Miller MULTIMATIC 220 Owners manual AC/DC

OM-281426A 2018−10

ProcessesProcesses

Multiprocess Welding

Description

Arc Welding Power Source
Wire Feeder

®

Multimatic 220

AC/DC

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

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_Thank 2017−06

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. Generator / Inverter Requirements 21......................................................

5-8. Stick Welding Connections 22.............................................................

5-9. TIG Welding Connections 23..............................................................

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. Controls, TIG Aluminum Manual Mode 31...................................................

6-3. Controls, TIG Steel/Stainless Manual Mode 32...............................................

6-4. Controls, Stick Manual Mode 32...........................................................

6-5. Controls, MIG Manual Mode 33............................................................

6-6. Welding Parameter Chart − 120V 34.......................................................

6-7. Welding Parameter Chart − 240V 35.......................................................

6-8. Entering Setup Menu 36..................................................................

6-9. Internal Motor 24 Inch Calibration (Menu 1 Of 12) 37..........................................

6-10. Internal Motor Run-In Speed (Menu 2 Of 12) 37..............................................

6-11. Spoolmatet 24 Inch Calibration (Menu 3 Of 12) 38...........................................

6-12. Spoolmate Run-In Speed (Menu 4 Of 12) 39.................................................

6-13. Process Logs (Menu 5 Of 12) 39..........................................................

6-14. Primary Logs (Menu 6 Of 12) 40...........................................................

6-15. Error Logs (Menu 7 Of 12) 40.............................................................

6-16. Factory Reset (Menu 8 Of 12) 41..........................................................

6-17. Display Software (Menu 9 Of 12) 41........................................................

6-18. Control Software (Menu 10 Of 12) 42.......................................................

6-19. QuickTecht(Menu 11 Of 12) 42...........................................................

6-20. TIG Postflow Control (Menu 12 Of 12) 43...................................................

SECTION 7 − MAINTENANCE & TROUBLESHOOTING 44.........................................

7-1. Routine Maintenance 44.................................................................

7-2. Overload Protection 44..................................................................

7-3. Changing Drive Roll Or Wire Inlet Guide 45.................................................

7-4. Error Messages 46......................................................................

7-5. Troubleshooting 48......................................................................

SECTION 8 − ELECTRICAL DIAGRAM 50........................................................

SECTION 9 − HIGH FREQUENCY 52............................................................

9-1. Welding Processes Requiring High Frequency 52............................................

9-2. Installation Showing Possible Sources Of HF Interference 52...................................

9-3. Recommended Installation To Reduce HF Interference 53.....................................

SECTION 10 − SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER

MACHINES 54................................................................................

10-1. Selecting Tungsten Electrode (Wear Clean Gloves To Prevent Contamination Of Tungsten) 54......

10-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding

Or AC Welding With Inverter Machines 55...................................................

SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW) 56........................................

11-1. Positioning The Torch 56.................................................................

11-2. Torch Movement During Welding 57........................................................

11-3. Positioning Torch Tungsten For Various Weld Joints 57........................................

TABLE OF CONTENTS

SECTION 12 − GUIDELINES FOR MIG WELDING (GMAW) 58.......................................

12-1. Typical GMAW (MIG) Process Connections 58..............................................

12-2. Typical GMAW (MIG) Process Control Settings 58...........................................

12-3. Holding And Positioning Welding Gun 59....................................................

12-4. Conditions That Affect Weld Bead Shape 59.................................................

12-5. Gun Movement During Welding 60.........................................................

12-6. Poor Weld Bead Characteristics 60........................................................

12-7. Good Weld Bead Characteristics 60.......................................................

12-8. Troubleshooting − Excessive Spatter 61....................................................

12-9. Troubleshooting − Porosity 61.............................................................

12-10. Troubleshooting − Excessive Penetration 61...............................................

12-11. Troubleshooting − Lack Of Penetration 62..................................................

12-12. Troubleshooting − Incomplete Fusion 62...................................................

12-13. Troubleshooting − Burn-Through 62.......................................................

12-14. Troubleshooting − Waviness Of Bead 63...................................................

12-15. Troubleshooting − Distortion 63..........................................................

12-16. Common GMAW (MIG) Shielding Gases 64................................................

12-17. Troubleshooting Guide For GMAW (MIG) Welding Process 64................................

SECTION 13 − GUIDELINES FOR STICK WELDING (SMAW) 66.....................................

13-1. Stick Welding Procedure 66..............................................................

13-2. Electrode And Amperage Selection Chart 67................................................

13-3. Striking An Arc 67.......................................................................

13-4. Positioning Electrode Holder 68...........................................................

13-5. Poor Weld Bead Characteristics 68........................................................

13-6. Good Weld Bead Characteristics 68.......................................................

13-7. Conditions That Affect Weld Bead Shape 69.................................................

13-8. Electrode Movement During Welding 69....................................................

13-9. Welding Lap Joints 69...................................................................

13-10. Welding Groove (Butt) Joints 70..........................................................

13-11. Welding T-Joints 70....................................................................

13-12. Weld Test 71..........................................................................

13-13. Troubleshooting 71.....................................................................

SECTION 14 − PARTS LIST 73..................................................................

14-1. Recommended MIG Spare Parts 73........................................................

14-2. Recommended TIG Spare Parts 73........................................................

SECTION 15 − SOFTWARE LICENSE AGREEMENT 74............................................

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

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

7

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

1-1. Symbol Usage

som 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.

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

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

D Disconnect input power or stop engine before installing or

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

. 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-281426 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-281426 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-281426 Page 3

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

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

navigation, safety services, computers, and
communications equipment.

D Have only qualified persons familiar with electronic equipment

perform this installation.

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

ly correct any interference problem resulting from the installa­tion.

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

equipment at once.

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

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

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.P65Warnings.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: [phone], website: www.global.ihs.com).

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

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

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

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

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02169 (phone: [phone], website:
www.nfpa.org and www. sparky.org).

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

D Electromagnetic energy can interfere with

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

D Be sure all equipment in the welding area is electromagnetically

compatible.

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

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

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D If interference still occurs, the user must take extra measures

such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

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: [phone], 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: [phone], web­site: www.ansi.org).

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

Quincy, MA 02169 (phone: [phone], website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-

try, Title 29, Code of Federal Regulations (CFR), Part 1910.177 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: [phone]) (there are 10 OS­HA Regional Offices—phone for Region 5, Chicago, is 312-353-2220,
website: www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro­cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace­makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:

1. Keep cables close together by twisting or taping them, or using a
cable cover.

2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.

