Miller Multimatic 200 User Manual

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OM-253 392F 201303
ProcessesProcesses
Multiprocess Welding
Description
Arc Welding Power Source Wire Feeder
Multimatic 200
Visit our website at
www.MillerWelds.com
File: Multiprocess
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From Miller to You
Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy.
Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The
Miller is the first welding 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
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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. MultiVoltage 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 AutoCratert (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.............................................
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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
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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
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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.
Page 7
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. 94110) 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
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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: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Glob-
al Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga­net.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060
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: 212-642-4900, web­site: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, 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: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, 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 passersby 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
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SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
7
Pour écarter les risques de blessure pour vousmême et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire.
fre_som_201110
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;
protégezles 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
Page 10
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 coupecircuits 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 coupecircuits 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.
Page 11
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
Page 12
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 radionavigation 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.
Page 13
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Glob-
al Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga­net.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060
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: 212-642-4900, web­site: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, 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: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, 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
Page 14
OM-253 392 Page 10
Page 15
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
Page 16
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
Page 17
. 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
Page 18
. 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.
Page 19
. 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
Page 20
. 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
Page 21
. 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
Page 22
. 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
Page 23
. 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
Page 24
. 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
Page 25
. 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
Page 26
. 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
Page 27
. 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
Page 28
. 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
Page 29
. 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 515P 3 Receptacle NEMA Type 515R
(Customer Supplied)
Connecting Plug To Power Cord
4 Plug NEMA Type 520P (Optional) 5 Receptacle NEMA Type 520R
(Customer Supplied) 6 Plug NEMA Type 650P 7 Receptacle NEMA Type 650R
(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 201010 / 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
Page 30
. 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 multivoltage plug connections, see Section 5-10.
1 Plug From Unit 2 Receptacle NEMA Type 515R
(Customer Supplied)
OM-253 392 Page 26
Input6 201103 253 921-B / Ref. 805 474-A
Page 31
. 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
Page 32
. 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
Page 33
. 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
Page 34
. 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
Page 35
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
Page 36
. A complete Parts List is available at www.MillerWelds.com
6-2. Weld Parameter Chart
OM-253 392 Page 32
Ref. 252 671-E
Page 37
. 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
Page 38
. 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
Page 39
. 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
Page 40
. 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.
. AutoCrater is disabled by
default.
Rotate adjustment knob clockwise to enable AutoCrater.
Rotate adjustment knob counter­clockwise to disable AutoCrater.
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
Page 41
. 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
Page 42
. 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
Page 43
. 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
Page 44
. 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
Page 45
. 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
Page 46
. 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.
Page 47
. 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
Page 48
SECTION 8 − ELECTRICAL DIAGRAM
OM-253 392 Page 44
Figure 8-1. Circuit Diagram
Page 49
251 419-D
OM-253 392 Page 45
Page 50
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
Page 51
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
Page 52
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
Page 53
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
Page 54
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
Page 55
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
Page 56
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.
Page 57
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
Page 58
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.
Page 59
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
Page 60
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
Page 61
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
Page 62
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
Page 63
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
Page 64
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
Page 65
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
Page 66
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.
Page 67
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
Page 68
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.
1025
2
1
1015
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
Page 69
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
Page 70
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......... .............. ...................................
QJL2330 Liner, Jump Steel .023−030 1........ ............. .....................................
QJL3545 Liner, Jump Steel .035−.045 1........ ............. .....................................
4323R Insulator, Nozzle (small) 1.......... ............... .........................................
DS−1 Diffuser, Centerfire (small nozzle) 1........... ............... ................................
T023 Tip, Centerfire .023 in. 1.......... ............... ..........................................
T030 Tip, Centerfire .030 in. 1.......... ............... ..........................................
T035 Tip, Centerfire .035 in. 1.......... ............... ..........................................
T045 Tip, Centerfire .045 in. 1.......... ............... ..........................................
NS1200B Nozzle, Centerfire Small Brass 1/2 in. Flush 1........ ............. .......................
NS5818C Nozzle, Centerfire Small Copper 5/8 in. Recess 1/8 in. 1........ ............. ..............
NS5800B Nozzle, Centerfire Small Brass 5/8 in. Flush 1........ ............. .......................
NS5818B Nozzle, Centerfire Small Brass 5/8 in. Recess 1/8 in. 1........ ............. ................
NS1218C Nozzle, Centerfire Small Copper 1/2 in. Recess 1/8 in. 1........ ............. ..............
NS1218B Nozzle, Centerfire Small Brass 1/2 in. Recess 1/8 in. 1........ ............. ................
4478 ORing, 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.
Q150 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 online at www. MillerWelds. com
OM-253 392 Page 66
Page 71
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
Page 72
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: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125
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.
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