Miller Multimatic 200 User Manual

OM-253 392F 2013−03

ProcessesProcesses

Multiprocess Welding

Description

Arc Welding Power Source
Wire Feeder

Multimatic 200

Visit our website at

www.MillerWelds.com

File: Multiprocess

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The

Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.

parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.

Working as hard as you do

− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest

distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 2009−09

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................

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

1-2. Arc Welding Hazards 1.................................................................

1-3. Additional Symbols For Installation, Operation, And Maintenance 3.............................

1-4. California Proposition 65 Warnings 4......................................................

1-5. Principal Safety Standards 4.............................................................

1-6. EMF Information 4.....................................................................

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5...........................

2-1. Symboles utilisés 5.....................................................................

2-2. Dangers relatifs au soudage à l’arc 5......................................................

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7.....

2-4. Proposition californienne 65 Avertissements 8..............................................

2-5. Principales normes de sécurité 9.........................................................

2-6. Informations relatives aux CEM 9.........................................................

SECTION 3 − DEFINITIONS 11..................................................................

3-1. Additional Safety Symbols And Definitions 11................................................

3-2. Miscellaneous Symbols And Definitions 12..................................................

SECTION 4 − SPECIFICATIONS 13..............................................................

4-1. Serial Number And Rating Label Location 13................................................

4-2. Specifications For MIG (GMAW) 13........................................................

4-3. Specifications For TIG (GTAW) 13.........................................................

4-4. Specifications For Stick (SMAW) 13........................................................

4-5. Dimensions And Weight 14...............................................................

4-6. Duty Cycle And Overheating For MIG 15....................................................

4-7. Duty Cycle And Overheating For TIG 16....................................................

4-8. Duty Cycle And Overheating For Stick 17...................................................

SECTION 5 − INSTALLATION 18................................................................

5-1. Selecting A Location 18..................................................................

5-2. Stick Welding Connections 19.............................................................

5-3. TIG Welding Connections DCEN (Direct Current Electrode Negative) 20.........................

5-4. Process/Polarity Table 21................................................................

5-5. Wire Welding Connections 21.............................................................

5-6. Wire Gun Connection Inside Unit 22........................................................

5-7. Connecting Shielding Gas Supply 23.......................................................

5-8. Electrical Service Guide 24...............................................................

5-9. Extension Cord Data 24..................................................................

5-10. Multi−Voltage Plug (MVP) Connection 25...................................................

5-11. Connecting 115 Volt Input Power 26........................................................

5-12. Connecting 1-Phase Input Power For 230 VAC 27............................................

5-13. Installing Wire Spool And Adjusting Hub Tension 29...........................................

5-14. Threading Welding Wire 30...............................................................

SECTION 6 − OPERATION 31...................................................................

6-1. Controls 31............................................................................

6-2. Weld Parameter Chart 32................................................................

6-3. Entering Setup Menu 33..................................................................

6-4. Adjusting Display Contrast (Menu 1 Of 10) 34...............................................

6-5. Calibrating Drive Motor (Menu 2 Of 10) 34..................................................

6-6. Calibrating Spoolmate 100 (Menu 3 Of 10) 35................................................

6-7. Enable/Disable Auto−Cratert (Menu 4 Of 10) 36.............................................

6-8. Viewing Burn-In Information (Menu 5 Of 10) 37...............................................

6-9. Viewing Software Information (Menu 6 Of 10) 37.............................................

6-10. Viewing Primary Power Information (Menu 7 Of 10) 37........................................

6-11. Viewing Process Logs (Menu 8 Of 10) 38...................................................

6-12. Viewing Error Logs (Menu 9 Of 10) 39......................................................

6-13. Performing A Factory Reset (Menu 10 Of 10) 40.............................................

TABLE OF CONTENTS

SECTION 7 − MAINTENANCE &TROUBLESHOOTING 41..........................................

7-1. Routine Maintenance 41.................................................................

7-2. Overload Protection 41..................................................................

7-3. Changing Drive Roll Or Wire Inlet Guide 42.................................................

7-4. Error Messages 42......................................................................

7-5. Troubleshooting 43......................................................................

SECTION 8 − ELECTRICAL DIAGRAM 44........................................................

SECTION 9 − MIG WELDING (GMAW) GUIDELINES 46............................................

9-1. Typical MIG Process Connections 46......................................................

9-2. Typical MIG Process Control Settings 47....................................................

9-3. Holding And Positioning Welding Gun 48....................................................

9-4. Conditions That Affect Weld Bead Shape 49.................................................

9-5. Gun Movement During Welding 50.........................................................

9-6. Poor Weld Bead Characteristics 50........................................................

9-7. Good Weld Bead Characteristics 50........................................................

9-8. Troubleshooting − Excessive Spatter 51....................................................

9-9. Troubleshooting − Porosity 51.............................................................

9-10. Troubleshooting − Excessive Penetration 51.................................................

9-11. Troubleshooting − Lack Of Penetration 52...................................................

9-12. Troubleshooting − Incomplete Fusion 52....................................................

9-13. Troubleshooting − Burn-Through 52........................................................

9-14. Troubleshooting − Waviness Of Bead 53....................................................

9-15. Troubleshooting − Distortion 53............................................................

9-16. Common MIG Shielding Gases 54.........................................................

9-17. Troubleshooting Guide For Semiautomatic Welding Equipment 54...............................

SECTION 10 − STICK WELDING (SMAW) GUIDELINES 56.........................................

SECTION 11 − SELECTING AND PREPARING A
TUNGSTEN

FOR DC OR AC WELDING WITH INVERTER MACHINES 63........................................

11-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) 63......

11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding

Or AC Welding With Inverter Machines 63...................................................

SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW) 64.......................................

12-1. Positioning The Torch 64.................................................................

12-2. Torch Movement During Welding 65........................................................

12-3. Positioning Torch Tungsten For Various Weld Joints 65........................................

SECTION 13 − PARTS LIST 66..................................................................

WARRANTY

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

som 2011−10

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.

1-2. Arc Welding Hazards

The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.

Only qualified persons should install, operate, maintain, and
repair this unit.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

D Do not touch live electrical parts.

D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work
or ground.

D Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on

unit.

D Additional safety precautions are required when any of the follow-

ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid­able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install, ground, and operate this equipment according to

its Owner’s Manual and national, state, and local codes.

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym­bols and related instructions below for necessary actions to avoid the
hazards.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

D When making input connections, attach proper grounding conduc-

tor first − double-check connections.

D Keep cords dry, free of oil and grease, and protected from hot metal

and sparks.

D Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly

with a separate cable.

D Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

D Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

D Use only well-maintained equipment. Repair or replace damaged

parts at once. Maintain unit according to manual.

D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

D Do not connect more than one electrode or work cable to any

single weld output terminal. Disconnect cable for process not in
use.

SIGNIFICANT DC VOLTAGE exists in inverter weld­ing power sources AFTER removal of input power.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section
before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed.
D Allow cooling period before working on equip-

ment.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and
clothing to prevent burns.

OM-253 392 Page 1

FUMES AND GASES can be hazardous.

)

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

D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the

arc to remove welding fumes and gases.

D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.

D Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch­person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath­ing air is safe.

D Do not weld in locations near degreasing, cleaning, or spraying op-

erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.

D Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

ARC RAYS can burn eyes and skin.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

D After completion of work, inspect area to ensure it is free of sparks,

glowing embers, and flames.

D Use only correct fuses or circuit breakers. Do not oversize or by-

pass them.

D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

FLYING METAL or DIRT can injure eyes.

D Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,
they can throw off slag.

D Wear approved safety glasses with side

shields even under your welding helmet.

BUILDUP OF GAS can injure or kill.

D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use

approved air-supplied respirator.

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

D Wear an approved welding helmet fitted with a proper shade of

filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).

D Wear approved safety glasses with side shields under your

helmet.

D Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

D Wear protective clothing made from durable, flame-resistant

material (leather, heavy cotton, or wool) and foot protection.

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

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

D Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not weld on containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).

D Do not weld where the atmosphere may contain flammable dust,

gas, or liquid vapors (such as gasoline).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.

D Do not use welder to thaw frozen pipes.

OM-253 392 Page 2

workpiece, and hot equipment can cause fires and

ELECTRIC AND MAGNETIC FIELDS (EMF
can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implanted

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their doctor

and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

D Wear approved ear protection if noise level is

high.

CYLINDERS can explode if damaged.

Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.

D Protect compressed gas cylinders from excessive heat, mechani-

cal shocks, physical damage, slag, open flames, sparks, and arcs.

D Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them
and associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders,

associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near

combustible surfaces.

D Do not install unit near flammables.

D Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are long enough to

extend beyond opposite side of unit.

D Keep equipment (cables and cords) away from moving vehicles

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

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

OVERUSE can cause OVERHEATING

D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper
face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

BATTERY EXPLOSION can injure.

D Do not use welder to charge batteries or jump

start vehicles unless it has a battery charging
feature designed for this purpose.

MOVING PARTS can injure.

D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards

closed and securely in place.

D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D Reinstall doors, panels, covers, or guards when maintenance is

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.

D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s

Manuals, industry standards, and national, state, and local
codes.

H.F. RADIATION can cause interference.

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and
communications equipment.

D Have only qualified persons familiar with

electronic equipment perform this installation.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa­tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep

spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

ARC WELDING can cause interference.