3. Do not coil or drape cables around your body.

OM-281426 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

7

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

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.

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

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

UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.

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

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

sans trous.

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

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

D Ne pas 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 telles que sols, grilles ou échafaudages ; en position
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à
souder AC à tension à vide réduite. Dans la plupart des situations,

. 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. En outre, ne pas travailler seul !

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

stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor­mes de sécurité).

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

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

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

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

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

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

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

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

D Vérifier fréquemment le cordon d’alimentation 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.

OM-281426 Page 5

LES PIÈCES CHAUDES peuvent

e

e

a

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 peut être dangereux pour votre santé.

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

niveau de l’arc pour l’évacuation des fumées et des gaz de
soudage. 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 et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.

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

Le rayonnement de l’arc du procédé de 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-281426 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 avec des protections homologués.

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

sur des substances inflammables.

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

de métal chaud.

D Des étincelles et des matériaux chauds du soudage peuvent

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

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

proximité.

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

peut déclencher un incendie de l’autre côté.

D Ne pas 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

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.

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.

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

D Le soudage, l’écaillement, le passage de la pièce à
la brosse en fil de fer, et le meulage génèrent des étincelles et des
particules métalliques volantes. Pendant la période de ref­roidissement des soudures, elles risquent de projeter du laitier.

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

facial.

LES ACCUMULATIONS DE GAZ
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-

duits inflammables.

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

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

LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.

D Utiliser l’anneau de levage uniquement pour

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

D 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

avant de poursuivre le soudage.

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

LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.

D Porter un écran facial pour protéger le visage et

les yeux.

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

D Les étincelles risquent de causer un incendie − éloigner toute

substance inflammable.

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.

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

L’EXPLOSION DE LA 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.

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

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

OM-281426 Page 7

LIRE LES INSTRUCTIONS.

D Lire et appliquer les instructions sur les

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

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

constructeur.

D Effectuer l’installation, l’entretien et toute intervention selon les

manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.

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

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

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

D Demander seulement à des personnes qualifiées familiarisées avec

des équipements électroniques de faire fonctionner l’installation.

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

qualifié les interférences résultant de l’installation.

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

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.P65Warnings.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 sensible tel que les ordinateurs et
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 sensible.

conformément à ce mode d’emploi.

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

2-5. Principales normes de sécurité

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

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

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

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

Engineering Documents (phone: [phone],
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02169 (phone: [phone], website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga­net.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2,
from Canadian Standards Association, Standards Sales, 5060 Spec-

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:

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

2. Ne pas se tenir au milieu des câbles de soudage. Disposer les

OM-281426 Page 8

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: [phone], web­site: www.ansi.org).

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

Quincy, MA 02169 (phone: [phone], 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: [phone]) (there are 10 OSHA
Regional Offices—phone for Region 5, Chicago, is 312-353-2220, web­site: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The Nation­al Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd,
Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

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

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

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

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

6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.

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

En ce qui concerne les implants médicaux :

Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par points,
de gougeage, du coupage plasma ou de chauffage par induction. Si le
médecin approuve, il est recommandé de suivre les procédures précé­dentes.

SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

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

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

Beware of electric shock from wiring.

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

Safe1 2012−05

Safe95 2012−05

Safe94 2012−08

Safe26 2012−05

V

Notes

>5min

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

Safe40 2012−05

V

V

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

Safe43 2017−04

OM-281426 Page 9

3-2. Miscellaneous Symbols And Definitions

A

V

U

0

Amperage

Voltage

Rated No Load

Voltage (OCV)

Direct Current

(DC)

Alternating

Current (AC)

Circuit Breaker

X

U

U

I

2

IP

1

2

Primary Voltage

Conventional
Load Voltage

Rated Welding

Current

Input Power Or In-

put Voltage

Gas Input

Internal Protection

Rating

Single Phase

Unlocked

Locked

Line Connection

Suitable for Some

S

Hz

Static Frequency

Lift Arc (GTAW)

Wire Feed Slow

Work Connection

Remote

Positive

Negative

Duty Cycle

Hazardous

Locations

Increase

Hertz

Single Phase

Converter-

Transformer-

Rectifier

TIG / Remote

Run-In

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

Gas Preflow

Cold Jog (Inch)

Toward Workpiece

Output Enabled

Notes

OM-281426 Page 10

High Frequency

On- Continuous

Reverse Polarity

. 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

105 A @ 19.2 Volts DC

60% Duty Cycle

Wire Type

And Diameter

200 A @ 24.0 Volts DC

20% Duty Cycle

170 A @ 21.5 Volts DC

40% Duty Cycle

Wire Type

And Diameter

Amperage

Range

30 − 125

Solid/Stainless Flux Cored Wire Feed Speed Range

.024 - .035 in.

(0.6 - 0.8 mm)

30 − 230 45

Solid/Stainless Flux Cored Wire Feed Speed Range

.024 − .035 in.

(0.6 − 0.9 mm)

Maximum Open-

Circuit Voltage

DC

45 23.6

.030 - .035 in.

(0.8 - 0.9 mm)

.030 − .045 in.

(0.8 − 1.2 mm)

Amperes Input at Rated

Load Output, 50/60 Hz,

Single-Phase

60 − 600 IPM (1.5 − 15.2 m/min)

27.2

21.5

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

130 A @ 15.2 Volts AC/DC

40% Duty Cycle

210 A @ 18.4 Volts AC/DC

20% Duty Cycle

Amperage

Range

20 − 140

20 − 210 46 22.4

Maximum Open-

Circuit Voltage

DC

46 21.2

Amperes Input at Rated

DC 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 AC/DC

40% Duty Cycle

200 A @ 28.4 Volts AC/DC

15% Duty Cycle

Amperage

Range

30 − 90

30 − 200 46 31.3

Maximum Open-

Circuit Voltage

DC

46 24.5

Amperes Input at Rated

DC 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.

IP21 2014−06

B. Temperature Specifications

Operating Temperature Range* Storage/Transportation Temperature Range

14 to 104°F (−10 to 40°C)

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

−4 to 131°F (−20 to 55°C)

Temp_2016-07

OM-281426 Page 11

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

4-6. Dimensions And Weight

Weight

56 lb (25.3 kg)

17 1/2 in.

(445 mm)

11 1/4 in.

(286 mm)

21 1/2 in.

