Miller Multimatic 215 Owners Manual
OM-272989A 2016−03
ProcessesProcesses
Multiprocess Welding
Description
Arc Welding Power Source
Wire Feeder
t
Multimatic 215
Visit our website at
www.MillerWelds.com
File: Multiprocess
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................
1-1. Symbol Usage 1.......................................................................
1-2. Arc Welding Hazards 1.................................................................
1-3. Additional Symbols For Installation, Operation, And Maintenance 3.............................
1-4. California Proposition 65 Warnings 4......................................................
1-5. Principal Safety Standards 4.............................................................
1-6. EMF Information 4.....................................................................
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5...........................
2-1. Symboles utilisés 5.....................................................................
2-2. Dangers relatifs au soudage à l’arc 5......................................................
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7.....
2-4. Proposition californienne 65 Avertissements 8..............................................
2-5. Principales normes de sécurité 8.........................................................
2-6. Informations relatives aux CEM 8.........................................................
SECTION 3 − DEFINITIONS 9..................................................................
3-1. Additional Safety Symbols And Definitions 9................................................
3-2. Miscellaneous Symbols And Definitions 10..................................................
SECTION 4 − SPECIFICATIONS 11..............................................................
4-1. Serial Number And Rating Label Location 11................................................
4-2. Unit Specifications For MIG (GMAW) 11....................................................
4-3. Unit Specifications For TIG (GTAW) 11.....................................................
4-4. Unit Specifications For Stick (SMAW) 11....................................................
4-5. Environmental Specifications 11...........................................................
4-6. Dimensions And Weight 12...............................................................
4-7. Duty Cycle And Overheating For MIG (GMAW) 13............................................
4-8. Duty Cycle And Overheating For TIG (GTAW) 14............................................
4-9. Duty Cycle And Overheating For Stick (SMAW) 15...........................................
SECTION 5 − INSTALLATION 16................................................................
5-1. Selecting A Location 16..................................................................
5-2. Multi−Voltage Plug (MVP) Connection 17...................................................
5-3. Electrical Service Guide 18...............................................................
5-4. Extension Cord Data 18..................................................................
5-5. Connecting 120 Volt Input Power 19........................................................
5-6. Connecting 1-Phase Input Power For 240 VAC 20............................................
5-7. Stick Welding Connections 22.............................................................
5-8. TIG Welding Connections DCEN (Direct Current Electrode Negative) 23.........................
5-9. Process/Polarity Table 24................................................................
5-10. MIG Welding Connections 24.............................................................
5-11. MIG Gun Connection Inside Unit 25........................................................
5-12. Connecting Shielding Gas Supply 26.......................................................
5-13. Installing Wire Spool And Adjusting Hub Tension 27...........................................
5-14. Threading Welding Wire 28...............................................................
5-15. Removing MIG Gun To Replace With A Spool Gun 29.........................................
TABLE OF CONTENTS
SECTION 6 − OPERATION 30...................................................................
6-1. Controls 30............................................................................
6-2. Welding Parameter Chart − 120V 31.......................................................
6-3. Welding Parameter Chart − 240V 32.......................................................
6-4. Entering Setup Menu 33..................................................................
6-5. Internal Motor 24 In. Calibration (Menu 1 Of 10) 34...........................................
6-6. Internal Motor Run-In (Menu 2 Of 10) 34....................................................
6-7. Spoolmatet 24 Inch Calibration (Menu 3 Of 10) 35...........................................
6-8. Spoolmate Run-In Speed (Menu 4 Of 10) 36.................................................
6-9. Process Logs (Menu 5 Of 10) 36..........................................................
6-10. Primary Logs (Menu 6 Of 10) 37...........................................................
6-11. Error Logs (Menu 7 Of 10) 37.............................................................
6-12. Factory Reset (Menu 8 Of 10) 38..........................................................
6-13. Display Software (Menu 9 Of 10) 38........................................................
6-14. Control Software (Menu 10 Of 10) 39.......................................................
SECTION 7 − MAINTENANCE &TROUBLESHOOTING 40..........................................
7-1. Routine Maintenance 40.................................................................
