Miller Multimatic 215 User Manual

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OM-272989D 2019−02

ProcessesProcesses

Multiprocess Welding

Description

Arc Welding Power Source Wire Feeder

Multimatic 215

For product information,

Owner’s Manual translations,

and more, visit

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, and our extensive service network is there to help fix the problem. Warranty and maintenance information for your particular model are also provided.

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

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_Thank1

2019−01

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 Inch Calibration (Menu 1 Of 10) 34..........................................

6-6. Internal Motor Run-In Speed (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. T

roubleshooting

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 64...................................................

SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW) 65.......................................

SECTION 13 − PARTS LIST 67..................................................................

WARRANTY COMPLETE PARTS LIST − Available at www.MillerWelds.com

44......................................................................

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

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

1-1. Symbol Usage

som 2018−01

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 equipment. A qualified person is defined as one who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to solve or resolve problems relating to the subject matter, the work, or the project and has received safety training to recognize and avoid the hazards involved.

During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

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

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 weld output in damp, wet, or confined spaces, 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.

Additional 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 (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).

safety precautions are required when any of the follow-

DC constant voltage (wire) welder, 2) a DC manual

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

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

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 unit, disconnect input power, and discharge input capaci-

tors according to instructions in Manual 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 Ventilate the work area and/or use local forced ventilation at the arc

to remove welding fumes and gases. The recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to which personnel are exposed.

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.

D Do not cut or weld on tire rims or wheels. Tires can explode if heat-

ed. Repaired rims and wheels can fail. See OSHA 29 CFR

1910.177 listed in Safety Standards.

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. 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.

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.

OM-272989 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 lev-

el 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. 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 proper equipment, correct procedures, and sufficient

number of persons to lift, move, and transport 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 correct procedures and equipment of ade-

quate capacity to lift and support unit.

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

extend beyond opposite side of unit.

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

when working from an aerial location.

D Follow the guidelines in the Applications Manual for the Revised

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

OVERUSE can cause OVERHEATING

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

starting to weld again.

D Do not block or filter airflow to unit.

FLYING SPARKS can injure.

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.

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.

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.

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.

OM-272989 Page 3

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

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

navigation, 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.

safety services, computers, and

1-4. California Proposition 65 Warnings

WARNING: This product can expose you to chemicals including lead, which are known to the state of California to cause cancer and birth defects or other reproductive harm.

For more information, go to www.P65W

arnings.ca.gov

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

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 website: www

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (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).

Documents (phone: 1-877-413-5184,

.global.ihs.com).

Electromagnetic 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.

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 02169 (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 1910.177 Subpart N, 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).

energy can interfere with

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.

OM-272989 Page 4

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.

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

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

2-1. Symboles utilisés

som_2018−01_fre

DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.

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

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.

’installation, doivent être confiés qu’à des personnes qualifiées. Une personne qualifiée est définie comme celle qui, par la possession statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec succès sa capacité à résoudre les problèmes liés à la tâche, le travail ou le projet et a reçu une formation en sécurité afin de reconnaître et d’éviter les risques inhérents.

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

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 utiliser de sortie de soudage CA dans des zones humides

ou confinées ou s’il y a un risque de chute.

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 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, l’entretien et les réparations ne

d’un diplôme reconnu, d’un certificat ou d’un

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.

telles que sols, grilles ou échafaudages ; en position

. 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.

l’utilisation d’un poste à souder DC à fil à tension constante est recommandée.

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 mes de sécurité).

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

conformément nationales, gouvernementales et locales.

D Toujours vérifier la terre du cordon d’alimentation. Vérifier et

s’assurer que le fil de terre du cordon d’alimentation est bien raccordé à la borne de terre du sectionneur ou que la fiche du cordon est raccordée à une prise correctement mise à la terre.

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

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

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

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

D Vérifier fréquemment le cordon d’alimentation et le conducteur de

mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −, le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraîner la mort.

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.

D Utiliser une protection différentielle lors de l’utilisation d’un équi-

pement auxiliaire dans des endroits humides ou mouillés.

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

D Éteignez l’unité, débranchez le courant électrique, et déchargez

les condensateurs d’alimentation selon les instructions indiquées dans le manuel avant de toucher les pièces.

En outre, ne pas travailler seul !

selon la norme OSHA 29 CFR 1910.147 (voir nor-

à son Manuel d’Utilisation et aux réglementations

OM-272989 Page 5

LES PIÈCES CHAUDES peuvent

provoquer des brûlures.

D Ne pas toucher à mains nues les parties chaudes. D Prévoir une période de refroidissement avant

de 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 pour éviter les brûlures.

LES FUMÉES ET LES GAZ peuvent être dangereux.

Le soudage génère des fumées et des gaz. Leur inhalation

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. Pour déterminer la bonne ventilation, il est recommandé de procéder à un prélèvement pour la composition et la quantité de fumées et de gaz auxquelles est exposé le personnel.

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

approuvé.

D Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.

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 dégager des fumées toxiques en cas de soudage.

et tous les métaux renfermant ces éléments peuvent

peut être dangereux pour votre santé.

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

Le rayonnement de l’arc du procédé de soudage génèr

infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur l peau. Des étincelles sont projetées pendant le 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 un équipement de protection pour le corps fait d’un matériau

résistant et ignifuge (cuir, coton robuste, laine). La protection du corps comporte des vêtements sans huile comme par ex. des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.

des rayons visibles et invisibles intenses (ultraviolets

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

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.

OM-272989 Page 6

provoquer leur éclatement. Des étincelles peuvent

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

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 couper ou souder des jantes ou des roues. Les pneus

peuvent exploser s’ils sont chauffés. Les jantes et les roues réparées peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans les normes de sécurité.

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 pas souder là où l’air ambiant pourrait contenir des poussières,

gaz ou émanations 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 un équipement de protection pour le corps fait d’un matériau

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

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

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

trace d’étincelles incandescentes ni de flammes.