(546 mm)

Notes

275173A

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-281426 Page 12

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

4-7. Duty Cycle And Overheating For MIG (GMAW)

240

220

200

180

160

140

120VAC 20A

120

100

Output Amperes

80

60

120VAC 15A

40

20

0

10 100

20

240VAC

50

% Duty Cycle

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 105A

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 170A

4 Minutes Welding 6 Minutes Resting

Overheating

0

Minutes

15

A or V

OR

Reduce Duty Cycle

duty1 4/95 − Ref. Duty Cycle Charts

OM-281426 Page 13

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

4-8. Duty Cycle And Overheating For TIG (GTAW)

240

220

200

180

160

120V 20A

140

120

100

Output Amperes

80

120V 15A

60

40

20

0

10 100

20

240V

50

% Duty Cycle

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 130A

4 Minutes Welding 6 Minutes Resting

240V Input

20% Duty Cycle At 210A

2 Minutes Welding 8 Minutes Resting

Overheating

OM-281426 Page 14

0

Minutes

15

A or V

OR

Reduce Duty Cycle

duty1 4/95 − Ref. Duty Cycle Charts

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

4-9. Duty Cycle And Overheating For Stick (SMAW)

240

220

200

180

160

240V

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.

140

120V 20A

120

100

Output Amperes

80

60

40

120V 15A

20

0

10 100

20

50

% Duty Cycle

120V Input

40% Duty Cycle At 90A

4 Minutes Welding 6 Minutes Resting

Overheating

240V Input

20% Duty Cycle At 185A

2 Minutes Welding 8 Minutes Resting

0

15

Minutes

Reduce Duty Cycle

A or V

OR

duty1 4/95 − Ref. Duty Cycle Charts

OM-281426 Page 15

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

SECTION 5 − INSTALLATION

5-1. Selecting A Location

Movement

1

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

Location And Airflow

18 in.

(460 mm)

! Special installation may be

required where gasoline or

2

18 in.

(460 mm)

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-281426 Page 16

loc_smallmig2 2018-05 161-122

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

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

Selecting Plug

2

3

4

5

1

! Do not cut off power cord con-

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

6

7

cord, connector, and plugs will
void product warranty.

Selecting Plug

1 Power Cord Connector From

Welding Power Source

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

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

(Customer Supplied)

Connecting Plug To Power Cord

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

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

(Customer Supplied)

! Follow electrical service guide for

240 VAC in Section 5-3. Do not use

plug rating to size branch circuit

protection.

Connecting Plug To Power Cord

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

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

Connect plug to receptacle.

MVP Plug1 2010−10 / Ref. 803 812-C

OM-281426 Page 17

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

5-3. Electrical Service Guide

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

In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and

630.12.

50/60 Hz

1-Phase

Input Voltage (V) 120 240
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)

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)

1max

(A) 15

1eff

1

Time-Delay Fuses

4

2

3

4

A 15 or 20

ampere

individual

branch circuit

protected by

time-delay

fuses or circuit

breaker is

required. See

Section 5-5.

Elec Serv 2017-01

50/60 Hz
1-Phase

32

40
45
12
34

(10)

12

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

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-281426 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.

2 Receptacle − NEMA Type 5−15R

(Customer Supplied)

1

2

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

OM-281426 Page 19

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

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

1

L2

3

L1

6

1

8

L1

=GND/PE Earth Ground

7

2

4

5

L2

Tools Needed:

240 VAC, 1

OM-281426 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

5-7. Generator / Inverter Requirements

Generator settings, if applicable.

! Engine Control Switch must be set at “RUN”

position − not “RUN/IDLE”.

! Set generator Fine Adjustment Control

Minimum auxiliary power require­ment at rated load is 10 KW continu­ous/12.5 KW peak at 240 volts AC
for full output. Smaller generators
will reduce output capability.

to 10 for maximum auxiliary power.

OM-281426 Page 21

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

5-8. Stick Welding Connections

! Turn off unit and disconnect

input power before making
connections.

! Do not use worn, damaged,

undersized, or repaired
cables.

1 Weld Output Receptacle
2 Work Clamp Receptacle
3 Stick Electrode Holder And

Cable
4 Work Clamp And Cable
Connect stick electrode holder

cable to the electrode output
receptacle, and connect work
clamp to work output receptacle.
Turn connectors clockwise.

Ensure all connections are tight.

OM-281426 Page 22

1

2

3

4

Ref. 282724A

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

5-9. TIG Welding Connections

! Turn off unit and disconnect

input power before making

connections.

! Do not use worn, damaged,

undersized, or repaired

cables.

1 Weld Output Receptacle
2 Work Clamp Receptacle
3 TIG Torch And Cable
4 Work Clamp And Cable
Connect TIG torch cable to the

electrode receptacle and connect
work cable to work receptacle. Turn
connectors clockwise.

Ensure all connections are tight.

5 Foot Control
6 Remote Control Cable
7 Remote Control Receptacle
Connect foot control to remote

control receptacle.
8 TIG Shielding Gas

Connection
Use Argon gas for TIG welding (see

Section 5-12).

5

3

6

4

8

7

1

2

Ref. 282724A / Ref. 282719A

OM-281426 Page 23

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

5-10. MIG Welding Connections

3

1

2

4

! Turn off unit and disconnect input

power before making connections.

! Do not use worn, damaged, under-

sized, or repaired cables.

1 Weld Output Receptacle
2 Work Clamp Receptacle
3 Mig Gun
4 Work Clamp And Cable

8

Connect work cable to work receptacle.
Turn connector clockwise.

Ensure all connections are tight.

5 Gun End
Connect gun end to drive assembly (see

Section 5-11).
6 Trigger Control Cable
7 Four Pin Trigger Control Cable

Receptacle

6

5

7

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

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).

OM-281426 Page 24

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

5-11. MIG Gun Connection Inside Unit

1

6

2

5

4

3

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

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

4

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.

4

CORRECT

INCORRECT

Ref. 267807A

OM-281426 Page 25

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

5-12. Connecting Shielding Gas Supply

1

2

3

Mixed Gas

1

9

2

3

CO2 Gas

8

10

4

5

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

1 Cap
2 Cylinder Valve
Remove cap, stand to side of valve,

and open valve slightly. Gas flow
blows dust and dirt from valve.
Close valve.

3 Cylinder
4 Regulator/Flowmeter
Install Regulator/Flowmeter so

face is vertical.
5 Regulator/Flowmeter Gas

Hose Connection

6 Welding Power Source CO

And Mixed Gas Hose
Connection

1

2

3

Argon Gas

4

8

5

7 Welding Power Source Argon

Gas Hose Connection

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

8 Flow Adjust
Typical flow rate for CO2 shielding

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

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

9CO2 Adapter (Customer

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

regulator/flowmeter and CO
cylinder.