MOVING PARTS can injure.

D Keep away from moving parts.
D Keep away from pinch points such as drive

rolls.

WELDING WIRE can injure.

D Do not press gun trigger until instructed to do

so.

D Do not point gun toward any part of the body,

other people, or any metal when threading
welding wire.

D Electromagnetic energy can interfere with

sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.

D Be sure all equipment in the welding area is

electromagnetically compatible.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D 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.

OM-253 392 Page 3

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

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

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga­net.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060

1-6. EMF Information

This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).

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

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may 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.

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-253 392 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

7

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.

fre_som_2011−10

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.

NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.

. Indique des instructions spécifiques.

Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.

2-2. Dangers relatifs au soudage à l’arc

Les symboles représentés ci-dessous sont utilisés dans ce ma­nuel pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions
en matière de sécurité indiquées ci-dessous ne constituent
qu’un sommaire des instructions de sécurité plus complètes
fournies dans les normes de sécurité énumérées dans la Sec­tion 2-5. Lire et observer toutes les normes de sécurité.

Seul un personnel qualifié est autorisé à installer, faire fonc­tionner, entretenir et réparer cet appareil.

Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil.

UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.

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

D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et

sans trous.

D S’isoler de la pièce à couper et du sol en utilisant des housses ou

des tapis assez grands afin d’éviter tout contact physique avec la
pièce à couper ou le sol.

D Ne pas se servir de source électrique à courant électrique dans les

zones humides, dans les endroits confinés ou là où on risque de
tomber.

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

MENT si le procédé de soudage le demande.

D Si l’utilisation d’une source électrique à courant électrique s’avère

nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.

D D’autres consignes de sécurité sont nécessaires dans les condi-

tions 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 !

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-

stallation, 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).

D Installez, mettez à la terre et utilisez correctement cet équipement

conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.

D 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.

D En effectuant les raccordements d’entrée, fixer d’abord le conduc-

teur de mise à la terre approprié et contre-vérifier les connexions.

D Les câbles doivent être exempts d’humidité, d’huile et de graisse;

protégez−les contre les étincelles et les pièces métalliques
chaudes.

D Vérifier fréquemment le cordon d’alimentation afin de s’assurer

qu’il n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est.
Un fil à nu peut entraîner la mort.

D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-

sante ou mal épissés.

D Ne pas enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement

avec un câble distinct.

D Ne pas toucher l’électrode quand on est en contact avec la pièce,

la terre ou une électrode provenant d’une autre machine.

D Ne pas toucher des porte électrodes connectés à deux machines

en même temps à cause de la présence d’une tension à vide dou­blée.

D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformé­ment à ce manuel.

D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’assurer que tous les panneaux et couvercles sont correctement

en place.

D Fixer le câble de retour de façon à obtenir un bon contact métal-

métal avec la pièce à souder ou la table de travail, le plus près pos­sible de la soudure.

D Isoler la pince de masse quand pas mis à la pièce pour éviter le

contact avec tout objet métallique.

D 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.

OM-253 392 Page 5

Il reste une TENSION DC NON NÉGLIGEABLE dans

s

e

­r

e

e

les sources de soudage onduleur UNE FOIS
l’alimentation coupée.

D Arrêter les convertisseurs, débrancher le courant électrique et

décharger les condensateurs d’alimentation selon les instructions
indiquées dans la partie Entretien avant de toucher les pièces.

LES PIÈCES CHAUDES peuvent
provoquer des brûlures.

D Ne pas toucher à mains nues les partie

chaudes.

D Prévoir une période de refroidissement avant d

travailler à l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser les outils recomman

dés et porter des gants de soudage et des vêtements épais pou
éviter les brûlures.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

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

D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au

niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage.

D Si la ventilation est médiocre, porter un respirateur anti-vapeurs

approuvé.

D Lire et comprendre les spécifications de sécurité des matériaux

(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégrais­seurs.

D Travailler dans un espace fermé seulement s’il est bien ventilé ou

en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.

D Ne pas souder dans des endroits situés à proximité d’opérations

de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for­mer des gaz hautement toxiques et irritants.

D Ne pas souder des métaux munis d’un revêtement, tels que l’acier

galvanisé, plaqué en plomb ou au cadmium à moins que le revête­ment n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.

LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.

Le rayonnement de l’arc du procédé de soudag

(ultraviolets et infrarouges) susceptibles de provoquer des brûlure
dans les yeux et sur la peau. Des étincelles sont projetées pendant l
soudage.

D Porter un casque de soudage approuvé muni de verres filtrants

approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).

D Porter des lunettes de sécurité avec écrans latéraux même sous

votre casque.

D Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.

D Porter des vêtements confectionnés avec des matières résistan-

tes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.

OM-253 392 Page 6

génère des rayons visibles et invisibles intense

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.

D Déplacer toutes les substances inflammables à une distance de

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

D Ne pas souder dans un endroit là où des étincelles peuvent tomber

sur des substances inflammables.

D Se protéger et d’autres personnes de la projection d’étincelles et

de métal chaud.

D Des étincelles et des matériaux chauds du soudage peuvent

facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.

D Surveiller tout déclenchement d’incendie et tenir un extincteur à

proximité.

D Le soudage effectué sur un plafond, plancher, paroi ou séparation

peut déclencher un incendie de l’autre côté.

D Ne pas effectuer le soudage sur des conteneurs fermés tels que

des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 et AWS A6.0
(voir les Normes de Sécurité).

D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou va-

peurs inflammables (vapeur d’essence, par exemple).

D Brancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provo­quant des risques d’électrocution, d’étincelles et d’incendie.

D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-

lées.

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

électrode ou couper le fil à la pointe de contact.

D Porter des vêtements de protection dépourvus d’huile tels que des

gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.

D Avant de souder, retirer toute substance combustible de vos po-

ches telles qu’un allumeur au butane ou des allumettes.

D Une fois le travail achevé, assurez−vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D Une fois le travail achevé, assurez−vous qu’il ne reste aucune

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

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

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

DES PIECES DE METAL ou DES
SALETES peuvent provoquer des
blessures dans les yeux.

D Le soudage, l’écaillement, le passage de la pièce à la brosse en

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

D Porter des lunettes de sécurité avec écrans latéraux ou un écran

facial.

LES ACCUMULATIONS DE GAZ

t

a
e

r

e

-

risquent de provoquer des blessures
ou même la mort.

D Fermer l’alimentation du gaz comprimé en cas

de non utilisation.

D Veiller toujours à bien aérer les espaces confi-

nés ou se servir d’un respirateur d’adduction
d’air homologué.

Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.

D Les porteurs de stimulateurs cardiaques et

autres implants médicaux doivent rester à
distance.

D Les porteurs d’implants médicaux doivent consulter leur

médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.

LE BRUIT peut endommager l’ouïe.

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

D Porter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent exploser

si elles sont endommagées.

Les bouteilles de gaz comprimé contiennent du gaz

sous haute pression. Si une bouteille est

endommagée, elle peut exploser. Du fait que les

bouteilles de gaz font normalement partie du

procédé de soudage, les manipuler avec

précaution.

D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,

des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.

D Placer les bouteilles debout en les fixant dans un support station-

naire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.

D Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,

tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.

D Détourner votre visage du détendeur-régulateur lorsque vous

ouvrez la soupape de la bouteille.

D Le couvercle du détendeur doit toujours être en place, sauf lorsque

la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.

D Utiliser les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever et déplacer les bouteilles.

D Lire et suivre les instructions sur les bouteilles de gaz comprimé,

l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécu­rité.

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

Risque D’INCENDIE OU
D’EXPLOSION.

D Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

D Ne pas installer l’appareil à proximité de pro-

duits inflammables.

D Ne pas surcharger l’installation électrique − s’assurer que

l’alimentation est correctement dimensionnée et protégée avant
de mettre l’appareil en service.

LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.

D Utiliser l’anneau de levage uniquement pour

soulever l’appareil, NON PAS les chariots, les
bouteilles de gaz ou tout autre accessoire.

D Utiliser un équipement de levage de capacité

suffisante pour lever l’appareil.

D En utilisant des fourches de levage pour déplacer l’unité, s’assu-

rer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.

D Tenir l’équipement (câbles et cordons) à distance des véhicules

mobiles lors de toute opération en hauteur.

D Suivre les consignes du Manuel des applications pour l’équation

de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds.

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

D Les étincelles risquent de causer un incendie − éloigner toute sub

stance inflammable.

L’EMPLOI EXCESSIF peut

SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement ; res-

pecter le cycle opératoire nominal.

D Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

LES ÉTINCELLES PROJETÉES

peuvent provoquer des blessures.

D Porter un écran facial pour protéger le visage e

les yeux.

D Affûter l’électrode au tungstène uniquement à l

meuleuse dotée de protecteurs. Cett
manœuvre est à exécuter dans un endroit sû
lorsque l’on porte l’équipement homologué d
protection du visage, des mains et du corps.

LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les cir-

cuits imprimés.

D Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

D Utiliser des pochettes et des boîtes antista-

tiques pour stocker, déplacer ou expédier des
cartes de circuits imprimes.

OM-253 392 Page 7

Les PIÈCES MOBILES peuvent

E

causer des blessures.