D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.

Ne pas augmenter leur puissance; ne pas les ponter.

D 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.

D Lire et comprendre les fiches de données de sécurité et les instruc-

tions du fabricant concernant les adhésifs, les revêtements, les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.

avec des protections homologués.

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

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.

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

LES ACCUMULATIONS DE GAZ 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 confinés 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

les bouteilles de gaz font normalement partie du procédé de soudage, les manipuler avec précaution.

endommagée, elle peut exploser. Du fait que

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 Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne

de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors de l’ouverture de la vanne.

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 Utilisez les équipements corrects, les bonnes procédures et suffi-

samment de personnes pour soulever, déplacer et transporter 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-

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

l’alimentation de mettre l’appareil en service.

duits inflammables.

est correctement dimensionnée et protégée avant

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 Utilisez les procédures correctes et des équipements d’une capa-

cité appropriée pour soulever et supporter l’appareil.

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

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

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.

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

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

avant de poursuivre le soudage.

LES ÉTINCELLES PROJETÉES peuvent provoquer des blessures.

D Porter un écran facial pour protéger le visage et

les yeux.

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

D Les étincelles risquent de causer un incendie − éloigner toute

substance inflammable.

D Affûter l’électrode au tungstène uniquement à

LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits 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 antistatiques pour stocker, dé-

placer ou expédier des cartes de circuits imprimes.

Les PIÈCES MOBILES peuvent 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.

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

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

L’EXPLOSION DE LA BATTERIE 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.

panneaux, recouvrements et dispositifs de protection.

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

pannage, 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

D Maintenir fermés et verrouillés les portes,

électrique.

OM-272989 Page 7

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les

étiquettes lation, 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’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de l’industrie,

ainsi que les codes municipaux.

et le Mode d’emploi avant l’instal-

LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer des interférences.

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

pements de radio−navigation et de communication, les services de sécurité et les ordinateurs.

D Demander seulement à des personnes qualifiées familiarisées avec

des équipements électroniques de faire fonctionner l’installation.

D L

’utilisateur

qualifié les interférences résultant de l’installation.

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

provoquer des interférences avec les équi-

est tenu de faire corriger rapidement par un électricien

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

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

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

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

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

D En cas d’interférences après avoir pris les mesures précédentes,

2-4. Proposition californienne 65 Avertissements

AVERTISSEMENT : ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction.

Pour plus d’informations, consulter www.P65W

arnings.ca.gov

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 l’équipement commandé par ordinateur tel que les robots.

patible électromagnétiquement.

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

électronique

conformément

il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de travail.

sensible.

à ce mode d’emploi.

de filtres de ligne ou la pose de protecteurs dans la zone

sensible tel que les ordinateurs et

2-5. Principales normes de sécurité

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

Engineering bal.ihs.com).

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

Engineering website: www National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (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 Spec-

Documents (phone: 1-877-413-5184, website: www.glo-

Documents (phone: 1-877-413-5184,

.global.ihs.com).

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs électromagnétiques soudage à l’arc (et de procédés connexes, y compris le soudage par points, le gougeage, le découpage plasma et les opérations de chauffage par induction) crée un champ électromagnétique (CEM) autour du circuit de soudage. Les champs électromagnétiques produits peuvent causer interférence à certains implants médicaux, p. ex. les stimulateurs cardiaques. Des mesures de protection pour les porteurs d’implants 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

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les OM-272989 Page 8

médicaux doivent être prises: Limiter par exemple tout accès

du ruban adhésif ou avec une housse.

(CEM) à certains endroits. Le courant issu d’un

trum 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 02169 (phone: 1-800-344-3555, website: www.nfpa.org). OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J, 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 Of site: 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).

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

4. Maintenir la tête et le torse aussi loin que possible du matériel du

5. Connecter la pince sur la pièce aussi près que possible de la

6. Ne pas travailler à proximité d’une source de soudage, ni

7. Ne pas souder tout en portant la source de soudage ou le

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.

fices—phone

câbles d’un côté et à distance de l’opérateur.

corps.

circuit de soudage.

soudure.

s’asseoir ou se pencher dessus.

dévidoir.

for Region 5, Chicago, is 312-353-2220, web-

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

Notes

>5min

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

Safe40 2012−05

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 2017−04

OM-272989 Page 9

3-2. Miscellaneous Symbols And Definitions

Amperage

Voltage

Rated No Load

Voltage (OCV)

Direct Current

(DC)

Alternating

Current (AC)

Circuit Breaker

Primary Voltage

Conventional Load Voltage

Rated Welding

Current

Input Power Or In-

put Voltage

Gas Input

Internal Protection

Rating

Single Phase

Line Connection

Suitable for Some

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

.023 - .035 in.

(0.6 - 0.8 mm)

30 − 230 58

Solid/Stainless

.023 − .035 in.

(0.6 − 0.9 mm)

Maximum Open-

Circuit Voltage

58 23.0

Flux Cored Wire Feed Speed Range

.030 - .035 in.

(0.8 - 0.9 mm)

Flux Cored Wire Feed Speed Range

.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

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

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

Minutes

A or V

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

Minutes

A or V

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

Minutes

A or V

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

! Do not move or operate unit where it could tip.

Location And Airflow

! Do not lift unit by strap threaded through both handles.

! Do not lift unit with cart attached.

! Special installation may be

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

1 Lifting Handles Use handles to lift unit. 2 Line Disconnect Device Locate unit near correct input

power supply.

OM-272989 Page 16

18 in.

(460 mm)

18 in.

(460 mm)

loc_smallmig2

2018-09 161-122

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

5-2. Multi−Voltage Plug (MVP) Connection

Selecting Plug

! Do not cut off power cord con-

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

cord, connector, and plugs will void product warranty.