7-2. Overload Protection 40..................................................................
7-3. Changing Drive Roll Or Wire Inlet Guide 41.................................................
7-4. Error Messages 42......................................................................
7-5. Troubleshooting 44......................................................................
SECTION 8 − ELECTRICAL DIAGRAM 46........................................................
SECTION 9 − GMAW WELDING (MIG) GUIDELINES 48............................................
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.......................................
SECTION 13 − PARTS LIST 66..................................................................
WARRANTY
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
som 2015−09
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 and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding 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.
D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off 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
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.
OM-272989 Page 1
FUMES AND GASES can be hazardous.
)
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying 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.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant mate-
rial (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
WELDING can cause fire or explosion.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or 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.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise lev-
el is high.
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 can contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-272989 Page 2
workpiece, and hot equipment can cause fires and
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. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
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 installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
H.F. RADIATION can cause interference.
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.
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.
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.
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.
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-272989 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 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).
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.
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 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 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
duct 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-272989 Page 4
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-272989 Page 9
3-2. Miscellaneous Symbols And Definitions
A
V
U
U
U
I
2
IP
0
1
2
Amperage
Voltage
Rated No Load
Voltage (OCV)
Direct Current
(DC)
Alternating
Current (AC)
Primary Voltage
Conventional
Load Voltage
Rated Welding
Current
Input Power Or In-
put Voltage
Gas Input
Internal Protection
Rating
Single Phase
Circuit Breaker
X
Line Connection
Suitable for Some
S
Hz
Static Frequency
Remote
Positive
Negative
Duty Cycle
Hazardous
Locations
Increase
Hertz
Single Phase
Converter-
Transformer-
Rectifier
Gas Tungsten Arc
Welding (GTAW)
Torch
Shielded Metal
Arc Welding
(SMAW)
Shielded Metal
Arc (SMAW)
Electrode Holder
Gas Metal Arc
Welding (GMAW)
Gas Metal Arc
Welding (GMAW)
MIG / Gun Control
Self-Shielded Flux
Cored Arc
Welding (FCAW)
Wire Feed Spool
Gun
Gas Tungsten Arc
Welding (GTAW) /
Tungsten Inert
Gas (TIG)
Welding
Gas Postflow
Notes
Unlocked
Locked
Lift Arc (GTAW)
TIG / Remote
Wire Feed Slow
Run-In
Gas Preflow
Cold Jog (Inch)
Toward Workpiece
OM-272989 Page 10
. A complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back of unit. Use rating label to determine input power requirements and/or
rated output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Unit Specifications For MIG (GMAW)
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-3, 5-5, and 5-6 for information on
connecting input power.
Input
Voltage
120 VAC
240 VAC
Rated Welding
Output
110 A @ 19.5 Volts DC
60% Duty Cycle
Wire Type
And Dia
200 A @ 24.0 Volts DC
20% Duty Cycle
150 A @ 21.5 Volts DC
40% Duty Cycle*
Wire Type
And Dia
Amperage
Range
30 − 125
Solid/Stainless Flux Cored Wire Feed Speed Range
.023 - .035 in.
(0.6 - 0.8 mm)
30 − 230 58
Solid/Stainless Flux Cored Wire Feed Speed Range
.023 − .035 in.
(0.6 − 0.9 mm)
Maximum Open-
Circuit Voltage
DC
58 23.0
.030 - .035 in.
(0.8 - 0.9 mm)
.030 − .045 in.
(0.8 − 1.2 mm)
Amperes Input at Rated
Load Output, 50/60 Hz,
Single-Phase
60 − 600 IPM (1.5 − 15.2 m/min)
25.8
16.7
60 − 600 IPM (1.5 − 15.2 m/min)
4-3. Unit Specifications For TIG (GTAW)
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-3, 5-5, and 5-6 for information on
connecting input power.