D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

D Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

D Ne pas diriger le pistolet vers soi, d’autres

personnes ou toute pièce mécanique en
engageant le fil de soudage.

L’EXPLOSION DE LA BATTERI
peut provoquer des blessures.

D Ne pas utiliser l’appareil de soudage pour

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

Les PIÈCES MOBILES peuvent
causer des blessures.

D S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes,

panneaux, recouvrements et dispositifs de
protection.

D Lorsque cela est nécessaire pour des travaux d’entretien et de

dépannage, faire retirer les portes, panneaux, recouvrements
ou dispositifs de protection uniquement par du personnel qua­lifié.

D Remettre les portes, panneaux, recouvrements ou dispositifs de

protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les

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

D N’utiliser que les pièces de rechange recommandées par le

constructeur.

D Effectuer l’entretien en respectant les manuels d’utilisation, les

normes industrielles et les codes nationaux, d’état et locaux.

LE RAYONNEMENT HAUTE

FRÉQUENCE (H.F.) risque de

provoquer des interférences.

D Le rayonnement haute fréquence (H.F.) peut

provoquer des interférences avec les équi­pements de radio−navigation et de com­munication, les services de sécurité et les ordi­nateurs.

D Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’installa­tion.

D L’utilisateur est tenu de faire corriger rapidement par un électricien

qualifié les interférences résultant de l’installation.

D Si le FCC signale des interférences, arrêter immédiatement l’ap-

pareil.

D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des

sources de haute fréquence, maintenir les éclateurs à une distan­ce correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.

LE SOUDAGE À L’ARC risque de

provoquer des interférences.

D L’énergie électromagnétique risque de

provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.

D Veiller à ce que tout l’équipement de la zone de soudage soit

compatible électromagnétiquement.

D Pour réduire la possibilité d’interférence, maintenir les câbles de

soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).

D Veiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

D Veiller à ce que ce poste de soudage soit posé et mis à la terre

conformément à ce mode d’emploi.

D En cas d’interférences après avoir pris les mesures précéden-

tes, il incombe à l’utilisateur de prendre des mesures supplé­mentaires telles que le déplacement du poste, l’utilisation de câ­bles blindés, l’utilisation de filtres de ligne ou la pose de protec­teurs dans la zone de travail.

2-4. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal­formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)

OM-253 392 Page 8

Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après

utilisation.

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

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

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga­net.com).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: Limiter par
exemple tout accès aux passants ou procéder à une évaluation des
risques individuels pour les soudeurs. Tous les soudeurs doivent
appliquer les procédures suivantes pour minimiser l’exposition aux
CEM provenant du circuit de soudage:

1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.

3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).

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

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,

Quincy, MA 02269 (phone: [phone], website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super­intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).

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-253 392 Page 9

OM-253 392 Page 10

SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

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

Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation − keep hands
and metal objects away.

Beware of electric shock from wiring.

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

Safe1 2012−05

Safe95 2012−05

Safe94 2012−08

Safe26 2012−05

V

Notes

>5min

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

Safe40 2012−05

V

V

Hazardous voltage remains on input capacitors after power is turned
off. Do not touch fully charged capacitors. Always wait 5 minutes after
power is turned off before working on unit, OR check input capacitor
voltage, and be sure it is near 0 before touching any parts.

Safe43 2012−05

OM-253 392 Page 11

3-2. Miscellaneous Symbols And Definitions

A

U

IP

Amperage

Gas Input Circuit Breaker

Primary Voltage Positive Negative

1

Gas Tungsten Arc
Welding (GTAW) /

Tungsten Inert Gas

(TIG) Welding

Internal Protection

Rating

Single Phase

Remote

Shielded Metal Arc

(SMAW) Stick

U

U

X

2

0

Direct Current

(DC)

Conventional
Load Voltage

Rated No Load

Voltage (Average)

Duty Cycle

Gas Metal Arc

Welding (GMAW)

MIG / Gun Control

Self-Shielded Flux

Cored Arc Weld-

ing (SMAW)

I

2

S

Alternating

Current (AC)

Rated Welding

Current

Line Connection

Gas Metal Arc

Welding (GMAW)

Suitable for Some

Hazardous

Locations

Gas Tungsten Arc

Welding (GTAW)

Torch

Lift Arc (GTAW)

TIG / Remote

V

Hz

Voltage

Increase

Shielded Metal Arc

Welding (SMAW)

Hertz

Single Phase

Static Frequency

Converter-

Transformer-

Rectifier

Input Power Or In-

put Voltage

Wire Feed Spool

Gun / MIG Alumin-

um

Notes

OM-253 392 Page 12

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

SECTION 4 − SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the side. 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. Specifications For MIG (GMAW)

Input

Voltage

120 VAC

230 VAC

Rated Welding

Output

110 A @ 19.5 Volts DC, 20%

Duty Cycle

75 A @ 17.75 Volts DC,

100% Duty Cycle*

Wire Type

And Dia

150 A @ 21.5 Volts DC, 20%

Duty Cycle

120 A @ 20 Volts DC, 100%

Duty Cycle*

Wire Type

And Dia

Amperage

Range

30 − 140

Solid/Stainless Flux Cored Wire Feed Speed Range

.023 - .035 in.

(0.6 - 0.8 mm)

30 − 200 90

Solid/Stainless Flux Cored Wire Feed Speed Range

.023 − .035 in.

(0.6 − 0.9 mm)

* CSA Rating

4-3. Specifications For TIG (GTAW)

Input

Voltage

120 VAC

230 VAC

* CSA Rating

Rated Welding

Output

150 A @ 16 Volts DC, 30%

Duty Cycle

70 A @ 13 Volts DC, 100%

Duty Cycle*

150 A @ 16 Volts DC, 30%

Duty Cycle

100 A @ 14 Volts DC, 100%

Duty Cycle*

Amperage

Range

5 − 150

5 − 150 90

Maximum Open-

Circuit Voltage

DC

90

.030 - .035 in.

(0.8 - 0.9 mm)

.030 − .045 in.

(0.8 − 1.2 mm)

Maximum Open-

Circuit Voltage

DC

90

Amperes Input at Rated

Load Output, 50/60 Hz,

Single-Phase

22.4

14.6*

70 − 425 IPM (1.75 − 10.8 m/min)

17.5

13.1*

70 − 425 IPM (1.75 − 10.8 m/min)

Amperes Input at Rated

Load Output, 50/60 Hz,

Single-Phase

27.0

10.5*

13.8

15.9*

4-4. Specifications For Stick (SMAW)

Input

Voltage

120 VAC

230 VAC

* CSA Rating

Rated Welding

Output

100 A @ 24 Volts DC, 35%

Duty Cycle

70 A @ 22.8 Volts DC, 100%

Duty Cycle*

150 A @ 26 Volts DC, 30%

Duty Cycle

100 A @ 24 Volts DC, 100%

Duty Cycle*

Amperage

Range

20 − 100

20 − 150 90

Maximum Open-

Circuit Voltage

DC

90

Amperes Input at Rated

Load Output, 50/60 Hz,

Single-Phase

23.8

16.5*

20.8

12.7*

OM-253 392 Page 13

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

4-5. Dimensions And Weight

Weight

29 lb (13.2 kg)

Notes

9-3/4 in.

(248 mm)

14-1/2 in.
(368 mm)

17 in.

(432 mm)

253 921-B

OM-253 392 Page 14

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

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

4-6. Duty Cycle And Overheating For MIG

200

180

160

140

120

120VAC

100

80

Output Amperes

60

40

20

230VAC

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.

0

10 100

20

% Duty Cycle

120V Input

20% Duty Cycle At 110A

2 Minutes Welding 8 Minutes Resting

230V Input

20% Duty Cycle At 150A

2 Minutes Welding 8 Minutes Resting

Overheating

50

100% Duty Cycle At 75A

Continuous

Welding

100% Duty Cycle At 120A

Continuous

Welding

0

A or V

Minutes

15

OR

Reduce Duty Cycle

duty1 4/95 − Ref. Duty Cycle Charts

OM-253 392 Page 15

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

4-7. Duty Cycle And Overheating For TIG

200

180

230V & 120V 20A

160

140

120

100

80

60

Output Amperes

40

20

120V 15A

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.

0

10 100

% Duty Cycle

120V Input

30% Duty Cycle At 150A

3 Minutes Welding 7 Minutes Resting

230V Input

30% Duty Cycle At 150A

3 Minutes Welding 7 Minutes Resting

Overheating

30

0

Minutes

15

50

100% Duty Cycle At 75A

Continuous

Welding

100% Duty Cycle At 100A

Continuous

Welding

A or V

OR

Reduce Duty Cycle

OM-253 392 Page 16

duty1 4/95 − Ref. Duty Cycle Charts

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

4-8. Duty Cycle And Overheating For Stick

200

180

230V

160

140

120

100

80

Output Amperes

60

40

20

120V 20A

120V 15A

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.

0

10 100

30

% Duty Cycle

120V Input

35% Duty Cycle At 100A

3-1/2 Minutes Welding 6-1/2 Minutes Resting

230V Input

30% Duty Cycle At 150A

3 Minutes Welding 7 Minutes Resting

Overheating

50

100% Duty Cycle At 70A

Continuous

Welding

100% Duty Cycle At 100A

Continuous

Welding

0

A or V

Minutes

15

OR

Reduce Duty Cycle

duty1 4/95 − Ref. Duty Cycle Charts

OM-253 392 Page 17

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

SECTION 5 − INSTALLATION

5-1. Selecting A Location

Tipping

! Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.