Modifying power

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

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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 2017−01

. 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

1-Phase

Input Voltage (V) Rated Maximum Supply Current I Maximum Effective Supply Current I Max Recommended Standard Fuse Rating In Amperes

Normal Operating Fuses

Min Input Conductor Size In AWG (mm2) Max Recommended Input Conductor Length In Feet (Meters) 51 (16) Min Grounding Conductor Size In AWG (mm2)

Reference: 2017 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) and is based on allowable ampacities of insulated copper conductors having a temperature rating of 167F (75C) with not more than

three single current−carrying conductors in a raceway. 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.

(A) 31.2

1max

(A) 13.8

1eff

Time-Delay Fuses

240 120

35 40

14 (2.1)

50/60 Hz

1-Phase

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 12 AWG 25 ft (7.5 m)

240 V 1 50/60 12 AWG 50 ft (15 m)

Phase

Hertz Conductor Size Max. Cord Length

Notes

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)

Input6 2011−03 275173A / Ref. 805 474-A

OM-272989 Page 19

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5-6. Connecting 1-Phase Input Power For 240 VAC

=GND/PE Earth Ground

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

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

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).

Ref. 275166A / Ref. 275167A / Ref. 275168A

OM-272989 Page 23

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

5-9. 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

5-10. MIG Welding Connections

Connect to negative (−) output receptacle

Connect to positive (+) output receptacle

(Direct Current Electrode Positive)

MIG − DCEP

Flux-Cored − DCEN

(Direct Current Electrode Negative)

Ref. 275172A / Ref. 275167A / Ref. 275168A

! 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.

OM-272989 Page 24

5 Gun End Connect gun end to drive assembly (see

Section 5-11). 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 5-12).

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

5-11. MIG Gun Connection Inside Unit

1 Gun Securing Knob

2 Gun Block

3 Gun Outlet Wire Guide

4 Gun End

Loosen knob. Insert end of gun through

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

knob.

5 Trigger Control Cable

214

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

Ref. 275167A

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.

Correct Incorrect

Ref. 267807A

OM-272989 Page 25

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

5-12. Connecting Shielding Gas Supply

Mixed Gas

CO2 Gas

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. 5 Regulator/Flowmeter Gas

Hose Connection 6 Welding Power Source CO

And Mixed Gas Hose

Connection 7 Welding Power Source Argon

Argon Gas

Gas Hose Connection Connect gas hose between

regulator/flowmeter 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

9CO2 Adapter (Customer

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

regulator/flowmeter cylinder.

gas hose

flow rate.

and CO

Tools Needed:

OM-272989 Page 26

MIG TIG

Ref. 804 654-A / 275168A

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

5-13. Installing Wire Spool And Adjusting Hub Tension

Tools Needed:

1/2 in.

1 Wire Spool 2 Retaining Nut − For 8 in.

(203 mm) Spool Only

Installing 8 in. (203 mm) Wire Spool

Adapter and retaining ring

Installing 4 in. (102 mm) Wire Spool

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

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

Ref. 275174A / 803 012 / 803 013 -B / Ref. 802 444-C

OM-272989 Page 27

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

5-14. Threading Welding Wire

3 6

521

. 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 through 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.

Press gun trigger until wire

comes out of gun. Reinstall

contact tip and nozzle

OM-272989 Page 28

Tighten

1 2 3

WOOD

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close

and latch door.

Ref. 275174A / 275167A / 801 083 / Ref. 800 924-D

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

5-15. Removing MIG Gun To Replace With A Spool Gun

Turn Off Power.

. Hold wire tightly to keep it

from unraveling.

Rewind Wire Onto Spool, Fasten

End Of Wire To Spool.

Cut Off End Of Wire.

Loosen Knob, Disconnect Gun Trigger

Plug, And Remove Gun From Unit.

(See Section 5-11 For Gun Installation.)

Open Pressure Assembly.

Knob

275178A / Ref. 802982A / Ref. 275174A / Ref. 267807A

OM-272989 Page 29

6-1. Controls

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

SECTION 6 − OPERATION

1 Process Select Button Press up and down buttons to select de-

sired 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

OM-272989 Page 30

Rear View

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

. When MIG Aluminum process is se-

lected, Wire/Rod/Tungsten buttons are used to select type of spool gun being used.

4 Material Thickness Buttons

Ref. 271491A / 275178A

Press the Plus (+) or Minus (−) button to select material thickness for the selected process.

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

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

6-2. Welding Parameter Chart − 120V

Ref. 272942-D

OM-272989 Page 31

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

6-3. Welding Parameter Chart − 240V

OM-272989 Page 32

Ref. 272942-D

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

6-4. Entering Setup Menu

1 Wire/Rod/Tungsten Minus (−) Button 2 Material Thickness Minus (−) Button 3 Material Thickness Plus (+) Button 4 Display To enter the setup menu, simultaneously

234

press then release the Wire/Rod/Tungsten Minus (−) button and Material Thickness Plus (+) button. After entering the setup menu, the Material Thickness light will flash.

To move to the next setup menu, press the Material Thickness Plus (+) button.

Ref. 271491A

To move to the previous setup menu, press the Material Thickness Minus (−) button.

To exit the setup menu, simultaneously press then release the Wire/Rod/ Tungsten Minus (−) button and the Material Thickness Plus (+) button.

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at the beginning of this manual.

OM-272989 Page 33

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

6-5. Internal Motor 24 Inch Calibration (Menu 1 Of 10)

1 324 5

. The unit’s internal drive motor is calibrated

at the factory. No calibration is needed unless drive motor or control board is changed.

1 Wire/Rod/Tungsten Minus (−) Button 2 Material Thickness Plus (+) Button 3 Material Thickness Minus (−) Button 4 Left Adjustment Knob 5 Right Adjustment Knob Cut wire flush at nozzle. Follow instructions in Section 6-4 to enter the

setup menu. To perform a motor calibration 24 in. run-out

test at 100 IPM, turn left Adjustment knob, and

verify that a check mark appears next to 100 IPM. Wait for the lock symbol to change from unlocked to locked.

