

Waviness Of Bead - weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes

Welding wire extends too far out of nozzle.

Unsteady hand.

Corrective Actions

Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

Support hand on solid surface or use two hands.

OM-279299 Page 57

10-15. Troubleshooting – Distortion

Distortion - contraction of weld metal during welding that forces base metal to move.

Illustration: Base metal moves in the direction of the weld bead.

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.

10-16. Common 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.

Gas

Spray Arc

Steel

Short Circuiting

Steel

GMAW-P

Steel

Spray Arc

Stainless

Steel

Application

Short Circuiting

Stainless

Steel

GMAW-P

Stainless

Steel

Spray Arc

Aluminum

All

Positions

Short Circuiting

Aluminum

All

Positions

GMAW-P

Aluminum

All

Positions

Argon

Argon + 1%

O

2

Argon + 2%

O

2

Argon + 5%

CO

2

Argon +

10% CO

2

Argon +

25% CO

2

Argon +

50% CO

2

Flat & Horizontal Fillet

Flat & Horizontal Fillet

Flat & Horizontal Fillet

Flat & Horizontal Fillet

CO

2

All

Positions

All

Positions

All

Positions

All

Positions

All

Positions

All

Positions

All

Positions

All

Positions

All

Positions

Flat & Horizontal Fillet

Flat & Horizontal Fillet

All

Positions*

All

Positions*

Helium

Argon +

Helium

90% HE +

7-1/2% AR

+ 2-1/2%

CO

2

65% AR +

33% HE +

2% CO

2

* Heavy Thicknesses

All

Positions

All

Positions

OM-279299 Page 58

10-17. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem

Wire feed motor operates, but wire does not feed.

Wire curling up in front of the wire feed rolls

(bird nesting).

Wire feeds, but no gas flows (GMAW).

Welding arc not stable.

Probable Cause

Too little pressure on wire feed rolls.

Incorrect wire feed rolls.

Wire spool brake pressure too high.

Restriction in the gun and/or assembly.

Too much pressure on wire feed rolls.

Incorrect cable liner or gun contact tip size.

Gun end not inserted into drive housing properly.

Dirty or damaged (kinked) liner.

Gas cylinder empty.

Gas nozzle plugged.

Gas cylinder valve not open or flowmeter not adjusted.

Restriction in gas line.

Loose or broken wires to gas solenoid.

Gas solenoid valve not operating.

Incorrect primary voltage connected to welding power source.

Wire slipping in drive rolls.

Wrong size gun liner or contact tip.

Incorrect voltage setting for selected wire feed speed on welding power source.

Loose connections at the gun weld cable or work cable.

Gun in poor shape or loose connection inside gun.

Remedy

Increase pressure setting on wire feed rolls.

Check size stamped on wire feed rolls, replace to match wire size and type if necessary.

Decrease brake pressure on wire spool.

Check and replace cable, gun, and contact tip if damaged. Check size of contact tip and cable liner, replace if necessary.

Decrease pressure setting on wire feed rolls.

Check size of contact tip and check cable liner length and diameter, replace if necessary.

Loosen gun securing bolt in drive housing and push gun end into housing just enough so it does not touch wire feed rolls.

Replace liner.

Replace empty gas cylinder.

Clean or replace gas nozzle.

Open gas valve at cylinder and adjust flow rate.

Check gas hose between flowmeter and wire feeder, and gas hose in gun and cable assembly.

Have Factory Authorized Service Agent repair wiring.

Have Factory Authorized Service Agent replace gas solenoid valve.

Check primary voltage and relink welding power source for correct voltage.

Adjust pressure setting on wire feed rolls. Replace worn drive rolls if necessary.

Match liner and contact tip to wire size and type.

Readjust welding parameters.

Check and tighten all connections.

Repair or replace gun as necessary.

OM-279299 Page 59

Notes

Notes

Notes

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.

Effective January 1, 2021

(Equipment with a serial number preface of NB or newer)

This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied.

LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to authorized distributors that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS

WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE

WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Notifications submitted as online warranty claims must provide detailed descriptions of the fault and troubleshooting steps taken to diagnose failed parts. Warranty claims that lack the required information as defined in the Miller Service Operation

Guide (SOG) may be denied by Miller.

Miller shall honor warranty claims on warranted equipment listed below in the event of a defect within the warranty coverage time periods listed below. Warranty time periods start on the delivery date of the equipment to the end-user purchaser, or 12 months after the equipment is shipped to a North American distributor, or

18 months after the equipment is shipped to an international distributor, whichever occurs first.

* TIG Torches (No Labor)

* Tregaskiss Guns (No Labor)

* Water Cooling Systems

* Wireless Remote Foot/Hand Controls and Receivers

* Work Stations/Weld Tables (No Labor)

5. 6 Months — Parts

* 12 Volt Automotive-Style Batteries

6. 90 Days — Parts

* Accessories (Kits)

* ArcReach Heater Quick Wrap and Air Cooled Cables

* Canvas Covers

* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls

* MDX Series MIG Guns

* M-Guns

* MIG Guns, Subarc (SAW) Torches, and External

Cladding Heads

* Remote Controls and RFCS-RJ45

* Replacement Parts (No labor)

* Spoolmate Spoolguns

1. 5 Years Parts — 3 Years Labor

* Original Main Power Rectifiers Only to Include SCRs,

Diodes, and Discrete Rectifier Modules

2. 3 Years — Parts and Labor Unless Specified

* Auto-Darkening Helmet Lenses (No Labor)

* Engine Driven Welder/Generators

(NOTE: Engines are Warranted Separately by the

Engine Manufacturer.)

* Insight Welding Intelligence Products (Except External

Sensors)

* Inverter Power Sources

* Plasma Arc Cutting Power Sources

* Process Controllers

* Semi-Automatic and Automatic Wire Feeders

* Transformer/Rectifier Power Sources

3. 2 Years — Parts and Labor

* Auto-Darkening Weld Masks (No Labor)

* Fume Extractors − Capture 5, Filtair 400 and Industrial

Collector Series

4. 1 Year — Parts and Labor Unless Specified

* ArcReach Heater

* AugmentedArc and LiveArc Welding Systems

* Automatic Motion Devices

* Bernard BTB Air-Cooled MIG Guns (No Labor)

* CoolBelt (No Labor)

* Desiccant Air Dryer System

* Field Options

(NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

* RFCS Foot Controls (Except RFCS-RJ45)

* Fume Extractors − Filtair 130, MWX and SWX Series,

ZoneFlow Extraction Arms and Motor Control Box

* HF Units

* ICE/XT Plasma Cutting Torches (No Labor)

* Induction Heating Power Sources, Coolers

(NOTE: Digital Recorders are Warranted

Separately by the Manufacturer.)

* Load Banks

* Motor-Driven Guns (except Spoolmate Spoolguns)

* PAPR Blower Unit (No Labor)

* Positioners and Controllers

* Racks (For Housing Multiple Power Sources)

* Running Gear/Trailers

* Subarc Wire Drive Assemblies

* Supplied Air Respirator (SAR) Boxes and Panels

Miller’s True Blue ® Limited Warranty shall not apply to:

1.

Consumable components; such as contact tips, cutting nozzles, contactors, brushes, relays, work station table tops and welding curtains, or parts that fail due to normal wear. (Exception: brushes and relays are covered on all engine-driven products.)

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.

4. Defects caused by accident, unauthorized repair, or improper testing.

MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL

AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN

THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

The exclusive remedies for warranty claims are, at Miller’s option, either: (1) repair; or (2) replacement; or, if approved in writing by Miller, (3) the pre-approved cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon use). Products may not be returned without Miller’s written approval. Return shipment shall be at customer’s risk and expense.

The above remedies are F.O.B. Appleton, WI, or Miller’s authorized service facility. Transportation and freight are the customer’s responsibility. TO THE EXTENT PERMITTED BY

LAW, THE REMEDIES HEREIN ARE THE SOLE AND

EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL

THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR

DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR

CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF

PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY

WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED

WARRANTY, GUARANTY, OR REPRESENTATION,

INCLUDING ANY IMPLIED WARRANTY OF

MERCHANTABILITY OR FITNESS FOR PARTICULAR

PURPOSE, ARE EXCLUDED AND DISCLAIMED BY

MILLER.

Some US states do not allow limiting the duration of an implied warranty or the exclusion of certain damages, so the above limitations may not apply to you. This warranty provides specific legal rights, and other rights may be available depending on your state. In Canada, some provinces provide additional warranties or remedies, and to the extent the law prohibits their waiver, the limitations set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary by province.

mil dom warr 2021-01

Owner’s Record

Please complete and retain with your personal records.

Serial/Style Number Model Name

Purchase Date

Distributor

Address

City

State

(Date which equipment was delivered to original customer.)

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 Protective Equipment (PPE)

Service and Repair Replacement Parts

Training (Schools, Videos, Books)

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.

Miller Electric Mfg. LLC

An Illinois Tool Works Company

1635 West Spencer Street

Appleton, WI 54914 USA

International Headquarters–USA

USA Phone: 920-735-4505

USA & Canada FAX: 920-735-4134

International FAX: 920-735-4125

For International Locations Visit www.MillerWelds.com

ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2021-12