1 Line Disconnect Device
Locate unit near correct input

power supply.

Location

18 in.

(460 mm)

1

18 in.

(460 mm)

! Do not move or operate unit

where it could tip.

loc_2 3/96 - 253 921-B

OM-253 392 Page 18

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

5-2. Stick Welding Connections

1

3

! Turn off unit and disconnect

input power before making
connections.

1 Positive Weld Output

Receptacle

2 Negative Weld Output

Receptacle

3 Stick Electrode Holder And

Cable
4 Work Clamp And Cable
Connect stick electrode holder

cable to the positive weld output
receptacle, and connect work
clamp to negative weld output
receptacle.

Ensure all connections are tight.

2

4

Ref. 254 251-B

OM-253 392 Page 19

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

5-3. TIG Welding Connections DCEN (Direct Current Electrode Negative)

! Turn off unit and disconnect

input power before making

connections.

1 Positive Weld Output

Receptacle
2 Negative Weld Output

Receptacle
3 TIG Torch And Cable

1

4

2

3

5

8

4 Work Clamp And Cable
Connect TIG torch cable to the

negative weld output receptacle
and connect work clamp to positive
weld output receptacle.

Ensure all connections are tight.

5 Foot Control
6 Finger Tip Control
7 Remote Control Cable
8 Six Pin Remote Control

Receptacle
Route control cable through MIG

gun hole.
Connect foot control or finger tip

control to six pin remote control
receptacle.

9 TIG Shielding Gas

Connection
Use Argon gas for TIG welding (see

Section 5-7).

6

7

9

OM-253 392 Page 20

Ref. 254 251-B / Ref. 254 249-B / Ref. 254 247-B

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

5-4. Process/Polarity Table

Process Polarity

Wire Drive Assembly Cable Work Cable

Cable Connections

GMAW − Solid wire with shielding gas DCEP − Reverse polarity Connect to positive (+)

output receptacle

FCAW − Self-shielding wire − no
shielding gas

DCEN − Straight Polarity Connect to negative (−)

output receptacle

5-5. Wire Welding Connections

1

2

3

4

MIG − DCEP

(Direct Current Electrode Positive)

3

4

1

(Direct Current Electrode Negative)

Connect to negative (−)
output receptacle

Connect to positive (+)
output receptacle

2

Flux-Cored − DCEN

! Turn off unit and disconnect input

power before making connections.

1 Positive Weld Output Receptacle
2 Negative Weld Output Receptacle
3 Wire Drive Assembly Cable
4 Work Clamp And Cable

Ensure all connections are tight.

7

6

8

5

Ref. 254 252-B / Ref. 254 249-A / Ref. 254 247-B

5 Gun End
Connect gun end to drive assembly (see

Section 5-6).
6 Trigger Control Cable
7 Four Pin Trigger Control Cable

Receptacle

Route trigger control cable through MIG
gun hole.

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

8 MIG Shielding Gas Connection

Use 75/25 mix or CO2 shielding gas for
solid wire. Use Argon shielding gas for
aluminum wire with spool gun (see Section
5-7).

OM-253 392 Page 21

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

5-6. Wire Gun Connection Inside Unit

6

5

3

4

2

1

1 Gun Securing Knob

2 Gun Block

3 Gun Outlet Wire Guide

4 Gun End

. Be sure that gun end is tight against drive assembly.

Correct Incorrect

Ref. 254 249-A

Loosen knob. Insert end of gun through

opening in front panel until gun end
bottoms against gun block. Tighten

knob.

5 Trigger Control Cable

44

6 Four Pin Trigger Control Cable

Receptacle

Route trigger control cable through MIG
gun hole.

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

Ref. 801 987

OM-253 392 Page 22

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

5-7. Connecting Shielding Gas Supply

1

2

3

Mixed Gas

1

9

2

3

CO2 Gas

8

10

4

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 Cylinder
4 Regulator/Flowmeter
Install so face is vertical.

1

2

3

Argon Gas

4

8

5

5 Regulator/Flowmeter Gas

Hose Connection

6 Welding Power Source CO

And Mixed Gas Hose
Connection

7 Welding Power Source Argon

Gas Hose Connection

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

8 Flow Adjust
Typical flow rate for CO2 shielding

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

Typical flow rate for Argon shielding
gas and TIG (GTAW) welding is 15
to 25 cfh and aluminum MIG
(GMAW) welding is 35 to 45 cfh.
Check wire manufacturer’s
recommended flow rate.

9 CO2 Adapter (Customer

Supplied)
10 O-Ring (Customer Supplied)
Install adapter with O-ring between

regulator/flowmeter and CO
cylinder.

2

2

6

7

MIG TIG

Tools Needed:

Ref. 804 654-A / 254 247-B

OM-253 392 Page 23

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

5-8. Electrical Service Guide

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and

630.12.

Elec Serv 2011−08

. Actual input voltage should not exceed  10% of indicated required input voltage. If actual input voltage is outside of this range, output may not

be available.

50/60 Hz 230

Single Phase

Input Voltage (V) 230
Input Amperes (A) At Rated Output 17.7
Max Recommended Standard Fuse Rating In Amperes

Time-Delay Fuses

Normal Operating Fuses

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG

Reference: 2011 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.

3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and

above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable

requirements.

4

4

1

2

3

20
25
14
65

(20)

14

50/60 Hz 120

Volts AC

A 15 or 20

ampere

individual

branch circuit

protected by

time-delay

fuses or

circuit breaker

is required.

See Section

5-11

5-9. Extension Cord Data

Input Power

Input Voltage

120 V 1 50/60 14 AWG 24 ft (7 m)

230 V 1 50/60 14 AWG 65 ft (20 m)

Phase

Hertz Conductor Size Max. Cord Length

OM-253 392 Page 24

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

5-10. Multi−Voltage Plug (MVP) Connection

Selecting Plug

2

3

4

5

1

! Do not cut off power cord con-

nector and rewire. The power
cord connector and plugs will
work with standard NEMA re­ceptacles. Modifying power

6

7

cord, connector, and plugs will
void product warranty.

Selecting Plug

1 Power Cord Connector From

Welding Power Source

Select plug for power supply receptacle
available at site. Not all plugs shown are
provided as standard with unit.

2 Plug − NEMA Type 5−15P
3 Receptacle − NEMA Type 5−15R

(Customer Supplied)

Connecting Plug To Power Cord

4 Plug − NEMA Type 5−20P (Optional)
5 Receptacle − NEMA Type 5−20R

(Customer Supplied)
6 Plug − NEMA Type 6−50P
7 Receptacle − NEMA Type 6−50R

(Customer Supplied)

! Follow electrical service guide for

230 VAC in Section 5-8. Do not use

plug rating to size branch circuit

protection.

MVP Plug1 2010−10 / Ref. 803 812-C

Connecting Plug To Power Cord

Align arrow on plug with arrow on power
cord connector. Push together.

Tighten threaded collar. As threaded collar
is tightened, push plug onto adapter until
collar is completely tight.

Connect plug to receptacle.

OM-253 392 Page 25

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

5-11. Connecting 115 Volt Input Power

! Installation must meet all

National and Local Codes − have
only qualified persons make this
installation.

! Special installation may be

required where gasoline or volatile
liquids are present − see NEC
Article 511 or CEC Section 20.

NOTICE − The Auto-Line circuitry in this
unit automatically links the power source
to the primary voltage being applied, either
115 or 230 VAC.

1

2

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

For 115 volts AC input power, a 15 or 20
ampere individual branch circuit protected
by time-delay fuses or circuit breaker is
required.

1 Multi-Voltage Plug And Power Cord

Connector (NEMA Type 5−15P Plug
Shown)

For multi−voltage plug connections, see
Section 5-10.

1 Plug From Unit
2 Receptacle − NEMA Type 5−15R

(Customer Supplied)

OM-253 392 Page 26

Input6 2011−03 253 921-B / Ref. 805 474-A

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

5-12. Connecting 1-Phase Input Power For 230 VAC

1

L2

3

L1

6

1

8

L1

=GND/PE Earth Ground

7

2

4

5

L2

Tools Needed:

230 VAC, 1

input4 2012-05 − 803 766-C / Ref. 802 443-A / 253 921-B

OM-253 392 Page 27

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

5-12. Connecting 1-Phase Input Power For 230 VAC (Continued)

! Installation must meet all National and

Local Codes − have only qualified per­sons make this installation.

! Disconnect and lockout/tagout input

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

! Always connect green or green/yellow

conductor to supply grounding termi­nal first, and never to a line terminal.

NOTICE − The Auto-Line circuitry in this unit
automatically links the power source to the

primary voltage being applied, either 115 or
230 VAC.

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

1 Input Power Cord
2 Disconnect Device (switch shown in the

OFF position)
3 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 Section 5-8 (fused
disconnect switch shown).