Be sure wire is cut flush at nozzle, then trigger the MIG gun. Motor will feed approximately 24 in. of wire through gun.

Cut wire flush at nozzle and measure run-out. If length of run-out is not 24 in., turn left Adjustment knob to increase/decrease length of run-out.

Wait for lock symbol to change from unlocked to locked and repeat test.

To perform a motor calibration 24 in. run-out test at 500 IPM, turn right Adjustment knob, and verify that a check mark appears next to 500 IPM.

6-6. Internal Motor Run-In Speed (Menu 2 Of 10)

1 23

Wait for the lock symbol to change from un-

Ref. 271491A

locked to locked. Be sure wire is cut flush at nozzle, then trigger

the MIG gun. Motor will feed approximately 24 in. of wire through gun.

Cut wire flush at nozzle and measure run-out. If length of run-out is not 24 in., turn right Adjustment knob to increase/decrease length of run-out.

Wait for lock symbol to change from unlocked to locked and repeat test.

To exit menu, simultaneously press and release the Wire/Rod/Tungsten Minus (−) button and Material Thickness Plus (+) button, or turn unit off and on.

1 Wire/Rod/Tungsten Minus (−)

Button 2 Auto-Set Button 3 Material Thickness Plus (+)

Button Follow instructions in Section 6-4 to

enter the setup menu. To change the run−in setting, press

the Auto−Set button. Run−in is the wire speed prior to the

welding arc being struck. When set to Automatic, the welder determines the optimal run−in speed for each start. When set to disabled, the run−in speed is the same as the weld wire speed.

To exit the menu, simultaneously press and release the Wire/Rod/ Tungsten Minus(−) button and Material Thickness Plus (+) button, or turn unit off and on.

OM-272989 Page 34

Ref. 271491A

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

6-7. Spoolmatet 24 Inch Calibration (Menu 3 Of 10)

1 23

1 Wire/Rod/Tungsten Minus (−)

Button

2 Material Thickness Plus (+)

Button

3 Material Thickness Minus (−)

Button 4 Left Adjustment Knob 5 Right Adjustment Knob

. Spoolmate 100 and 150 drive

motors are unique to this weld-

ing power source. Motor cali-

bration is necessary any time a

different Spoolmate 100 or 150

is connected to the Multimatic

215.

Connect Spoolmate to unit. Cut wire flush at nozzle. Follow instructions in Section 6-4 to

enter the setup menu. To perform a Spoolmate calibration

24 in. run-out test at 200 IPM, turn left Adjustment knob, and verify that a check mark appears next to 200 IPM.

Wait for the lock symbol to change from unlocked to locked.

Cut wire flush at nozzle and then trigger the Spoolmate.

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

Cut wire flush at nozzle and measure run−out.

If wire length is not 24 in., use left Adjustment knob to increase/decrease length of the run-out.

Wait for the lock symbol to change from unlocked to locked, and repeat the test.

To perform a Spoolmate calibration 24 in. run-out test at 500 IPM, turn right Adjustment knob and verify that a check mark appears next to 500 IPM.

Wait for the lock symbol to change from unlocked to locked.

Cut wire flush at nozzle and then trigger the Spoolmate.

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

Cut wire flush at nozzle and measure run−out.

If wire length is not 24 in., use right Adjustment knob to increase/decrease length of the run−out.

Wait for the lock symbol to change from unlocked to locked, and repeat the test.

To exit menu, simultaneously press and release the Wire/Rod/Tungsten Minus (−) button and Material Thickness Plus (+) button, or turn unit off and on.

Ref. 271491A

OM-272989 Page 35

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

6-8. Spoolmate Run-In Speed (Menu 4 Of 10)

1 23

1 Wire/Rod/Tungsten Minus (−)

Button 2 Auto-Set Button 3 Material Thickness Plus (+)

Button Follow instructions in Section 6-4 to

enter the setup menu. To change the run−in setting, press

the Auto−Set button. Run−in is the speed of the wire prior

to the welding arc being struck. When set to Automatic, the welder

determines the optimal run−in speed for each start. When set to Disabled, the run−in speed is the same as the weld wire

speed. To exit menu, simultaneously press

and release the Wire/Rod/Tungsten Minus (−) button and Material Thickness Plus (+) button, or turn unit off and on.

6-9. Process Logs (Menu 5 Of 10)

1 2

Ref. 271491A

1 Material Thickness Minus (−)

Button 2 Material Thickness Plus (+)

Button 3 Process Select Follow instructions in Section 6-4 to

enter the setup menu. Process Logs menu displays man-

ual time, Auto−Set time, weld cycles, and Auto−Set cycles for the selected process.

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

To exit menu, simultaneously press and release the Wire/Rod/Tungsten Minus (−) button and Material Thickness Plus (+) button, or turn unit off and on.

OM-272989 Page 36

Ref. 271491A

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

6-10. Primary Logs (Menu 6 Of 10)

1 2

1 Material Thickness Minus (−)

Button 2 Material Thickness Plus (+)

Button Follow instructions in Section 6-4 to

enter the setup menu. Primary Logs menu displays power

cycles, 120 volt time, and 240 volt time.

To exit menu, simultaneously press and release the Wire/Rod/Tungsten Minus (−) button and Material Thickness Plus (+) button, or turn unit off and on.

6-11. Error Logs (Menu 7 Of 10)

1 2

Ref. 271491A

1 Material Thickness Minus (−)

Button 2 Material Thickness Plus (+)

Button Follow instructions in Section 6-4 to

enter the setup menu. Error Logs screen displays welder

over−temperature errors, shorted output errors, shorted trigger errors, motor current errors, and stuck electrode errors.