2

2

Tools Needed:

OM-281426 Page 26

MIG

6

7

TIG

Ref. 804 654-A / 282718A

. 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

2

Warning

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.

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

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

Ref. 282721A / 803 012 / 803 013 -B / Ref. 802 444-C

OM-281426 Page 27

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

5-14. Threading Welding Wire

1 Wire Spool
2 Welding Wire

2

4

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

Warning

7

Tools Needed:

1

5

3

6

. Hold wire tightly to keep it

from unraveling.

6 in.

(150 mm)

Warning

Warning

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

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

Close and tighten pressure

assembly, and let go of wire.

Press gun trigger until wire

comes out of gun. Reinstall

contact tip and nozzle

OM-281426 Page 28

Warning

Remove gun nozzle and contact tip. Turn On.

Tighten

1
2
3

WOOD

4

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close

and latch door.

Ref. 282721A / 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

Tools Needed:

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.

Open Pressure Assembly.

Knob

Warning

Warning

Insert Power Pin, Connect Spool Gun

Trigger Plug, And Tighten Knob.

282718A / Ref. 802982A / Ref. 282722A / Ref. 282721A

OM-281426 Page 29

6-1. Controls

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

SECTION 6 − OPERATION

3

2

4

1

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

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

to-Set is On when illuminated.
3 Wire/Rod/Tungsten Buttons
Press the Plus (+) or Minus (−) button to

6

5

8

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
Press the Plus (+) or Minus (−) button to

6

7

Ref. 281252A / 282718A

select material thickness for the selected
process.

5 Display
6 Adjustment Knobs
7 Tig Arc Start Select Buttons
Press the up and down buttons to select de-

sired TIG arc start.
8 Power Switch
Use switch to turn unit On or Off.

OM-281426 Page 30

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

6-2. Controls, TIG Aluminum Manual Mode

2

4

1

1 Auto-Set Button
Press button to turn Auto-Set fea-

ture On or Off. Auto-Set is On when
illuminated.

3

5

6

2 Tungsten Size Buttons
Press the Plus (+) or Minus (-) but-

ton to adjust up or down.
3 Balance Adjustment Buttons
Press the Plus (+) or Minus (-) but-

ton to adjust up or down. The range
is 60-80%. Pro-Set value is 75%
(See tip below).

4 Frequency Adjustment Knob
Frequency range is 60-150 Hz.

Pro-Set value is 120 Hz (See tip be­low).

5 Amperage Adjustment Knob
6 TIG Arc Start Select Buttons
Press the up and down buttons to

select desired TIG arc start. Lift-Arc
not available for TIG aluminum.

TIP: AC Frequency controls the
width of the arc cone. Increasing
the AC Frequency provides a more
focused arc and increased direc­tional control.

Note: Decreasing the AC Frequen­cy softens the arc and broadens the
weld puddle for a wider weld.

TIP: AC Balance controls the
cleaning action. If floating black
spots appear in the puddle the bal­ance setting is too high. Turn the
balance down until the puddle be­comes clear.

Notes

Ref. 281252A

OM-281426 Page 31

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

6-3. Controls, TIG Steel/Stainless Manual Mode

2

3

1

4 5

1 Auto-Set Button
Press button to turn Auto-Set fea-

ture On or Off. Auto-Set is On when
illuminated.

2 Tungsten Size Buttons
Press the Plus (+) or Minus (-) but-

ton to adjust up or down.
3 Pulse Adjustment Knob
The range is OFF - 150 PPS (Puls-

es per Second). Pro-Set value is
100 PPS (See tips below).

4 Amperage Adjustment Knob
5 TIG Arc Start Select Buttons
Press the up and down buttons to

select desired TIG arc start.
TIPS: Low-Speed Pulse: 1 to 10

pulses per second (PPS) will pro­duce a distinct ripple pattern in the
weld bead. It can be used to time
filler addition, reduce distortion and
improve control.

High Speed Pulse: 100 pulses per
second (PPS) and higher helps to
focus the arc for increased stability,
penetration and travel speed. In­creased puddle agitation improves
weld microstructure.

Ref. 281252A

6-4. Controls, Stick Manual Mode

1

2

1 Auto-Set Button
Press button to turn Auto-Set fea-

ture On or Off. Auto-Set is On when
illuminated.

2 DIG Adjustment Knob
The range is Off - 99%. Pro-Set val-

ue is 30% for 7018 electrodes. (See
tip below).

3 Amperage Adjustment Knob
TIP: DIG (Arc Force Control) con-

trols the amount of additional am­perage at low voltage (short arc
length) conditions. Adjust the DIG
percentage for different joint config­urations and electrodes.

3

OM-281426 Page 32

Ref. 281252A

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

6-5. Controls, MIG Manual Mode

1

1 Auto-Set Button
Press button to turn Auto-Set fea-

ture On or Off. Auto-Set is On when
illuminated.

2 Volts Adjustment Knob
3 Wire Feed Speed Adjustment

Knob

2

Notes

3

Ref. 281252A

OM-281426 Page 33

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

6-6. Welding Parameter Chart − 120V

OM-281426 Page 34

Ref. 282870-A

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

6-7. Welding Parameter Chart − 240V

Ref. 282870-A

OM-281426 Page 35

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

6-8. Entering Setup Menu

1

4

2

3

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

Notes

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. 281252A

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.

OM-281426 Page 36

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

6-9. Internal Motor 24 Inch Calibration (Menu 1 Of 12)

1

4

. 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 6-8 to enter the

2

3

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.

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.

To perform a motor calibration 24 in. run-out
test at 500 ipm, turn right Adjustment knob,

5

Ref. 281252A

and verify that a check mark appears next to
500 ipm.

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.

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

6-10. Internal Motor Run-In Speed (Menu 2 Of 12)

1

2

3

1 Wire/Rod/Tungsten Minus (−)

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

Button
Follow instructions in Section 6-8 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.

Ref. 281252A

OM-281426 Page 37

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

6-11. Spoolmatet 24 Inch Calibration (Menu 3 Of 12)

1

4 5

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

220.

Connect Spoolmate to unit.
Cut wire flush at nozzle.
Follow instructions in Section 6-8 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.

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.

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.

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.

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-281426 Page 38

Ref. 281252A

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

6-12. Spoolmate Run-In Speed (Menu 4 Of 12)

1

23

1 Wire/Rod/Tungsten Minus (−)

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

Button
Follow instructions in Section 6-8 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.