8 Receptacle (NEMA 6-50R)

Customer Supplied

Close and secure door on disconnect device.
Remove lockout/tagout device, and place
switch in the On position.

input4 2012−05 − 803 766-C

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-253 392 Page 28

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

5-13. Installing Wire Spool And Adjusting Hub Tension

1

2

Installing 4 in. (102 mm) Wire Spool

1 Wire Spool
2 Retaining Nut [For 8 in. (203

mm) Spool Only]

Installing 8 in. (203 mm) Wire Spool

Adapter used with 8 in.

(203 mm) spool only.

When a slight force is needed
to turn spool, tension is set.

When a slight force is needed
to turn spool, tension is set.

Align locking hole in
spool with locking
pin on spool hub.

Tools Needed:

Retaining ring used with 8 in.

(203 mm) spool only.

1/2 in.

Ref. 254 253-A / 803 012 / 803 013 -B / Ref. 802 444-C

OM-253 392 Page 29

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

5-14. Threading Welding Wire

521 3 6

4

7

. Hold wire tightly to keep it

from unraveling.

1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4 Pressure Adjustment Knob
5 Drive Roll
6 Outlet Wire Guide
7 Gun Conduit Cable
Lay gun cable out straight.

Tools Needed:

6 in.

(150 mm)

Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;

continue to hold wire.

. Use pressure indicator scale to set a desired

Close and tighten pressure

assembly, and let go of wire.

Tighten

1
2
3
4

drive roll pressure. Begin with a setting of 2.
If necessary, make additional adjustments
after trying this initial setting.

Pressure
Indicator

Scale

Remove gun nozzle and contact tip. Turn On.

Tighten

Press gun trigger until wire

comes out of gun. Reinstall

contact tip and nozzle

OM-253 392 Page 30

1
2
3

WOOD

4

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close

and latch door.

Ref. 254 253-A / Ref. 804 913-A

6-1. Controls

1

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

SECTION 6 − OPERATION

2

1 Process Select Knob
Turn knob to select the desired

welding process.
2 Auto-Set Button
Press button to turn Auto-Set On or

Off.
3 Wire/Rod/Tungsten Buttons
Press the Plus (+) or Minus (−)

button to select the size of wire, rod,
or tungsten for the selected
process.

4 Material Thickness Buttons
Press the Plus (+) or Minus (−)

button to select material thickness
for the selected process.

5 Display
6 Adjustment Knob
7 Power Switch
Use switch to turn unit On or Off.

3

5

6

7

Rear
View

4

6

Ref. 249 632-E / 253 923-B

OM-253 392 Page 31

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

6-2. Weld Parameter Chart

OM-253 392 Page 32

Ref. 252 671-E

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

6-3. Entering Setup Menu

1 Wire/Rod/Tungsten Minus (−)

Button

2 Material Thickness Plus (+)

Button
3 Display
When unit is turned off, press and

hold Wire/Rod/Tungsten Minus (−)
button and Material Thickness Plus
(+) button simultaneously.

Turn unit power on.
When Display shows MULTIMATIC

200 setup screen, release the two
buttons simultaneously.

The contrast adjustment screen
should be displayed.

1

3

2

Ref. 249 632-E

OM-253 392 Page 33

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

6-4. Adjusting Display Contrast (Menu 1 Of 10)

1 Adjustment Knob
2 Material Thickness Plus (+)

Button
Follow instructions in Section 6-3 to

enter the setup menu.
The Display Contrast should now

appear on the display.
To adjust display contrast, turn

either Adjustment knob.
Cycle through menu items using

the Material Thickness Plus (+) but­ton or cycle unit power to save set­tings and exit menu.

Cycle unit power before welding
to complete initialization process.

2

1

1

Ref. 249 632-E

6-5. Calibrating Drive Motor (Menu 2 Of 10)

. The unit’s internal drive motor is calibrated at the factory. No calibration is needed unless drive motor or user interface board is changed. Contact

nearest factory authorized Service Agent or Miller Electric Mfg. Co. Service department.

OM-253 392 Page 34

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

6-6. Calibrating Spoolmate 100 (Menu 3 Of 10)

2

1 Material Thickness Plus (+)

Button
2 Left Adjustment Knob
3 Right Adjustment Knob

. Spoolmate 100 drive motors

are unique to this welding

power source. Motor calibra-

tion is necessary any time a dif-

ferent Spoolmate 100 is con-

nected to the Multimatic 200.

Connect Spoolmate 100 to unit. Cut
wire flush at nozzle.

Follow instructions in Section 6-3 to
enter the setup menu.

Press Material Thickness Plus (+)
button twice after entering setup to
enter the Spoolmate Calibration
menu.

To perform a Spoolmate calibration
24 in. runout test at 100 ipm, turn left
Adjustment knob and verify that a
(n) check mark appears next to
100 IPM. Be sure that wire is cut
flush at nozzle, then trigger the
Spoolmate 100.

Spoolmate will feed approximately
24 in. of wire through gun.

1

Cut wire flush at nozzle and meas­ure run-out.

If wire is not 24 inches long, use left
Adjustment knob to increase or de­crease the length of the run-out and
repeat the test.

To perform a Spoolmate calibration
24 in. runout test at 300 ipm, turn
right Adjustment knob and verify
that a (n) check mark appears next
to 300 IPM. Be sure tthat wire is cut
flush at nozzle, then trigger the
Spoolmate 100.

Spoolmate will feed approximately
24 in. of wire through gun.

Cut wire flush at nozzle and meas­ure run-out.

3

If wire is not 24 inches long, use
right Adjustment knob to increase
or decrease the length of the
run-out and repeat the test.

Cycle through menu items using
the Material Thickness Plus (+) but­ton or cycle unit power to save set­tings and exit menu.

Cycle unit power before welding
to complete initialization process.

Tools Needed:

Ref. 249 632-E

OM-253 392 Page 35

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

6-7. Enable/Disable Auto−Cratert (Menu 4 Of 10)

1 Adjustment Knob
2 Material Thickness Plus (+)

Button
Follow instructions in Section 6-3 to

enter the setup menu.
Press Material Thickness Plus (+)

button three times after entering
setup to enter the Auto−Crater fea-
ture menu.

. Auto−Crater is disabled by

default.

Rotate adjustment knob clockwise
to enable Auto−Crater.

Rotate adjustment knob counter­clockwise to disable Auto−Crater.

Cycle through menu items using
the Material Thickness Plus (+) but­ton or cycle unit power to save set­tings and exit menu.

Cycle unit power before welding
to complete initialization process.

2

1

1

OM-253 392 Page 36

Ref. 249 632-E

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

6-8. Viewing Burn-In Information (Menu 5 Of 10)

. Burn-In information is for factory and service use only.

Follow instructions in Section 6-3 to enter the setup menu.
Press Material Thickness Plus (+) button four times after entering setup to enter the Burn-In information screen.
Burn-In information displays electrical information unique to the unit.
Cycle through menu items using the Material Thickness Plus (+) button or cycle unit power to save settings and exit menu.

Cycle unit power before welding to complete initialization process.

6-9. Viewing Software Information (Menu 6 Of 10)

. Software information is for factory and service use only.

Follow instructions in Section 6-3 to enter the setup menu.
Press Material Thickness Plus (+) button five times after entering setup to enter the Software information screen.
Software information displays software information unique to the unit.
Cycle through menu items using the Material Thickness Plus (+) button or cycle unit power to save settings and exit menu.

Cycle unit power before welding to complete initialization process.

6-10. Viewing Primary Power Information (Menu 7 Of 10)

. Primary Power information is for factory and service use only.

Follow instructions in Section 6-3 to enter the setup menu.
Press Material Thickness Plus (+) button six times after entering setup to enter the Primary Power Logs screen.
Primary Power Logs screen displays unit power on time.
Cycle through menu items using the Material Thickness Plus (+) button or cycle unit power to save settings and exit menu.

Cycle unit power before welding to complete initialization process.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-253 392 Page 37

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

6-11. Viewing Process Logs (Menu 8 Of 10)

2

1 Material Thickness Plus (+)

Button
2 Process Select Knob
Follow instructions in Section 6-3 to

enter the setup menu.
Press Material Thickness Plus (+)

button seven times after entering
setup to enter the Process Logs
screen.

Process Logs screen displays
manual minutes, Auto-Set minutes,
weld cycles, and Auto-Set cycles
for the selected process.

To view other processes, use the
Process Select knob to select the
desired weld process.

Cycle through menu items using
the Material Thickness Plus (+) but­ton or cycle unit power to save set­tings and exit menu.

Cycle unit power before welding
to complete initialization process.

1

OM-253 392 Page 38

Ref. 249 632-E

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

6-12. Viewing Error Logs (Menu 9 Of 10)

1 Material Thickness Plus (+)

Button
Follow instructions in Section 6-3 to

enter the setup menu.
Press Material Thickness Plus (+)

button eight times after entering
setup to enter the Process Logs
screen.

Error Logs screen displays unit
over-temperature errors, shorted
output errors, shorted trigger er­rors, input voltage errors, and input
current errors.

Cycle through menu items using
the Material Thickness Plus (+) but­ton or cycle unit power to save set­tings and exit menu.

Cycle unit power before welding
to complete initialization process.

1

Ref. 249 632-E

OM-253 392 Page 39

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

6-13. Performing A Factory Reset (Menu 10 Of 10)

1 Material Thickness Plus (+)

Button
2 Auto-Set Button

. A Factory Reset will reset the

primary log data, process log

data, and error log data. Con-

trast settings, motor calibration

settings, Spoolmate Calibra-

tion settings, Burn-In informa-

tion, and Software information

will all be retained.