To exit menu, simultaneously press and release the Wire/Rod/Tungsten Minus (−) button and Material Thickness Plus (+) button, or turn unit off and on.

Ref. 271491A

OM-272989 Page 37

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

6-12. Factory Reset (Menu 8 Of 10)

1 Material Thickness Minus (−)

Button 2 Material Thickness Plus (+)

Button

1 23

3 Auto-Set Button

. A Factory Reset will reset the

primary logs data, process logs

data, error logs data, selected

process, and all process set-

tings. Motor calibration set-

tings, Spoolmate Calibration

settings, and software informa-

tion will all be retained.

Follow instructions in Section 6-4 to enter the setup menu.

To perform a Factory Reset, press the Auto−Set button.

To exit menu, simultaneously press and release the Wire/Rod/Tungsten Minus (−) button and Material Thickness Plus (+) button, or turn unit off and on.

6-13. Display Software (Menu 9 Of 10)

Ref. 271491A

. Display Software information is

for factory and service use

only.

Follow instructions in Section 6-4 to enter the setup menu.

To exit menu, simultaneously press and release the Wire/Rod/Tungsten Minus (−) button and Material Thickness Plus (+) button, or turn unit off and on.

OM-272989 Page 38

Ref. 271491A

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

6-14. Control Software (Menu 10 Of 10)

. Control Software information is

for factory and service use

only.

Follow instructions in Section 6-4 to enter the setup menu.

To exit menu, simultaneously press and release the Wire/Rod/Tungsten Minus (−) button and Material Thickness Plus (+) button, or turn unit off and on.

Notes

Ref. 271491A

OM-272989 Page 39

. 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

7-2. Overload Protection

l Repair Or Replace Cracked Weld Cable

! Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

Reference

Supplementary CB1 protects unit from overload. If

CB1 opens, unit shuts down. Reset supplementary protector.

Protector CB1

OM-272989 Page 40

275178A

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

7-3. Changing Drive Roll Or Wire Inlet Guide

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 includes three

different sized grooves. The text aligned with the drive roll retaining pin indicates the selected groove.

3 Retaining Pin To secure drive roll, locate open slot

and push drive roll completely over retaining pin, then rotate drive roll to desired slot.

. See Section 13-1 for optional

drive rolls.

.024 Groove

Table 7-1. Drive Roll Grooves And Wire Type Compatibility

Groove Compatible Wire

.024

.030−.035

.030−.035 V-Knurled

.030−.035 Groove

.030-.035 V-Knurled Groove

.024 Solid Wire .030−.035 Solid Wire .030−.035 Flux-Core

267893A

OM-272989 Page 41

7-4. Error Messages

Message Error Remedy

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

Overtemp−Please wait while the welder cools down.

Shorted trigger−Release 4−pin trigger to clear error.

Shorted trigger-Release 8−pin trigger to clear error.

Internal temperature of welder has exceeded the maximum limit.

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

MIG gun is held during jog for more than 16 feet of wire.

Spool gun is held during jog for more than 10 seconds.

MIG gun or spool gun trigger is engaged for more than 1 second after the arc is broken.

After an overtemp error, the MIG or spool gun trigger is held after the welder has completed cooling.

MIG gun or spool gun trigger is engaged while the process is changed to Flux Cored or a MIG process.

MIG gun or spool gun trigger lead voltage exceeds 9 volts caused by the electrode being shorted to the trigger lead.

MIG gun or spool gun trigger leads are shorted together.

The 8−pin trigger is engage on power up.

The 8−pin trigger is engage while the process is changed to TIG Lift−Arc Remote.

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

Release 4−pin trigger to clear error.

Fix or replace damaged gun.

Release the 8−pin trigger.

Shorted trigger-Release trigger to clear error.

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

Stuck electrode-Free stuck electrode to clear error.

Stuck electrode-Free tungsten to clear error.

Motor error−Motor has drawn too much current.

The 4−pin or 8−pin trigger is held during TIG preflow for more than 10 seconds.

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

MIG gun or spool gun contact tip came into contact with the workpiece while welding.

The weld voltage is less than 10 volts for more than

0.2 seconds while welding.

Output rectifier is damaged.

Control board is damaged.

Stick welding electrode has become stuck in weld puddle and turned output off.

Tungsten electrode has become stuck in weld puddle and turned output off.

Tungsten has contacted workpiece for more than 5 seconds without starting an arc.

Too much pressure on pressure adjust knob. Reduce pressure on the pressure adjust knob.

The gun liner is obstructed. Clear obstruction or replace gun liner.

The gun contact tip is obstructed. Clear obstruction or replace contact tip.

The welding wire is entangled. Untangle welding wire.

Release the 4−pin or 8−pin triggers.

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

Contact Miller Electric Mfg. Co. service department.

Remove Stick welding electrode from workpiece and output will turn back on after about one second.

Remove the tungsten from workpiece and output will turn back on after about one second.

OM-272989 Page 42

The control board is damaged. Contact Miller Electric Mfg. Co. service department.

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

Message RemedyError

Fan error-The fan is running too slow or is damaged.

Thermal error−Primary thermistor range error.

Thermal error−Secondary thermistor range error.

Boost error−Cycle power to clear error.

Over voltage−Cycle power to clear error.

Under voltage−Cycle power to clear error.

The fan blades are obstructed. Clear obstruction from fan.

The fan wiring harness is disconnected. Reconnect the fan.

The fan is damaged.

The control board is damaged.

The primary circuit thermistor is unplugged. Reconnect the primary circuit thermistor.

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

The control board is damaged.

The secondary circuit thermistor is unplugged. Reconnect the secondary circuit thermistor.

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

The control board is damaged.

The primary boost has not successfully been established.

Primary voltage is above 310 volts. Reduce primary voltage below 310 volts.

The primary voltage is below 90 volts. Increase primary voltage above 90 volts.