6-13. Process Logs (Menu 5 Of 12)

12

Ref. 281252A

1 Material Thickness Minus (−)

Button
2 Material Thickness Plus (+)

Button
3 Process Select
Follow instructions in Section 6-8 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.

3

Ref. 281252A

OM-281426 Page 39

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

6-14. Primary Logs (Menu 6 Of 12)

12

1 Material Thickness Minus (−)

Button
2 Material Thickness Plus (+)

Button
Follow instructions in Section 6-8 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.

6-15. Error Logs (Menu 7 Of 12)

12

Ref. 281252A

1 Material Thickness Minus (−)

Button
2 Material Thickness Plus (+)

Button
Follow instructions in Section 6-8 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.

OM-281426 Page 40

Ref. 281252A

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

6-16. Factory Reset (Menu 8 Of 12)

3

1 Material Thickness Minus (−)

Button
2 Material Thickness Plus (+)

Button

1

2

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 6-8 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.

6-17. Display Software (Menu 9 Of 12)

Ref. 281252A

. Display Software information is

for factory and service use

only.

Follow instructions in Section 6-8 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.

Ref. 281252A

OM-281426 Page 41

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

6-18. Control Software (Menu 10 Of 12)

. Control Software information is

for factory and service use

only.

Follow instructions in Section 6-8 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.

6-19. QuickTech™(Menu 11 Of 12)

1

2

Ref. 281252A

1 Wire/Rod/Tungsten Minus (−)

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

3

Button
Follow instructions in Section 6-8 to

enter the setup menu.
To enable or disable QuickTech™,

press the Auto-Set button.

QuickTech automatically selects
the right process and polarity. Just
hit the trigger or foot control and the
machine automatically switches to
the correct process recalling the
last process settings used.

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-281426 Page 42

Ref. 281252A

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

6-20. TIG Postflow Control (Menu 12 Of 12)

1

2

3

1 Wite/Rod/Tungsten Minus (−)

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

Button
4 Right Encoder
Follow instructions in Section 6-8 to

enter the setup menu.
To adjust TIG postflow, turn right

encoder.
Postflow can be adjusted from Au-

to-25 seconds.
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

4

Ref. 281252A

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-281426 Page 43

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

SECTION 7 − MAINTENANCE & TROUBLESHOOTING

7-1. Routine Maintenance

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

Every
3
Months

l Damaged Or Unreadable
Labels

Every
6
Months

~ Inside Unit ~ Clean Drive Rolls

OR

7-2. Overload Protection

l Repair Or Replace
Cracked Weld Cable

! Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

Reference

1 Supplementary Protector CB1
CB1 protects unit from overload. If

CB1 opens, unit shuts down.
Reset supplementary protector.

1

282718A

OM-281426 Page 44

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

7-3. Changing Drive Roll Or Wire Inlet Guide

1

3

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 14-1 for optional

drive rolls.

2

.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-281426 Page 45

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

Spool gun trigger 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 14−pin trigger is engaged on power up.

The 14−pin trigger is held during TIG preflow for
more than 15 seconds.

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

Release 4−pin trigger to clear error.

Fix or replace damaged gun.

Release the 14−pin trigger.

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

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

The weld voltage is less than 10 volts for more than

0.2 seconds while welding.

Output rectifier is damaged.

The secondary control board is damaged.

The primary 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.

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

Contact Miller Electric Mfg. LLC 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-281426 Page 46

The internal motor is damaged. Contact Miller Electric Mfg. LLC service depart-

ment.

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

Message RemedyError

Motor error−Motor has drawn too
much current.

Motor error−Motor has drawn too
much current.

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

Thermal error−Primary thermistor
range error.

Thermal error−Secondary ther­mistor range error.

Thermal error−Magnetic thermis­tor range error.

The primary control board is damaged. Contact Miller Electric Mfg. LLC service depart-

The spool gun motor is damaged. Fix or replace damaged gun.

The fan blades are obstructed. Clear obstruction from fan.

The fan wiring harness is disconnected.

The fan is damaged.

The primary control board is damaged.

The primary circuit thermistor is unplugged.

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

The primary control board is damaged.

The secondary circuit thermistor is unplugged.

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

The control board is damaged.

The magnetic circuit thermistor is unplugged.

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

ment.

Contact Miller Electric Mfg. LLC service department

Contact Miller Electric Mfg. LLC service department

Contact Miller Electric Mfg. LLC service department

Contact Miller Electric Mfg. LLC service department

Boost error−Cycle power to clear
error.

Over voltage−Cycle power to
clear error.

Under voltage−Cycle power to
clear error.

Network error−Communication
between micros has been lost.

Network error−Communication
between boards has been lost.

Secondary Current FB error−
Check Weld Current FB device.

Weld over voltage error - Cycle
power to clear error.

The primary 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.

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

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

The primary control board is damaged.

The interface board is damaged.

The wiring harness between the control board and
weld current sensor is damaged.

The weld current sensor is damaged.

The secondary control board is damaged. Cycle power to clear error. If this error persists after

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

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

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

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

a power cycle, contact Miller Electric Mfg. LLC ser­vice department.

Clamp error - Cycle power to
clear error.

The secondary control board is damaged. Cycle power to clear error. If this error persists after

a power cycle, contact Miller Electric Mfg. LLC ser­vice department.

OM-281426 Page 47

. 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-281426 Page 48

Notes

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

OM-281426 Page 49

SECTION 8 − ELECTRICAL DIAGRAM

OM-281426 Page 50

Figure 8-1. Circuit Diagram

281418-A

OM-281426 Page 51

SECTION 9 − HIGH FREQUENCY

9-1. Welding Processes Requiring High Frequency

1

1 High-Frequency Voltage
TIG − helps arc jump air gap

between torch and workpiece and/
or stabilize the arc.

TIG

9-2. Installation Showing Possible Sources Of HF Interference

Weld Zone

11, 12

50 ft

(15 m)

10
9
8

7

3

13

2

high_freq 2018-01

14

Sources of Direct High-Frequency
Radiation

1 High-Frequency Source (welding

power source with built-in HF or

separate HF unit)
2 Weld Cables
3 Torch
4 Work Clamp
5 Workpiece
6 Work Table

OM-281426 Page 52

1

4 5 6

Best Practices
Not Followed

Sources of Conduction of High
Frequency

7 Input Power Cable
8 Line Disconnect Device
9 Input Supply Wiring

Sources of Reradiation of High
Frequency

10 Ungrounded Metal Objects
11 Lighting
12 Wiring
13 Water Pipes and Fixtures
14 External Phone and Power Lines

S-0694

9-3. Recommended Installation To Reduce HF Interference

6

8

Ground all metal ob­jects and all wiring in
welding zone using
#12 AWG wire.