Follow instructions in Section 6-3 to
enter the setup menu.

Press Material Thickness Plus (+)
button nine times after entering
setup to enter the Factory Reset
screen.

To perform a Factory Reset, press
the Auto-Set button. To exit this

2

screen without performing a factory
reset, press the Material Thickness
Plus (+) button.

Cycle unit power before welding
to complete initialization process.

1

OM-253 392 Page 40

Ref. 249 632-E

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

SECTION 7 − MAINTENANCE &TROUBLESHOOTING

7-1. Routine Maintenance

n = Check Z = Change ~ = Clean l = Replace
* To be done by Factory Authorized Service Agent

Every
3
Months

l Damaged Or Unreadable
Labels

Every
6
Months

~ Inside Unit ~ Clean Drive Rolls

OR

7-2. Overload Protection

l Repair Or Replace
Cracked Weld Cable

1

! Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

Reference

1 Supplementary Protector CB1
CB1 protects unit from overload. If

CB1 opens, unit shuts down.
Reset supplementary protector.

253 923-B

OM-253 392 Page 41

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

7-3. Changing Drive Roll Or Wire Inlet Guide

1

2

3

.024 Groove.030/.035 Groove

1 Inlet Wire Guide
Remove guide by pressing on

barbed area or cutting off one end
near housing and pulling it out of
hole. Push new guide into hole from
rear until it snaps in place.

2 Drive Roll
The drive roll consists of two

different sized grooves. The
stamped markings on the end
surface of the drive roll refers to the
groove on the opposite side of the
drive roll. The groove closest to the
motor shaft is the proper groove to
thread (see Section 5-14).

3 Retaining Pin
To secure drive roll, locate open slot

and push drive roll completely over
retaining pin, then rotate drive roll
1/4 turn to closed slot.

Stamped .024

Stamped .030/.035

7-4. Error Messages

Message Error Remedy

NETWORK 1 ERROR The two microcontrollers on the control board are no

NETWORK 2 ERROR The microcontroller on the user interface board is

CABLE ERROR

longer communicating.

no longer communicating with the microcontroller on
the control board.

The microcontroller on the user interface board is
no longer communicating with the microcontroller on
the control board.

A process that requires a welding gun to not be
attached to the internal motor is selected, but the
wire drive assembly cable is attached to either the
positive or negative stud of the power source.

802 984-A

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

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

Connect the wire drive assembly cable to either the
positive or negative stud, or select a different
process.

Remove the wire drive assembly cable to either the
positive or negative stud, or select a different
process.

OVERTEMP The internal temperature of the unit has exceeded

SHORTED OUTPUT ERROR The unit had determined that the welding gun has

ROD STUCK ERROR The unit had determined that the stick welding rod

SHORTED 4-PIN TRIGGER
ERROR

OM-253 392 Page 42

the maximum limit.

become shorted to the workpiece and turned off the
output.

has become stuck in the welding puddle and turned
off the output.

The 4-pin trigger has been held down on power up,
or the trigger has been held too long without
initiating an arc.

Wait for the unit to cool down. If the fan is not
running, contact Miller Electric Mfg. Co. service
department.

Once the trigger has been released, the error will
clear.

Remove the stick welding rod from the workpiece
and the output will turn back on after about 1
second.

Release the 4-pin trigger.

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

Message RemedyError

SHORTED 6-PIN REMOTE
ERROR

BRIDGE CURRENT ERROR Too much current has passed through the inverter

PRIMARY THERMISTOR
ERROR

SECONDARY THERMISTOR
ERROR

PRIMARY VOLTAGE ERROR The primary voltage has exceeded the maximum

PRIMARY CURRENT ERROR Too much current has passed through the primary

PRIMARY BOOST NOT READY The primary boost has not successfully been

The 6-pin remote has been held down on power
up, or the remote has been held too long without
initiating an arc.

bridge circuit of the unit.

The primary circuit thermistor is reading too high or
too low for a valid temperature.

The secondary circuit thermistor is reading too high
or too low for a valid temperature.

allowable limit.

circuit of the unit.

established.

7-5. Troubleshooting

Release the 6-pin remote.

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

Contact Miller Electric Mfg. Co. service department.

Contact Miller Electric Mfg. Co. service department.

Reduce the primary voltage to an acceptable level.

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

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

Trouble Remedy

No weld output; unit completely
inoperative.

No weld output; unit is on.

Erratic or improper welding arc or
output.

Fan not operating. Unit not warmed up enough to require fan cooling.

Stick welding problems: Hard starts;
poor welding characteristics; unusual
spattering.

TIG welding problems: Wandering arc;
hard starts; poor welding characteris­tics; spattering problems.

TIG welding problems: Tungsten
electrode oxidizing and not remaining
bright after welding.

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.
Unit overheated causing thermal shutdown. Allow unit to cool with fan On (see Section 4-6,4-7 and

4-8).
Reduce duty cycle or amperage.
Check and correct blocked/poor airflow to unit (see Section 5-1).
Turn Power Off and back On again. If light continues to flash, check with Factory Authorized Service

Agent.
Line voltage too high or too low. Line voltage must be within 10%.

Remote trigger left on. Turn off remote trigger, wait five seconds, and restart operation.
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.

Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor and control circuitry.
Use proper type and size of electrode.

Verify electrode polarity; check and correct poor connections.

Make sure a remote control is not connected.
Use proper type and size of tungsten.

Use properly prepared tungsten.
Verify electrode polarity.

Shield weld zone from drafts.
Check for correct type shielding gas.
Check and tighten gas fittings.
Verify electrode polarity.

OM-253 392 Page 43

SECTION 8 − ELECTRICAL DIAGRAM

OM-253 392 Page 44

Figure 8-1. Circuit Diagram

251 419-D

OM-253 392 Page 45

SECTION 9 − MIG WELDING (GMAW) GUIDELINES

9-1. Typical MIG Process Connections

Regulator/

Flowmeter

Wire Feeder/

Power Source

mig1 2009−12

! Weld current can damage

electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.

Shielding Gas

Gun

Gas

Workpiece

Work Clamp

Ref. 801 909-A

OM-253 392 Page 46

9-2. Typical MIG Process Control Settings

. These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure

they comply to specifications.

Material thickness determines weld
parameters.

1/8 or 0.125 in.

Convert Material

Thickness to

Amperage (A)

(0.001 in. = 1 ampere)

0.125 in. = 125 A

.035 in

Wire

Size

0.023 in.

0.030 in.

0.035 in.

Recommendation

3.5 in. per ampere
2 in. per ampere

1.6 in. per ampere

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)

Set voltage midway between high/low voltage

Voltage controls height and
width of weld bead.

Wire Size Amperage Range

0.023 in.

0.030 in.

0.035 in.

30 − 90 A
40 − 145 A
50 − 180 A

Wire Speed

(Approx.)

3.5 x 125 A = 437 ipm
2 x 125 A = 250 ipm

1.6 x 125 A = 200 ipm

Select Wire Size

Select Wire Speed

(Amperage)

125 A based on 1/8 in.

material thickness

ipm = inches per minute

Select Voltage

Wire speed (amperage) controls weld
penetration (wire speed = burn-off rate)

OM-253 392 Page 47

9-3. Holding And Positioning Welding Gun

. Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in. (13 mm)

past end of nozzle, and tip of wire is positioned correctly on seam.

1

2

5

4

0-15

90 90

End View of Work Angle Side View of Gun Angle

GROOVE WELDS

45

0-15

1 Hold Gun and Control Gun

Trigger

2 Workpiece

3

3 Work Clamp
4 Electrode Extension (Stickout)

1/4 to 1/2 in. (6 To 13 mm)

5 Cradle Gun and Rest Hand on

Workpiece

45

End View of Work Angle Side View of Gun Angle

FILLET WELDS

S-0421-A

OM-253 392 Page 48

9-4. Conditions That Affect Weld Bead Shape

. 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.

10

Push

Perpendicular

GUN ANGLES AND WELD BEAD PROFILES

Short Normal Long

ELECTRODE EXTENSIONS (STICKOUT)

Short Normal Long

10

Drag

FILLET WELD ELECTODE EXTENSIONS (STICKOUT)

Slow

Normal Fast

GUN TRAVEL SPEED

S-0634

OM-253 392 Page 49

9-5. Gun Movement During Welding

. 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

1 2

3

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.

S-0054-A

9-6. Poor Weld Bead Characteristics

1 Large Spatter Deposits

1

2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration

2

9-7. Good Weld Bead Characteristics

2

4

3

4

3

5

1 Fine Spatter
2 Uniform Bead

1

5

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

S-0053-A

S-0052-B

OM-253 392 Page 50

9-8. Troubleshooting − Excessive Spatter

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

S-0636

Possible Causes Corrective Actions

Wire feed speed too high. Select lower wire feed speed.

Voltage too high. Select lower voltage range.

Electrode extension (stickout) too long. Use shorter electrode extension (stickout).

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

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

Dirty welding wire. Use clean, dry welding wire.

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

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

9-9. Troubleshooting − Porosity

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

S-0635

Possible Causes Corrective Actions

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

Remove spatter from gun nozzle.

Check gas hoses for leaks.