Input
Voltage
120 VAC
240 VAC
Rated Welding
Output
140 A @ 15.6 Volts DC
40% Duty Cycle
190 A @ 17.6 Volts DC
20% Duty Cycle
Amperage
Range
20 − 150
20 − 210 58 18.0
Maximum Open-
Circuit Voltage
DC
58 24.6
Amperes Input at Rated
Load Output, 50/60 Hz,
Single-Phase
4-4. Unit Specifications For Stick (SMAW)
. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-3, 5-5, and 5-6 for information on
connecting input power.
Input
Voltage
120 VAC
240 VAC
Rated Welding
Output
90 A @ 23.6 Volts DC
40% Duty Cycle
190 A @ 27.6 Volts DC
20% Duty Cycle
Amperage
Range
30 − 100
30 − 200 58 27.0
Maximum Open-
Circuit Voltage
DC
58 22.7
Amperes Input at Rated
Load Output, 50/60 Hz,
Single-Phase
4-5. Environmental Specifications
A. IP Rating
IP Rating
IP21
This equipment is designed for indoor use and is not intended to be used or stored outside.
OM-272989 Page 11
IP21 2014−06
. A complete Parts List is available at www.MillerWelds.com
4-6. Dimensions And Weight
Weight
38 lb (17.2 kg)
12 1/2 in.
(318 mm)
11 1/4 in.
(286 mm)
20 1/2 in.
(521 mm)
Notes
275173A
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-272989 Page 12
. A complete Parts List is available at www.MillerWelds.com
4-7. Duty Cycle And Overheating For MIG (GMAW)
240V
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.
60% Duty Cycle At 110A
6 Minutes Welding 4 Minutes Resting
20% Duty Cycle At 200A
2 Minutes Welding 8 Minutes Resting
120V Input
240V Input
40% Duty Cycle At 150A
4 Minutes Welding 6 Minutes Resting
Overheating
0
Minutes
15
A or V
OR
Reduce Duty Cycle
duty1 4/95 − Ref. Duty Cycle Charts
OM-272989 Page 13
. A complete Parts List is available at www.MillerWelds.com
4-8. Duty Cycle And Overheating For TIG (GTAW)
240V
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.
120V Input
40% Duty Cycle At 140A
4 Minutes Welding 6 Minutes Resting
240V Input
20% Duty Cycle At 190A
2 Minutes Welding 8 Minutes Resting
Overheating
OM-272989 Page 14
0
Minutes
15
A or V
OR
Reduce Duty Cycle
duty1 4/95 − Ref. Duty Cycle Charts
. A complete Parts List is available at www.MillerWelds.com
4-9. Duty Cycle And Overheating For Stick (SMAW)
240V
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.
120V Input
40% Duty Cycle At 90A
4 Minutes Welding 6 Minutes Resting
240V Input
20% Duty Cycle At 190A
2 Minutes Welding 8 Minutes Resting
Overheating
0
Minutes
15
A or V
OR
Reduce Duty Cycle
duty1 4/95 − Ref. Duty Cycle Charts
OM-272989 Page 15
. A complete Parts List is available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Selecting A Location
Movement
Location And Airflow
! Do not move or operate
unit where it could tip.
! Special installation may be
required where gasoline or
2
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1 Lifting Handles
Use handles to lift unit.
2 Line Disconnect Device
Locate unit near correct input
power supply.
OM-272989 Page 16
18 in.
(460 mm)
1
18 in.
(460 mm)
loc_smallmig 2015-12
. A complete Parts List is available at www.MillerWelds.com
5-2. Multi−Voltage Plug (MVP) Connection
Selecting Plug
2
3
4
5
1
! Do not cut off power cord con-
nector and rewire. The power
cord connector and plugs will
work with standard NEMA receptacles. Modifying power
6
7
cord, connector, and plugs will
void product warranty.
Selecting Plug
1 Power Cord Connector From
Welding Power Source
Select plug for power supply receptacle
available at site. Not all plugs shown are
provided as standard with unit.
2 Plug − NEMA Type 5−15P
3 Receptacle − NEMA Type 5−15R
(Customer Supplied)
Connecting Plug To Power Cord
4 Plug − NEMA Type 5−20P (Optional)
5 Receptacle − NEMA Type 5−20R
(Customer Supplied)
6 Plug − NEMA Type 6−50P
7 Receptacle − NEMA Type 6−50R
(Customer Supplied)
! Follow electrical service guide for
240 VAC in Section 5-3. Do not use
plug rating to size branch circuit
protection.
Connecting Plug To Power Cord
Align arrow on plug with arrow on power
cord connector. Push together.
Tighten threaded collar. As threaded collar
is tightened, push plug onto adapter until
collar is completely tight.
Connect plug to receptacle.
MVP Plug1 2010−10 / Ref. 803 812-C
OM-272989 Page 17
. A complete Parts List is available at www.MillerWelds.com
5-3. 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 2014−01
. 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 240
Single Phase
Input Voltage (V) 240
Input Amperes (A) At Rated Output 29.3
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: 2014 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
35
40
14
51
(16)
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
5-5
5-4. Extension Cord Data
Input Power
Input Voltage
120 V 1 50/60 14 AWG 24 ft (7 m)
240 V 1 50/60 14 AWG 51 ft (16 m)
Phase
Hertz Conductor Size Max. Cord Length
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-272989 Page 18
. A complete Parts List is available at www.MillerWelds.com
5-5. Connecting 120 Volt Input Power
! Installation must meet all
National and Local Codes − have
only qualified persons make this
installation.
! Special installation may be
required where gasoline or volatile
liquids are present − see NEC
Article 511 or CEC Section 20.
NOTICE − The Auto-Line circuitry in this
unit automatically links the power source
to the primary voltage being applied, either
120 or 240 VAC.
See rating label on unit and check input
voltage available at site.
For 120 volts AC input power, a 15 or 20
ampere individual branch circuit protected
by time-delay fuses or circuit breaker is
required.
1 Multi-Voltage Plug And Power Cord
Connector (NEMA Type 5−15P Plug
Shown)
For multi−voltage plug connections, see
Section 5-2.
1 Plug From Unit
2 Receptacle − NEMA Type 5−15R
(Customer Supplied)
1
2
Input6 2011−03 275173A / Ref. 805 474-A
OM-272989 Page 19
. A complete Parts List is available at www.MillerWelds.com
5-6. Connecting 1-Phase Input Power For 240 VAC
1
L2
3
L1
6
1
8
L1
=GND/PE Earth Ground
7
2
4
5
L2
Tools Needed:
240 VAC, 1
OM-272989 Page 20
input4 2012-05 − 803 766-C / Ref. 802 443-A / 275173A
. A complete Parts List is available at www.MillerWelds.com
5-6. Connecting 1-Phase Input Power For 240 VAC (Continued)
! Installation must meet all National and
Local Codes − have only qualified persons make this installation.
! Disconnect and lockout/tagout input
power before connecting input conductors from unit. Follow established
procedures regarding the installation
and removal of lockout/tagout
devices.
! Always connect green or green/yellow
conductor to supply grounding terminal first, and never to a line terminal.
NOTICE − The Auto-Line circuitry in this unit
automatically links the power source to the
primary voltage being applied, either 120 or
240 VAC.
See rating label on unit and check input voltage available at site.
1 Input Power Cord
2 Disconnect Device (switch shown in the
OFF position)
3 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 5-3 (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-272989 Page 21
. A complete Parts List is available at www.MillerWelds.com
5-7. Stick Welding Connections
! 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.
OM-272989 Page 22
1
3
2
4
Ref. 275166A
. A complete Parts List is available at www.MillerWelds.com
5-8. 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
4 Work Clamp And Cable
Connect TIG torch cable to the
1
4
2
3
negative weld output receptacle
and connect work cable to positive
weld output receptacle.
Ensure all connections are tight.
5 Foot Control
6 Finger Tip Control
7 Remote Control Cable
8 Remote Control Receptacle
Route control cable through MIG
gun hole.
Connect foot control or finger tip
control to remote control
receptacle.
9 TIG Shielding Gas
Connection
Use Argon gas for TIG welding (see
Section 5-12).
5
6
7
8
9
Ref. 275166A / Ref. 275167A / Ref. 275168A
OM-272989 Page 23
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