Contact Miller Electric Mfg. Co. service department.

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

Network error−Communication between micros has been lost.

Network error−Communication between boards has been lost.

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

Cable error−Wire feed housing cable is touching electrode or work.

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

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

The control board is damaged.

The interface board is damaged.

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

The control board is damaged. Contact Miller Electric Mfg. Co. service department.

A process that does not require a welding gun to 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.

The control board is damaged. Contact Miller Electric Mfg. Co. service department.

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

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

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

OM-272989 Page 43

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

7-5. Troubleshooting

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. 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-272989 Page 44

Notes

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

OM-272989 Page 45

SECTION 8 − ELECTRICAL DIAGRAM

OM-272989 Page 46

Figure 8-1. Circuit Diagram

272984-A

OM-272989 Page 47

SECTION 9 − GMAW WELDING (MIG) GUIDELINES

9-1. Typical GMAW (MIG) Process Connections

Regulator/ Flowmeter

Wire Feeder/

Welding Power Source

! 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

Gas

9-2. Typical GMAW (MIG) Process Control Settings

1/16 or

0.0625 in.

Gun

Workpiece

Work Clamp

GMAW1 2018−01 (GMAW Only) − Ref. 801909-A

. These settings are guidelines only. Material

and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications.

1 Material Thickness Material thickness determines weld parameters. Convert material thickness to amperage (A):

0.001 in. (0.025 mm) = 1 ampere

0.0625 in. (1.59 mm)  0.001 = 62.5 A 2 Select Wire Size See table below. 3 Select Wire Feed Speed (Amperage) Wire feed speed (amperage) controls weld pene-

tration. See table below. 4 Select Voltage Voltage controls height and width of weld bead. Low Voltage: wire stubs into work

High Voltage: arc is unstable (spatter) Set voltage midway between high and low voltage.

Wire Size Amperage Range Recommended Wire Feed Speed Wire Feed Speed*

0.023 in. (0.58 mm) 30−90 A 3.5 in. (89 mm) per amp 3.5 x 62.5 A = 219 ipm (5.56 mpm)

0.030 in. (0.76 mm) 40−145 A 2 in. (51 mm) per amp 2 x 62.5 A = 125 ipm (3.19 mpm)

0.035 in. (0.89 mm) 50−180 A 1.6 in. (41 mm) per amp 1.6 x 62.5 A = 100 ipm (2.56 mpm)

*62.5 A based on 1/16 in. (1.6 mm) material thickness. ipm = inches per minute; mpm = meters per minute

OM-272989 Page 48

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 Hold Gun and Control Gun

Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension (Stickout)

Solid Wire − 3/8 to 1/2 in.

(9 to 13 mm)

5 Cradle Gun and Rest Hand on

Workpiece

0-15

90 90

End View of Work Angle Side View of Gun Angle

Groove Welds

9-4. Conditions That Affect Weld Bead Shape

10

Push

Gun Angles And Weld Bead Profiles

Perpendicular

45

End View of Work Angle Side View of Gun Angle

Fillet Welds

0-15

S-0421-A

. Weld bead shape depends

on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire

10

feed speed (weld current), and voltage.

Drag

Short Normal Long

Electrode Extensions (Stickout)

Slow

Gun Travel Speed

Short Normal Long

Fillet Weld Electode Extensions (Stickout)

Normal Fast

S-0634

OM-272989 Page 49

9-5. Gun Movement During Welding

1 2

9-6. Poor Weld Bead Characteristics

. Normally, a single stringer

bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better.

1 Stringer Bead − Steady

Movement Along Seam

2 Weave Bead − Side To Side

Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide

area in one pass of the electrode.

S-0054-A

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

5 Poor Penetration

9-7. Good Weld Bead Characteristics

1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During

Welding Weld a new bead or layer for each

1/8 in. (3.2 mm) thickness in metals being welded.

4 No Overlap 5 Good Penetration into Base

Metal

S-0053-A

S-0052-B

OM-272989 Page 50

9-8. Troubleshooting − Excessive Spatter

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

S-0636

Possible Causes Corrective Actions

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

Voltage too high. Select lower voltage range.

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

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

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

Dirty welding wire. Use clean, dry welding wire.

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

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

9-9. Troubleshooting − Porosity

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

S-0635

Possible Causes Corrective Actions

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

Remove spatter from gun nozzle.

Check gas hoses for leaks.

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

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

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

Dirty welding wire. Use clean, dry welding wire.

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

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

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

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

9-10. Troubleshooting − Excessive Penetration

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

Excessive Penetration

Possible Causes Corrective Actions

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

Good Penetration

Increase travel speed.

S-0639

OM-272989 Page 51

9-11. Troubleshooting − Lack Of Penetration

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

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

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

maintaining proper welding wire extension and arc characteristics.

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

Keep arc on leading edge of weld puddle.

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

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

Reduce travel speed.

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

S-0638

9-12. Troubleshooting − Incomplete Fusion

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

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.

S-0637

Possible Causes Corrective Actions

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

Increase and/or maintain steady travel speed.

OM-272989 Page 52

S-0640

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

Notes

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-272989 Page 53

9-16. Common GMAW (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

Spray Arc

Steel

Short

Circuiting

Steel

Spray Arc

Stainless

Steel

Short

Circuiting

Stainless

Steel

Spray Arc

Aluminum

Short

Circuiting

Aluminum

Argon All Positions All Positions All Positions

Argon + 1% O

Argon + 2% O

Argon + 5%

Argon + 10%

Argon + 25%

Argon + 50%

Flat &

Horizontal Fillet

Flat &

Horizontal Fillet

Flat &

Horizontal Fillet

Flat &

Horizontal Fillet

All Positions

Helium All Positions

Flat &

Horizontal Fillet

Flat &

Horizontal Fillet

All Positions

GMAW-P

Argon +

Helium

Tri-Mix

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

All Positions

OM-272989 Page 54

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.