Nonmetal

Building

3

50 ft

(15 m)

1

Weld Zone

2

4

Ground
workpiece if
required by
codes.

7

50 ft

(15 m)

5

8

Best Practices Followed

1 High-Frequency Source (welding

power source with built-in HF or
separate HF unit)

Ground metal machine case (clean paint
from around hole in case, and use case
screw), work output terminal, line discon­nect device, input supply, and worktable.

2 Center Point of Welding Zone
Midpoint between high-frequency source

and welding torch.
3 Welding Zone
A circle 50 ft (15 m) from center point in all

directions.
4 Weld Output Cables
Keep cables short and close together.

Metal Building

8

11

10

5 Conduit Joint Bonding and Grounding
Electrically join (bond) all conduit sections

using copper straps or braided wire.
Ground conduit every 50 ft (15 m).

6 Water Pipes and Fixtures
Ground water pipes every 50 ft (15 m).
7 External Power or Telephone Lines
Locate high-frequency source at least 50 ft

(15 m) away from power and phone lines.
8 Grounding Rod
Consult the National Electrical Code for

specifications.

9

8

Ref. S-0695

Metal Building Requirements

9 Metal Building Panel Bonding

Methods

Bolt or weld building panels together, install
copper straps or braided wire across
seams, and ground frame.

10 Windows and Doorways
Cover all windows and doorways with

grounded copper screen of not more than
1/4 in (6.4 mm) mesh.

11 Overhead Door Track
Ground the track.

OM-281426 Page 53

SECTION 10 − 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.

10-1. 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-281426 Page 54

10-2. 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
contaminated causing lower weld quality.

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.

Radial Grinding

Causes Wandering Arc

Wrong Tungsten

Preparation

1-1/2 To 4 Times

Electrode Diameter

2

Ideal Tungsten Preparation − Stable Arc

4

1

3

15° to 30°

Notes

OM-281426 Page 55

SECTION 11 − GUIDELINES FOR TIG WELDING (GTAW)

11-1. 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 10-2.

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°

2

1

10−15°

4

3/16 in

Bottom View Of Gas Cup

90°

5

3

4

5
6

6

1/16 in

Ref. gtaw_Phase_2018−01

-

OM-281426 Page 56

Ref.161892

11-2. Torch Movement During Welding

Tungsten Without Filler Rod

Welding direction

Form pool Tilt torch Move torch to front

Tungsten With Filler Rod

Welding direction

Form pool Tilt torch Add filler metal

Remove rod

75°

75°

15°

Move torch to front

of pool. Repeat process.

11-3. 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-281426 Page 57

SECTION 12 − GUIDELINES FOR MIG WELDING (GMAW)

12-1. Typical GMAW (MIG) Process Connections

! Weld current can damage

electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as

Regulator/
Flowmeter

Wire Feeder/

Welding Power Source

Shielding Gas

close to the weld as possible.

Gun

Gas

12-2. Typical GMAW (MIG) Process Control Settings

1

2

3

1/16 or

0.0625 in.

4

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-281426 Page 58

12-3. Holding And Positioning Welding Gun

1

2

5

4

. 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.

3

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

12-4. Conditions That Affect Weld Bead Shape

10°

Push

Gun Angles And Weld Bead Profiles

Perpendicular

45°

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-281426 Page 59

12-5. Gun Movement During Welding

1 2

3

12-6. 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

1

5 Poor Penetration

2

12-7. Good Weld Bead Characteristics

2

4

3

4

3

5

1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During

Welding
Weld a new bead or layer for each

1

5

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-281426 Page 60

12-8. Troubleshooting − Excessive Spatter

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

S-0636

Possible Causes Remedy

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.

12-9. Troubleshooting − Porosity

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

S-0635

Possible Causes Remedy

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.

12-10. Troubleshooting − Excessive Penetration

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

Excessive Penetration

Possible Causes Remedy

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

Good Penetration

Increase travel speed.

S-0639

OM-281426 Page 61

12-11. Troubleshooting − Lack Of Penetration

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

Lack of Penetration Good Penetration

Possible Causes Remedy

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

12-12. Troubleshooting − Incomplete Fusion

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

Possible Causes Remedy

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.

12-13. Troubleshooting − Burn-Through

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

S-0637

Possible Causes Remedy

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

Increase and/or maintain steady travel speed.

OM-281426 Page 62

S-0640

12-14. Troubleshooting − Waviness Of Bead

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

Possible Causes Remedy

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.

12-15. 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 Remedy

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-281426 Page 63

12-16. 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%

CO

2

Argon + 10%

CO

2

Argon + 25%

CO

2

Argon + 50%

CO

2

CO

2

Flat &

2

Horizontal Fillet

Flat &

2

Horizontal Fillet

Flat &

Horizontal Fillet

Flat &

Horizontal Fillet

All Positions

All Positions

All Positions

All Positions

Helium All Positions

Flat &

Horizontal Fillet

Flat &

Horizontal Fillet

All Positions

All Positions

All Positions

All Positions

1

GMAW-P

Argon +

Helium

Tri-Mix

All Positions

2

All Positions

1

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

2

12-17. Troubleshooting Guide For GMAW (MIG) Welding Process

Problem Probable Cause Remedy

Wire feed motor operates, but
wire does not feed.

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

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.

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

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

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

and diameter, replace if necessary.

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

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

OM-281426 Page 64

Dirty or damaged (kinked) liner. Replace liner.

Problem RemedyProbable Cause

Wire feeds, but no gas flows.

Welding arc not stable.

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.

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.

gas hose in gun and cable assembly.

solenoid valve.

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

drive rolls if necessary.

Readjust welding parameters.

OM-281426 Page 65

SECTION 13 − GUIDELINES FOR STICK WELDING (SMAW)

13-1. 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

5

4

2

3

6

1

7

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
13-2).

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-281426 Page 66

stick 2018-01 − 151593

13-2. Electrode And Amperage Selection Chart

ELECTRODE

6010

&

6011

6013

7014

7018

7024

Ni-Cl

308L

DIAMETER

3/32

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

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

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

1/4
3/32

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

1/4
3/32

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

1/4
3/32

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

1/4
3/32

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

1/8
5/32

RANGE

AMPERAGE

50

100

150

200

250

300

350

400

450

ELECTRODE

6010
6011
6013

7014

7018

7024

NI-CL

308L

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

EP
EP

EP,EN

EP,EN

EP

EP,EN

EP
EP

DC*

AC

HORIZ*

POSITION

ALL
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

13-3. Striking An Arc

! Weld current starts when elec-

trode touches workpiece.

1 Electrode

1

2

3

1

2

3

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-281426 Page 67

13-4. Positioning Electrode Holder

1

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.

2

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.

1

45°

45°

Fillet Welds

13-5. Poor Weld Bead Characteristics

1

10°-30°

2

2

S-0060

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

4

3

5

S-0053-A

13-6. Good Weld Bead Characteristics

1

OM-281426 Page 68

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

13-7. 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

13-8. Electrode Movement During Welding

1

3

S-0061

. Normally, a single stringer

bead is satisfactory for most
narrow groove weld joints;

2

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.

13-9. Welding Lap Joints

30°
Or Less

2

S-0054-A

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

30°
Or Less

1

3

1

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-281426 Page 69

13-10. Welding Groove (Butt) Joints

1

1/16 in.

(1.6 mm)

3

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

2

4

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.

13-11. Welding T-Joints

1

45°

Or

2

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

1

13-8. Remove slag before making
another weld pass.

2

3

OM-281426 Page 70

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

13-12. Weld Test

3

2 To 3 in.

(51-76 mm)

1/4 in.

(6.4 mm)

2
1

13-13. 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.

3

2 To 3 in.

(51-76 mm)

2

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

1

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

S-0057-B

Possible Causes Remedy

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 Remedy

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 Remedy

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-281426 Page 71

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

Lack of Penetration

Possible Causes Remedy

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 Remedy

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 Remedy

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 Remedy

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 Remedy

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

Make tack welds along joint before starting welding operation.

OM-281426 Page 72

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

SECTION 14 − PARTS LIST

14-1. Recommended MIG Spare Parts

Part

No.

248282 M-100 Gun, 10FT .030-.035 1......... .............. .....................................

246372 Nozzle, slip type .500 orf flush 1......... .............. ...................................

♦226190 Nozzle, slip type Flux Cored 1......... ............. .....................................

169716 Adapter, Contact Tip 1......... .............. ...........................................

♦087299 Tip, contact scr .023 wire x 1.125......... ............. ..................................

♦000067 Tip, contact scr .030 wire x 1.125......... ............. ..................................

♦000068 Tip, contact scr .035 wire x 1.125......... ............. ..................................

♦000069 Tip, contact scr .045 wire x 1.125......... ............. ..................................

♦194010 Liner, monocoil .023/.025 wire x 15ft (consisting of) 1......... ............. .................

♦194011 Liner, monocoil .030/.035 wire x 15ft (consisting of) 1......... ............. .................

♦194012 Liner, monocoil .035/.045 wire x 15ft (consisting of) 1......... ............. .................

079975 O-RING, .187 ID x .103CS rbr 1......... .............. ...................................

261157 Roll, Drive .024, .030-.035V Wire, .035VK Wire 1......... .............. ....................

♦202926 Roll, Drive VK .030-.035/.045 Wire 1......... ............. ...............................

♦OPTIONAL

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

QuantityDescription

14-2. Recommended TIG Spare Parts

Part

No.

WP1712RDI25 Tig Torch, A-150 12.5FT 1...... ........... .......................................

194744 Foot Control, RFCS-14HD 1.......... .............. .....................................

AK2C Accessory Kit, Ceriated 1.......... ............... ........................................

AK-150MFC Accessory Kit, FX 1........ ............ .............................................

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

QuantityDescription

OM-281426 Page 73

SECTION 15 − SOFTWARE LICENSE AGREEMENT

The accompanying software (“Software”) is provided by Miller Electric Mfg. LLC (“Miller”), 1635 W. Spencer St., P.O. Box 1079, Appleton, WI
54912, to qualified purchasers for use in conjunction with Miller welding equipment only.

IMPORTANT−READ CAREFULLY: This Software License Agreement (”Agreement”) is a legal agreement between You (either an individual or
a single entity) and Miller Electric Mfg. LLC (“Miller”). BY OPENING THE SEALED SOFTWARE PACKET(S) AND/OR USING THE SOFT­WARE, YOU ARE AGREEING TO BE BOUND BY THE TERMS OF THIS AGREEMENT. If You do not agree to the terms of this Agreement,
promptly return the unopened Software packet(s) and the accompanying items, including any Miller hardware, written materials, and binders or
other containers, to the place you obtained them for a full refund.

SOFTWARE LICENSE.
The Software is protected by copyright laws and international copyright treaties, as well as other intellectual property laws and treaties. The

Software is licensed, not sold.

1. GRANT OF LICENSE. This Agreement grants you the limited, non−exclusive right to use one copy of the Software on a single Miller
Welding system at a time. No concurrent usage of this Software is permitted, except in the case where the intention of the Software is to
modify the Miller Welding system, such as a Software update or to enable a software feature.

2. DESCRIPTION OF OTHER RIGHTS AND LIMITATIONS.

S Limitations on Reverse Engineering, Decompilation, and Disassembly. You may not reverse engineer, decompile, or disassemble the

Software, except and only to the extent such activity is expressly permitted by applicable law notwithstanding this limitation.

S Termination. Without prejudice to any other rights, Miller may terminate this Agreement if you fail to comply with the terms and condi-

tions of this Agreement. Upon termination of this Agreement for any reason, you must destroy all copies of the Software and all of its
component parts.

S Transfer. You may permanently transfer the Software, together with all of your rights under this Agreement, to another end user, pro-

vided you transfer all of the Software (including any component parts, media and printed materials, any upgrades and this Agreement)
and you retain no copies. In addition the end user receiving the transferred Software must agree to all terms of this Agreement.

3. INTELLECTUAL PROPERTY RIGHTS. All title and intellectual property rights in and to the Software, and any copies You are permitted to
make herein are owned by Miller. All rights not expressly granted are reserved by Miller.

4. U.S. GOVERNMENT RESTRICTED RIGHTS. All Software provided to the U.S. Government pursuant to solicitations issued on or after
December 1, 1995 is provided with the commercial license rights and restrictions described elsewhere herein. All Software provided to the
U.S. Government pursuant to solicitations issued prior to December 1, 1995 is provided with ”Restricted Rights” as provided for in FAR,
48 CFR 52.227−14 (JUNE 1987) or DFAR, 48 CFR 252.227−7013 (OCT 1988), as applicable.