Place nozzle 1/4 to 1/2 in. (6-13 mm) from workpiece.

Hold gun near bead at end of weld until molten metal solidifies.

Wrong gas. Use welding grade shielding gas; change to different gas.

Dirty welding wire. Use clean, dry welding wire.

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

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

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

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

9-10. Troubleshooting − Excessive Penetration

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

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

Good Penetration

Increase travel speed.

S-0639

OM-253 392 Page 51

9-11. Troubleshooting − Lack Of Penetration

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

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

S-0638

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while

Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.

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

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

maintaining proper welding wire extension and arc characteristics.

Keep arc on leading edge of weld puddle.

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

Reduce travel speed.

9-12. Troubleshooting − Incomplete Fusion

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

S-0637

Possible Causes Corrective Actions

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

welding.

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

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

9-13. Troubleshooting − Burn-Through

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

Possible Causes Corrective Actions

Excessive heat input. Select lower voltage range and reduce wire feed speed.

S-0640

OM-253 392 Page 52

Increase and/or maintain steady travel speed.

9-14. Troubleshooting − Waviness Of Bead

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

Possible Causes Corrective Actions

Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle.

Unsteady hand. Support hand on solid surface or use two hands.

9-15. Troubleshooting − Distortion

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

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

S-0641

S-0642

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.

OM-253 392 Page 53

9-16. 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.

Application

Gas

Argon X

Argon + 25% CO

80% or greater Argon +

balance CO2 or Oxygen

100% CO

Tri-Mix

1 Limited short circuiting use

2 90% HE + 7-1/2% AR + 2-1/2% CO

2

2

2

Spray Arc Steel Short Circuiting Steel

X X

2

X

1

X

Short Circuiting

Stainless Steel

X

9-17. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem Probable Cause Remedy

Wire feed motor operates, but
wire does not feed.

Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls.

Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to match

wire size and type if necessary.

Wire spool brake pressure too high. Decrease brake pressure on wire spool.

Aluminum

Wire curling up in front of the
wire feed rolls (bird nesting).

Wire feeds, but no gas flows.

Restriction in the gun and/or assembly. Check and replace cable, gun, and contact tip if

Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.

Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner length

Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push gun

Dirty or damaged (kinked) liner. Replace liner.

Gas cylinder empty. Replace empty gas cylinder.

Gas nozzle plugged. Clean or replace gas nozzle.

Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.

Restriction in gas line. Check gas hose between flowmeter and wire feeder, and

Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wiring.

Gas solenoid valve not operating. Have Factory Authorized Service Agent replace gas

Incorrect primary voltage connected to welding power
source.

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

and diameter, replace if necessary.

end into housing just enough so it does not touch wire
feed rolls.

gas hose in gun and cable assembly.

solenoid valve.

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

Welding arc not stable.

OM-253 392 Page 54

Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn

drive rolls if necessary.

Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type.

Problem RemedyProbable Cause

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

Loose connections at the gun weld cable or work cable. Check and tighten all connections.

Gun in poor shape or loose connection inside gun. Repair or replace gun as necessary.

Readjust welding parameters.

OM-253 392 Page 55

SECTION 10 − STICK WELDING (SMAW) GUIDELINES

10-1. Stick Welding Procedure

! Weld current starts when

electrode touches work-

Tools Needed:

Equipment Needed:

Constant Current

Welding Power Source

5

4

2

3

piece.

! Weld current can damage

electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp
as close to the weld as
possible.

. Always wear appropriate per-

sonal protective clothing.

1 Workpiece
Make sure workpiece is clean be-

fore welding.
2 Work Clamp
3 Electrode
A small diameter electrode re-

quires less current than a large
one. Follow electrode manufactur­er’s instructions when setting weld
amperage (see Section 10-2).

4 Insulated Electrode Holder
5 Electrode Holder Position
6 Arc Length
Arc length is the distance from the

electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.

7 Slag
Use a chipping hammer and wire

brush to remove slag. Remove
slag and check weld bead before
making another weld pass.

OM-253 392 Page 56

6

1

7

stick 2010−02 − 151 593

10-2. Electrode and Amperage Selection Chart

ELECTRODE

6010

&

6011

6013

7014

7018

7024

Ni-Cl

308L

DIAMETER

3/32

1/8
5/32
3/16
7/32

1/4
1/16
5/64
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
7/32

1/4
3/32

1/8
5/32
3/16
3/32

1/8
5/32

RANGE

AMPERAGE

50

100

150

200

250

300

350

400

450

ELECTRODE

6010

6011

6013

7014

7018

7024

NI-CL

308L

*EP = ELECTRODE POSITIVE (REVERSE POLARITY)
EN = ELECTRODE NEGATIVE (STRAIGHT POLARITY)

EP
EP

EP,EN

EP,EN

EP

EP,EN

EP
EP

DC*

AC

POSITION

ALL
ALL
ALL

ALL

ALL

FLAT
HORIZ
FILLET

ALL
ALL

PENETRATION

DEEP

MIN. PREP, ROUGH

DEEP

LOW

MED

LOW HYDROGEN,

MED

LOW

LOW
LOW

USAGE

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

STRONG

SMOOTH, EASY,

FASTER

CAST IRON
STAINLESS

Ref. S-087 985-A

10-3. Striking an Arc

1 Electrode
2 Workpiece
3 Arc

Scratch Technique

1

Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
goes out, electrode was lifted too
high. If electrode sticks to work-

2

piece, use a quick twist to free it.

Tapping Technique

Bring electrode straight down to

3

1

workpiece; then lift slightly to start
arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free
it.

2

3

S-0049 / S-0050

OM-253 392 Page 57

10-4. Positioning Electrode Holder

1

1 End View Of Work Angle
2 Side View Of Electrode Angle

10-30

90 90

Groove Welds

1

45

45

Fillet Welds

10-5. Poor Weld Bead Characteristics

10-30

2

2

2

S-0060

1 Large Spatter Deposits
2 Rough, Uneven Bead
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration

4

3

1

10-6. Good Weld Bead Characteristics

1

OM-253 392 Page 58

5

S-0053-A

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.

5234

4 No Overlap
5 Good Penetration into Base

Metal

S-0052-B

10-7. Conditions That Affect Weld Bead Shape

Correct Angle

Angle Too Small

Electrode Angle

10 - 30

Drag

. Weld bead shape is affected

by electrode angle, arc
length, travel speed, and thick­ness of base metal.

Angle Too Large

Spatter

Arc Length

Too Short

Travel Speed

Slow

Normal Too Long

Normal Fast

10-8. Electrode Movement During Welding

1

3

S-0061

. 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

2

stringer beads work 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. Do not let weave width ex­ceed 2-1/2 times diameter of
electrode.

S-0054-A

OM-253 392 Page 59

10-9. Groove (Butt) Joints

1

3

1/16 in.

(1.6 mm)

30

1 Tack Welds
Prevent edges of joint from draw-

ing together ahead of electrode by
tack welding the materials in posi­tion before final weld.

2

4

2 Square Groove Weld
Good for materials up to 3/16 in. (5

mm) thick.
3 Single V-Groove Weld
Good for materials 3/16 − 3/4 in.

(5-19 mm) thick. Cut bevel with
oxyacetylene or plasma cutting
equipment. Remove scale from
material after cutting. A grinder can
also be used to prepare bevels.

Create 30 degree angle of bevel on
materials in V-groove welding.

4 Double V-Groove Weld
Good for materials thicker than

3/16 in. (5 mm).

S-0062

10-10. Lap Joint

2

10-11. Tee Joint

1 Electrode
2 Single-Layer Fillet Weld
Move electrode in circular motion.

30
Or Less

1

3

1

45

Or

2

Less

2

30
Or Less

1

3

3 Multi-Layer Fillet Weld
Weld a second layer when a heavi-

er fillet is needed. Remove slag be­fore making another weld pass.
Weld both sides of joint for maxi­mum strength.

1 Electrode
2 Fillet Weld
Keep arc short and move at defi-

nite rate of speed. Hold electrode
as shown to provide fusion into the
corner. Square edge of the weld
surface.

For maximum strength weld both
sides of upright section.

1

3 Multi-Layer Deposits
Weld a second layer when a heavi-

er fillet is needed. Use any of the
weaving patterns shown in Section
10-8. Remove slag before making
another weld pass.

S-0063 / S-0064

OM-253 392 Page 60

S-0060 / S-0058-A / S-0061

10-12. Weld Test

3

2 To 3 in.

(51-76 mm)

1/4 in.

(6.4 mm)

10-13. Troubleshooting

1 Vise
2 Weld Joint
3 Hammer
Strike weld joint in direction shown.

A good weld bends over but does
not break.

3

2 To 3 in.

(51-76 mm)

2
1

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

2

1

S-0057-B

Possible Causes Corrective Actions

Arc length too long. Reduce arc length.

Damp electrode. Use dry electrode.

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

Possible Causes Corrective Actions

Amperage too high for electrode. Decrease amperage or select larger electrode.

Arc length too long or voltage too high. Reduce arc length or voltage.

Possible Causes Corrective Actions

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

welding.

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

Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding

weld bead.

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

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

welding.

OM-253 392 Page 61

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

Lack of Penetration

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.

Improper weld technique. Keep arc on leading edge of weld puddle.

Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.

Excessive Penetration

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Good Penetration

Reduce travel speed.