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.

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

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

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.

drive rolls if necessary.

Readjust welding parameters.

OM-272989 Page 55

SECTION 10 − STICK WELDING (SMAW) GUIDELINES

10-1. Stick Welding Procedure

! Weld current starts when

electrode touches workpiece.

! Weld current can damage

electronic parts in vehicles.

Tools Needed:

Equipment Needed:

Constant Current

Welding Power Source

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 Place as close to the weld as

possible. 3 Electrode Before striking an arc, insert an

electrode in the electrode holder. A small diameter electrode requires less current than a large one. Follow recommendations of the electrode manufacturer 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. Correct arc length is related to electrode diameter. Examine the weld bead to determine if the arc length is correct.

Arc length for 1/16 and 3/32 in. diameter electrodes should be about 1/16 in. (1.6 mm); arc length for 1/8 and 5/32 in. electrodes should be about 1/8 in. (3 mm).

7 Slag Use a chipping hammer and wire

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

OM-272989 Page 56

stick 2018-01 − 151593

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

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 EP

DC*

HORIZ*

POSITION

ALL ALL ALL

ALL

FLAT

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

! Weld current starts when elec-

trode touches workpiece.

1 Electrode

2 Workpiece 3 Arc

Scratch Technique

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 workpiece, use a quick twist to free it.

Tapping Technique

Bring electrode straight down to 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.

S-0049 / S-0050

OM-272989 Page 57

10-4. Positioning Electrode Holder

90 90

Groove Welds

10-30

1 End View Of Work Angle 2 Side View Of Electrode

Angle

After learning to start and hold an arc, practice running beads of weld metal on flat plates using a full electrode.

Hold the electrode nearly perpendicular to the work, although tilting it ahead (in the direction of travel) will be helpful.

. To produce the best results,

hold a short arc, travel at a uniform speed, and feed the electrode downward at a constant rate as it melts.

45

Fillet Welds

10-5. Poor Weld Bead Characteristics

10-30

S-0060

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

S-0053-A

10-6. Good Weld Bead Characteristics

OM-272989 Page 58

1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During

Welding

Weld a new bead or layer for each 1/8 in. (3.2 mm) thickness in metals being welded.

4 No Overlap

5234

5 Good Penetration into Base

Metal

S-0052-B

10-7. Conditions That Affect Weld Bead Shape

Correct Angle

Angle Too Small

Electrode Angle

10 - 30

Drag

. Weld bead shape is affected

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

Angle Too Large

Spatter

Arc Length

Too Short

Travel Speed

Slow

Normal Too Long

Normal Fast

10-8. Electrode Movement During Welding

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 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.

10-9. Welding Lap Joints

30 Or Less

S-0054-A

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

30 Or Less

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.

S-0063 / S-0064

OM-272989 Page 59

10-10. Welding Groove (Butt) Joints

1/16 in.

(1.6 mm)

30

1 Tack Welds Prevent butt joint distortion by tack

welding the materials in position before final weld.

Workpiece distortion occurs when heat is applied locally to a joint. One side of a metal plate will curl

up toward the weld. Distortion will also cause the edges of a butt joint to pull together ahead of the electrode as the weld cools.

2 Square Groove Weld 3 Single V-Groove Weld 4 Double V-Groove Weld Materials up to 3/16 in. (5 mm)

thick can often be welded without special preparation using the square groove weld. However, when welding thicker materials it may be necessary to prepare the edges (V-groove) of butt joints to ensure good welds.

The single or double V-groove weld is good for materials 3/16 − 3/4 in. (5-19 mm) thick. Generally, the single V-groove is used on materials up to 3/4 in. (19 mm) thick and when, regardless of thickness, you can weld from one side only. Create a 30 degree bevel with oxyacetylene or plasma cutting equipment. Remove scale from material after cutting. A grinder can also be used to prepare bevels.

10-11. Welding T-Joints

45

Less

S-0062

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.

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.

OM-272989 Page 60

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

10-12. Weld Test

2 To 3 in.

(51-76 mm)

1/4 in.

(6.4 mm)

2 1

10-13. Troubleshooting

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

bends over but does not break. If the weld breaks, examine it to determine the cause.

2 To 3 in.

(51-76 mm)

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

If the weld is porous (many holes), the arc length was probably too long.

If the weld contains bits of slag, the arc may have been too long or the electrode was moved incorrectly which allowed molten slag to be trapped in the weld. This may happen on a V-groove joint made in several layers and calls for additional cleaning between layers.

If the original beveled surface is visible the material was

not fully melted which is often caused by insufficient heat or too fast a travel speed.

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.

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

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.

welding.

OM-272989 Page 61

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

Lack of Penetration

Possible Causes Corrective Actions

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

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

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

Excessive Penetration

Possible Causes Corrective Actions

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

Good Penetration

Reduce travel speed.

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

Good Penetration

Increase and/or maintain steady travel speed.

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

Possible Causes Corrective Actions

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

Increase and/or maintain steady travel speed.

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

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

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

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

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

Make tack welds along joint before starting welding operation.

OM-272989 Page 62

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

SECTION 11 − SELECTING AND PREPARING A TUNGSTEN

FOR DC OR AC WELDING WITH INVERTER MACHINES

gtaw_Inverter_2018-01

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)

A. Select Tungsten Electrode.

. 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% Ceriated, 1.5% Lanthanum, Or 2% Thorium Alloy Tungstens

.010 in. (.25 mm) Up to 15 Up to 15 .020 in. (.50 mm) 5-20 5-20

.040 in. (1 mm) 15-80 15-80 1/16 in. (1.6 mm) 70-150 70-150 3/32 in. (2.4 mm) 150-250 140-235

1/8 in. (3.2 mm) 250-400 225-325

5/32 in. (4.0 mm) 400-500 300-400

3/16 in (4.8 mm) 500-750 400-500

1/4 in. (6.4 mm) 750-1000 500-630

Typical argon shielding gas flow rates are 10 to 25 CFH (cubic feet per hour).