5. EXPORT RESTRICTIONS. You acknowledge that the Software is subject to U.S. export jurisdiction. You agree to comply with all applica­ble international and national laws that apply to the Software, including the U.S. Export Administration Regulations, as well as end−user,
end−use and country destination restrictions issued by U.S. and other governments.

MISCELLANEOUS. If you acquired this Software in the United States, this Agreement is governed by the laws of the State of Wisconsin. If this
Software was acquired outside the United States, then local law may apply.

DISCLAIMER OF WARRANTIES. TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW, MILLER PROVIDES TO YOU THE
SOFTWARE, AND ANY (IF ANY) SUPPORT SERVICES RELATED TO THE SOFTWARE (”SUPPORT SERVICES”) AS IS AND WITH ALL
FAULTS; AND MILLER HEREBY DISCLAIMS WITH RESPECT TO THE SOFTWARE AND SUPPORT SERVICES ALL WARRANTIES AND
CONDITIONS, WHETHER EXPRESS, IMPLIED OR STATUTORY, INCLUDING, BUT NOT LIMITED TO, ANY (IF ANY) WARRANTIES OR
CONDITIONS OF OR RELATED TO: MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, LACK OF VIRUSES, ACCURACY
OR COMPLETENESS OF RESPONSES, RESULTS, WORKMANLIKE EFFORT AND LACK OF NEGLIGENCE. ALSO THERE IS NO WAR­RANTY, DUTY OR CONDITION OF TITLE, QUIET ENJOYMENT, QUIET POSSESSION, OR CORRESPONDENCE TO DOCUMENTATION
PROVIDED OR NONINFRINGEMENT. THE ENTIRE RISK ARISING OUT OF USE OR PERFORMANCE OF THE SOFTWARE AND ANY
SUPPORT SERVICES REMAINS WITH YOU.

EXCLUSION OF INCIDENTAL, CONSEQUENTIAL AND CERTAIN OTHER DAMAGES. TO THE MAXIMUM EXTENT PERMITTED BY AP­PLICABLE LAW, IN NO EVENT SHALL MILLER OR ITS SUPPLIERS BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT, OR CON­SEQUENTIAL DAMAGES WHATSOEVER (INCLUDING, BUT NOT LIMITED TO, DAMAGES FOR LOSS OF PROFITS OR CONFIDENTIAL
OR OTHER INFORMATION, FOR BUSINESS INTERRUPTION, FOR PERSONAL INJURY, FOR LOSS OF PRIVACY, FOR FAILURE TO
MEET ANY DUTY INCLUDING OF GOOD FAITH OR OF REASONABLE CARE, FOR NEGLIGENCE, AND FOR ANY OTHER PECUNIARY
OR OTHER LOSS WHATSOEVER) ARISING OUT OF OR IN ANY WAY RELATED TO THE USE OF OR INABILITY TO USE THE SOFT­WARE, THE PROVISION OF OR FAILURE TO PROVIDE SUPPORT SERVICES, OR OTHERWISE UNDER OR IN CONNECTION WITH
ANY PROVISION OF THIS AGREEMENT, EVEN IN THE EVENT OF THE FAULT, TORT (INCLUDING NEGLIGENCE), STRICT LIABILITY,
BREACH OF CONTRACT OR BREACH OF WARRANTY OF MILLER OR ANY SUPPLIER, AND EVEN IF MILLER OR ANY SUPPLIER HAS
BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.

LIMITATION OF LIABILITY AND REMEDIES. MILLER SHALL NOT BE LIABLE FOR ANY DAMAGES OF ANY KIND WHATSOEVER ARIS­ING OUT OF YOUR RELIANCE ON THE SOFTWARE OR YOUR USE OR THE USE BY YOUR EMPLOYEES OR AUTHORIZED INDEPEN­DENT CONTRACTORS OF ANY WELDING PRODUCT IN CONNECTION WITH OR IN CONJUNCTION WITH THE SOFTWARE. NOT­WITHSTANDING ANY DAMAGES THAT YOU MIGHT INCUR FOR ANY REASON WHATSOEVER (INCLUDING, WITHOUT LIMITATION,
ALL DAMAGES REFERENCED ABOVE AND ALL DIRECT OR GENERAL DAMAGES), THE ENTIRE LIABILITY OF MILLER AND ANY OF
ITS SUPPLIERS UNDER ANY PROVISION OF THIS AGREEMENT AND YOUR EXCLUSIVE REMEDY FOR ALL OF THE FOREGOING
SHALL BE LIMITED TO THE GREATER OF THE AMOUNT ACTUALLY PAID BY YOU FOR THE SOFTWARE OR U.S. $5.00. THE FORE­GOING LIMITATIONS, EXCLUSIONS AND DISCLAIMERS SHALL APPLY TO THE MAXIMUM EXTENT PERMITTED BY APPLICABLE LAW,
EVEN IF ANY REMEDY FAILS ITS ESSENTIAL PURPOSE.

242053-B

OM-281426 Page 74

Notes

Notes

Warranty Questions?

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

Your distributor also gives
you ...

Service

You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.

Support

Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

Effective January 1, 2018

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

Within the warranty periods listed below, Miller will repair or replace any
warranted parts or components that fail due to such defects in material
or workmanship. Miller must be notified in writing within thirty (30) days
of such defect or failure, at which time Miller will provide instructions on
the warranty claim procedures to be followed. If notification is submitted
as an online warranty claim, the claim must include a detailed
description of the fault and the troubleshooting steps taken to identify
failed components and the cause of their failure.

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

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

Diodes, and Discrete Rectifier Modules

2. 3 Years — Parts and Labor
* Auto-Darkening Helmet Lenses (Except Classic

Series) (No Labor)

* Engine Driven Welder/Generators

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

* 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
* External Monitoring Equipment and Sensors
* Field Options

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

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

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

* Load Banks
* Motor-Driven Guns (except Spoolmate Spoolguns)
* PAPR Blower Unit (No Labor)
* Positioners and Controllers
* Racks
* Running Gear/Trailers
* Spot Welders
* Subarc Wire Drive Assemblies
* TIG Torches (No Labor)
* Tregaskiss Guns (No Labor)
* Water Cooling Systems
* Wireless Remote Foot/Hand Controls and Receivers
* Work Stations/Weld Tables (No Labor)

guarantees or warranties expressed or implied.

5. 6 Months — Parts
* Batteries

6. 90 Days — Parts
* Accessory (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.

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.

miller_warr 2018-01

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

For International Locations Visit

www.MillerWelds.com

Contact the Delivering Carrier to:

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2018 Miller Electric Mfg. LLC 2018−01

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.