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

Good Penetration

Increase and/or maintain steady travel speed.

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

Possible Causes Corrective Actions

Excessive heat input. Select lower amperage. Use smaller electrode.

Increase and/or maintain steady travel speed.

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

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

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

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

Excessive heat input. Use restraint (clamp) to hold base metal in position.

Make tack welds along joint before starting welding operation.

OM-253 392 Page 62

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

SECTION 11 − SELECTING AND PREPARING A

TUNGSTEN

FOR DC OR AC WELDING WITH INVERTER MACHINES

gtaw_Inverter_2011-06

Whenever possible and practical, use DC weld output instead of AC weld output.

11-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten)

. Not all tungsten electrode manufacturers use the same colors to identify tungsten type. Contact the tungsten electrode manufacturer or reference

the product packaging to identify the tungsten you are using.

Amperage Range - Gas Type - Polarity

Electrode Diameter (DCEN) − Argon

Direct Current Electrode Negative

(For Use With Mild Or Stainless Steel)

2% Ceria, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens

.010 in. (1 mm) Up to 25 Up to 20
.020 in. (1 mm) 15-40 15-35

.040 in. (1 mm) 25-85 20-80
1/16 in. (1.6 mm) 50-160 50-150
3/32 in. (2.4 mm) 130-250 135-235

1/8 in. (3.2 mm) 250-400 225-360
5/32 in. (4.0 mm) 400-500 300-450
3/16 in (4.8 mm) 500-750 400-500

1/4 in. (6.4 mm) 750-1000 600-800

Balance Control @ 65% Electrode Negative

Typical argon shielding gas flow rates are 11 to 35 CFH (cubic feet per hour).

Figures listed are a guide and are a composite of recommendations from American Welding Society (AWS) and electrode manufacturers.

AC − Argon

(For Use With Aluminum)

11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding

Or AC Welding With Inverter Machines

Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires.
Use local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety
information. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust
from thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an
environmentally safe way. Wear proper face, hand, and body protection. Keep flammables away.

Radial Grinding

Causes Wandering Arc

Wrong Tungsten

Preparation

2-1/2 Times

Electrode Diameter

2

4

Ideal Tungsten Preparation − Stable Arc

1 Grinding Wheel
Grind end of tungsten on fine grit, hard

3

abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated causing lower weld quality.

1

2 Tungsten Electrode
A 2% ceriated tungsten is recommended.
3 Flat
Diameter of this flat determines amperage

capacity.
4 Straight Ground
Grind lengthwise, not radial.

OM-253 392 Page 63

SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW)

12-1. Positioning The Torch

! Grinding the tungsten electrode

produces dust and flying sparks
which can cause injury and start
fires. Use local exhaust (forced
ventilation) at the grinder or wear
an approved respirator. Read
MSDS for safety information.
Consider using cerium or lantha­num based tungsten instead of
thoriated. Thorium dust contains
low-level radioactive material.
Properly dispose of grinder dust
in an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flam­mables away.

1 Workpiece
Make sure workpiece is clean before

welding.
2 Work Clamp
Place as close to the weld as possible.
3 Torch
4 Filler Rod (If Applicable)
5 Gas Cup
6 Tungsten Electrode
Select and prepare tungsten according

to Section 11.

Guidelines:

The inside diameter of the gas cup
should be at least three times the
tungsten diameter to provide adequate
shielding gas coverage. (For example,
if tungsten is 1/16 in. diameter, gas cup
should be a minimum of 3/16 in.
diameter.

Tungsten extension is the distance the
tungsten extends out gas cup of torch.

The tungsten extension should be no
greater than the inside diameter of the
gas cup.

Arc length is the distance from the
tungsten to the workpiece.

10−25

2

1

10−15

4

3/16 in.

Bottom View Of Gas Cup

90

5

3

4

5

6

6

1/16 in.

OM-253 392 Page 64

Ref. ST-161 892

12-2. Torch Movement During Welding

Tungsten Without Filler Rod

Welding direction

Form pool Tilt torch Move torch to front

Tungsten With Filler Rod

Welding direction

Form pool Tilt torch Add filler metal

Remove rod

75

75

15

Move torch to front

of pool. Repeat process.

12-3. Positioning Torch Tungsten For Various Weld Joints

Butt Weld And Stringer Bead

of pool. Repeat process.

ST-162 002-B

“T” Joint

90

20-40

30

20

15

Lap Joint

70

75

90

10

15

20

75

15

Corner Joint

75

ST-162 003 / S-0792

OM-253 392 Page 65

SECTION 13 − PARTS LIST

13-1. Recommended Spare Parts

Part

No.

235 570

194 010 Liner, Monocoil .023−.025 15 ft 1......... .............. ...................................

194 011 Liner, Monocoil .030−.035 15 ft 1.......... .............. ...................................

194 012 Liner, Monocoil .035−.045 15 ft 1......... .............. ...................................

QJL−2330 Liner, Jump Steel .023−030 1........ ............. .....................................

QJL−3545 Liner, Jump Steel .035−.045 1........ ............. .....................................

4323R Insulator, Nozzle (small) 1.......... ............... .........................................

DS−1 Diffuser, Centerfire (small nozzle) 1........... ............... ................................

T−023 Tip, Centerfire .023 in. 1.......... ............... ..........................................

T−030 Tip, Centerfire .030 in. 1.......... ............... ..........................................

T−035 Tip, Centerfire .035 in. 1.......... ............... ..........................................

T−045 Tip, Centerfire .045 in. 1.......... ............... ..........................................

NS−1200B Nozzle, Centerfire Small Brass 1/2 in. Flush 1........ ............. .......................

NS−5818C Nozzle, Centerfire Small Copper 5/8 in. Recess 1/8 in. 1........ ............. ..............

NS−5800B Nozzle, Centerfire Small Brass 5/8 in. Flush 1........ ............. .......................

NS−5818B Nozzle, Centerfire Small Brass 5/8 in. Recess 1/8 in. 1........ ............. ................

NS−1218C Nozzle, Centerfire Small Copper 1/2 in. Recess 1/8 in. 1........ ............. ..............

NS−1218B Nozzle, Centerfire Small Brass 1/2 in. Recess 1/8 in. 1........ ............. ................

4478 O−Ring, MIG Gun Power Pin 2........... ............... ....................................

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Q−150 MIG Gun

QuantityDescription

13-2. Drive Rolls

PART NO. WIRE DIAMETER INCHES (mm)

220 179 .024 (.6) and .030/.035 (.8 and .9) (Standard)
202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove)

. A complete Parts List is available on−line at www. MillerWelds. com

OM-253 392 Page 66

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, 2013

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

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

LIMITED WARRANTY − Subject to the terms and conditions below,
Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original
retail purchaser that new Miller equipment sold after the effective
date of this limited warranty is free of defects in material and
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Miller will repair or replace
any warranted parts or components that fail due to such defects in
material or workmanship. Miller must be notified in writing within
thirty (30) days of such defect or failure, at which time Miller will
provide instructions on the warranty claim procedures to be
followed.

Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment
to the original end-user purchaser, and not to exceed one year after
the equipment is shipped to a North American distributor or eighteen
months after the equipment is shipped to an International distributor.

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
* Auto-Darkening Helmet Lenses (Except Classic

Series) (No Labor)

* Engine Driven Welding Generators

(NOTE: Engines are Warranted Separately by the
Engine Manufacturer.)

* Inverter Power Sources (Unless Otherwise Stated)
* Oxy-Fuel Cutting Torches (No Labor)
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Smith Series 30 Flowgauge, Flowmeter, and Pressure

Regulators (No Labor)
* Transformer/Rectifier Power Sources
* Water Coolant Systems (Integrated)

3. 2 Years — Parts and Labor
* Auto-Darkening Helmet Lenses − Classic Series Only

(No Labor)

* Fume Extractors − Filtair 400 and Industrial Collector

Series

4. 1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors
* 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.)
* Flowgauge and Flowmeter Regulators (No Labor)
* RFCS Foot Controls (Except RFCS-RJ45)
* Fume Extractors − Filtair 130, MWX and SWX Series
* 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
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* Water Coolant Systems (Non-Integrated)
* Weldcraft-Branded TIG Torches (No Labor)
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)

guarantees or warranties expressed or implied.

5. 6 Months — Parts
* Batteries
* Bernard Guns (No Labor)
* Tregaskiss Guns (No Labor)

6. 90 Days — Parts
* Accessory (Kits)
* Canvas Covers
* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* M-Guns
* MIG Guns and Subarc (SAW) Guns
* Remote Controls and RFCS-RJ45
* Replacement Parts (No labor)
* Roughneck Guns
* Spoolmate Spoolguns

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.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in appropriate
cases, (3) the reasonable cost of repair or replacement at an
authorized Miller service station; or (4) payment of or credit for the
purchase price (less reasonable depreciation based upon actual
use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.

Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.

In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available, but
may vary from province to province.

miller_warr 2013-01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information

and Parts)
Circuit Diagrams
Welding Process Handbooks

To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller

Miller Electric Mfg. Co.

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA

USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]

For International Locations Visit

www.MillerWelds.com

Contact the Delivering Carrier to:

ORIGINAL INSTRUCTIONS − PRINTED IN USA  2013 Miller Electric Mfg. Co. 2013−01

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.