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

AC − Argon

Unbalanced Wave

(For Use With Aluminum)

B. Electrode Composition.

Tungsten Type Application Notes

2% Cerium (Grey*)

1.5−2% Lanthanum (Yellow/Blue)

2% Thorium (Red)

Pure Tungsten (Green)

* Color may vary depending on manufacturer, please refer to manufacturer’s guide for color designation.

Good all−around tungsten for both AC and DC welding.

Excellent low amp starts for AC and DC welding.

Commonly used for DC welding, not ideal for AC.

Not Recommended for inverters!

For best results in most applications use a sharpened cerium or lanthanum electrode for AC and DC welding.

OM-272989 Page 63

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.

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

abrasive wheel before welding. Do not use wheel for other jobs or tungsten can become

Radial Grinding

Causes Wandering Arc

Wrong Tungsten

Preparation

1-1/2 To 4 Times

Electrode Diameter

Ideal Tungsten Preparation − Stable Arc

15 to 30

contaminated 2 Tungsten Electrode A 2% ceriated tungsten is recommended. 3 Ideal Grind Angle Range: 15 to 30

. 30 degrees is the recommended elec-

trode grind angle.

4 Straight Ground Grind lengthwise, not radial.

causing lower weld quality.

Notes

OM-272989 Page 64

SECTION 12 − GUIDELINES FOR TIG WELDING (GTAW)

Ref. gtaw_Phase_2018−01

12-1. Positioning The Torch

! Grinding the tungsten elec-

trode 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 11-2.

Guidelines:

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

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

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

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

10−25

10−15

3/16 in

Bottom View Of Gas Cup

90

5 6

1/16 in

Ref.161892

OM-272989 Page 65

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

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.

162002-B

“T” Joint

90

20-40

30

20

15

Lap Joint

70

75

20

75

15

10

Corner Joint

90

75

15

162003 / 0792

OM-272989 Page 66

SECTION 13 − PARTS LIST

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

13-1. Drive Rolls

For All Feed Head Assemblies

Part No. Wire Diameter - in. (mm)

261157 .024 (.6) and .030/.035 (0.8 and 0.9) and .030/.035 (0.8 and 0.9) (VK Groove)

220179 .024 (.6) and .030/.035 (0.8 and 0.9) (Standard) 202926 .030/.035 (0.8 and 0.9) and .045 (1.2 VK Groove)

Optional

13-2. MDX Welding Gun Consumables

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

Notes

OM-272989 Page 67

Notes

Warranty Questions?

Call 1-800-4-A-MILLER for your local Miller distributor.

Your distributor also gives you ...

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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, 2019

(Equipment with a serial number preface of MK 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. LLC, Appleton, Wisconsin, warrants to authorized distributors that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

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

Miller shall honor warranty claims on warranted equipment listed below in the event of a defect within the warranty coverage time periods listed below. Warranty time periods start on the delivery date of the equipment to the end-user purchaser, or 12 months after the equipment is shipped to a North American distributor, or 18 months after the equipment is shipped to an international distributor, whichever occurs first.

1. 5 Years Parts — 3 Years Labor * Original Main Power Rectifiers Only to Include SCRs,

Diodes, and Discrete Rectifier Modules

2. 3 Years — Parts and Labor Unless Specified * Auto-Darkening Helmet Lenses (No Labor) (See

Classic Series Exception Below)

* Engine Driven W

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

* Insight Welding Intelligence Products * Inverter Power Sources * Plasma Arc Cutting Power Sources * Process Controllers * Semi-Automatic and Automatic Wire Feeders * Transformer/Rectifier Power Sources

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

(No Labor) * Auto-Darkening Weld Masks (No Labor) * Fume Extractors − Capture 5, Filtair 400 and Industrial

Collector Series

4. 1 Year — Parts and Labor Unless Specified * AugmentedArc and LiveArc Welding Systems * Automatic Motion Devices * Bernard BTB Air-Cooled MIG Guns (No Labor) * CoolBelt and CoolBand Blower Unit (No Labor) * Desiccant Air Dryer System * Field Options

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

* RFCS Foot Controls (Except RFCS-RJ45) * Fume Extractors − Filtair 130, MWX and SWX Series * HF Units * ICE/XT Plasma Cutting Torches (No Labor) * Induction Heating Power Sources, Coolers

(NOTE: Digital Recorders are Warranted Separately by the Manufacturer.)

* Load Banks * Motor-Driven Guns (except Spoolmate Spoolguns) * PAPR Blower Unit (No Labor) * Positioners and Controllers * Racks (For Housing Multiple Power Sources) * Running Gear/Trailers * Spot Welders

elder/Generators

guarantees or warranties expressed or implied.

* Subarc Wire Drive Assemblies * TIG Torches (No Labor) * Tregaskiss Guns (No Labor) * Water Cooling Systems * Wireless Remote Foot/Hand Controls and Receivers * Work Stations/Weld Tables (No Labor)

5. 6 Months — Parts * Batteries

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

Non-Electronic Controls * M-Guns * MIG Guns, Subarc (SAW) Torches, and External

Cladding Heads * Remote Controls and RFCS-RJ45 * Replacement Parts (No labor) * 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.

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

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

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

The above remedies are F.O.B. Appleton, WI, or Miller’s authorized service facility. Transportation and freight are the customer’s responsibility. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY, OR REPRESENTATION, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, ARE EXCLUDED AND DISCLAIMED BY MILLER.

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

mil dom warr 2019-01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

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

and Parts) Circuit Diagrams Welding Process Handbooks

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

Miller Electric Mfg. LLC

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  2019 Miller Electric Mfg. LLC 2019−01

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.

Miller Multimatic 215 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual