Miller Spectrum 625 X-TREME, XT40 Torch Owner's Manual

OM-264 267C 2014−09

Processes

Air Plasma Cutting
and Gouging

Description

Air Plasma Cutter

R

Spectrum 625 X-TREME

And XT40 Torch

Visit our website at

www.MillerWelds.com

File: Plasma Cutters

From Miller to You

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

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

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

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

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

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

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

Working as hard as you do

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

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

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

Mil_Thank 2009−09

TABLE OF CONTENTS

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

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

1-2. Plasma Arc Cutting 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. Signification des symboles 5.............................................................

2-2. Dangers liés au coupage à l’arc au plasma 5...............................................

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

2-4. Proposition californienne 65 Avertissements 9..............................................

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

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

SECTION 3 − DEFINITIONS 10..................................................................

3-1. Additional Safety Symbols And Definitions 10................................................

3-2. Miscellaneous Symbols And Definitions 10..................................................

SECTION 4 − SPECIFICATIONS 11..............................................................

4-1. Serial Number And Rating Label Location 11................................................

4-2. Unit Specifications 11....................................................................

4-3. Torch Dimensions And Weight 12..........................................................

4-4. Duty Cycle And Overheating 13...........................................................

4-5. Power Source Dimensions And Weight 13..................................................

4-6. Environmental Specifications 13...........................................................

SECTION 5 − INSTALLATION 14................................................................

5-1. Selecting A Location 14..................................................................

5-2. Connecting Gas/Air Supply 14............................................................

5-3. Connecting And Disconnecting Torch 15....................................................

5-4. Connecting And Disconnecting Work Cable 15...............................................

5-5. Connecting Work Clamp 16...............................................................

5-6. Electrical Service Guide 16...............................................................

5-7. Extension Cord Data 16..................................................................

5-8. Multi−Voltage Plug Adapter (MVP) Connection 17............................................

5-9. Connecting 120 Volt Input Power 18........................................................

5-10. Connecting 1-Phase Input Power For 240 VAC 20............................................

SECTION 6 − OPERATION 22...................................................................

6-1. Controls 22............................................................................

6-2. Cutting Speed 24.......................................................................

6-3. Trigger Safety Lock 25...................................................................

6-4. Plasma Cutting System Practices 25.......................................................

6-5. Sequence Of Cutting Operation 26.........................................................

6-6. Sequence Of Gouging Operation 27........................................................

6-7. Sequence Of Piercing Operation 28........................................................

SECTION 7 − MECHANIZED OPERATION 29.....................................................

7-1. XT40M Mounting Position 29..............................................................

7-2. Remote Control Receptacle 29............................................................

7-3. Remote Control Cable Functions 29........................................................

7-4. Remote Control Cable Connection 30......................................................

SECTION 8 − MAINTENANCE & TROUBLESHOOTING 31.........................................

8-1. Routine Maintenance 31.................................................................

TABLE OF CONTENTS

8-2. Wrapper Removal 31....................................................................

8-3. Checking Or Replacing Filter Element 32...................................................

8-4. Checking Shield Cup Shutdown System 32.................................................

8-5. Checking/Replacing Retaining Cup, Tip, And Electrode 33.....................................

8-6. Status/Trouble Lights 34.................................................................

8-7. Troubleshooting Power Source 35.........................................................

8-8. Troubleshooting Torch 35.................................................................

SECTION 9 − ELECTRICAL DIAGRAM 36........................................................

SECTION 10 − PARTS LIST 40..................................................................

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

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

pom_2013−09

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

1-1. Symbol Usage

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. Plasma Arc Cutting Hazards

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

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

During operation, keep everybody, especially children, away.

CUTTING can cause fire or explosion.

Hot metal and sparks blow out from the cutting arc.
The flying sparks and hot metal, hot workpiece, and
hot equipment can cause fires and burns. Check
and be sure the area is safe before doing any cutting.

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

is not possible, tightly cover them with approved covers.

D Do not cut where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that sparks and hot materials from cutting 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 cutting on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D Do not cut 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 Connect work cable to the work as close to the cutting area as prac-

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

D Do not use plasma cutter to thaw frozen pipes.
D Never cut containers with potentially flammable materials inside −

they must be emptied and properly cleaned first.

D Do not cut where the atmosphere may contain flammable dust, gas,

or liquid vapors (such as gasoline).

D Do not cut pressurized cylinders, pipes, or vessels.
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 Do not locate unit on or over combustible surfaces.
D Remove any combustibles, such as a butane lighter or matches,

from your person before doing any cutting.

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.

. 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.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The torch and work circuit are
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also

higher voltages than welding to start and maintain the arc (200 to 400
volts dc are common), but may also use torches designed with safety
interlock systems which turn off the machine when the shield cup is
loosened or if tip touches electrode inside the nozzle. 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 touch torch parts if in contact with the work or ground.
D Turn off power before checking, cleaning, or changing torch parts.
D Disconnect input power before installing or servicing this equip-

ment. Lockout/tagout input power according to OSHA CFR

1910.147 (see Safety Standards).

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

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

D 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 − always verify
the supply ground.

D When making input connections, attach proper grounding conduc-

tor first.

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 dam-

age 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 wrap torch cable around your body.
D Ground the workpiece to a good electrical (earth) ground if required

by codes.

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

parts at once.

D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Do not bypass or try to defeat the safety interlock systems.
D Use only torch(es) specified in Owner’s Manual.
D Keep away from torch tip and pilot arc when trigger is pressed.
D Clamp work cable with good metal-to-metal contact to workpiece

(not piece that will fall away) or worktable as near the cut as
practical.

D Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

live when power is on. Plasma arc cutting requires

OM-264 267 Page 1

ELECTRIC SHOCK can kill.

FUMES AND GASES can be hazardous.

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

D Turn Off unit, disconnect input power, check voltage on input ca-

pacitors, and be sure it is near zero (0) volts before touching any
parts. Check capacitors according to instructions in Maintenance
Section of Owner’s Manual or Technical Manual before touching
any parts.

EXPLODING PARTS can injure.

D On inverter power sources, failed parts can ex-

plode or cause other parts to explode when
power is applied. Always wear a face shield
and long sleeves when servicing inverters.

FLYING SPARKS can injure.

Sparks and hot metal blow out from the cutting arc.
Chipping and grinding cause flying metal.

D Wear approved face shield or safety goggles with side shields.
D Wear proper body protection to protect skin.
D Wear flame-resistant ear plugs or ear muffs to prevent sparks from

entering ears.

ARC RAYS can burn eyes and skin.

Arc rays from the cutting process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin.

D Wear face protection (helmet or shield) with a proper shade of filter

lenses to protect your face and eyes from arc rays and sparks when
cutting or watching. ANSI Z49.1 (see Safety Standards) suggests a
No. 9 shade (with No. 8 as minimum) for all cutting currents less
than 300 amperes. Z49.1 adds that lighter filter shades may be used
when the arc is hidden by the workpiece. As this is normally the case
with low current cutting, the shades suggested in Table 1 are pro­vided for the operator’s convenience.

D Wear approved safety glasses with side shields under your helmet

or shield.

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 material

(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.

Table 1. Eye Protection For Plasma Arc Cutting

Current Level In Amperes Minimum Shade Number

Below 20

20 − 40
40 − 60

60 − 100

#4
#5
#6
#8

NOISE can damage hearing.

Prolonged noise from some cutting applications can
damage hearing if levels exceed limits specified by
OSHA (see Safety Standards).

D Use approved ear plugs or ear muffs if noise level is high.
D Warn others nearby about noise hazard.

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

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

arc to remove cutting 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 man-

ufacturer’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. Fumes from cutting and oxygen depletion
can alter air quality causing injury or death. Be sure the breathing air
is safe.

D Do not cut in locations near degreasing, cleaning, or spraying oper-

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

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

plated steel, unless the coating is removed from the cutting 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 when cut.

D Do not cut containers with toxic or reactive materials inside or

containers that have held toxic or reactive materials − they must be
emptied and properly cleaned first.

PLASMA ARC can injure.

The heat from the plasma arc can cause serious
burns. The force of the arc adds greatly to the burn
hazard. The intensely hot and powerful arc can
quickly cut through gloves and tissue.

D Keep away from the torch tip.
D Do not grip material near the cutting path.
D The pilot arc can cause burns − keep away from torch tip when trig-

ger is pressed.

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 Point torch away from your body and toward work when pressing

the torch trigger − pilot arc comes on immediately.

D Turn off power source and disconnect input power before disas-

sembling torch or changing torch parts.

D Use only torch(es) specified in the Owner’s Manual.

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 metalworking pro­cesses, be sure to treat them carefully.

D Protect compressed gas cylinders from excessive heat, mechani-

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

D Install and secure cylinders in an upright position by chaining them

to a stationary support or equipment cylinder rack to prevent falling
or tipping.

D Keep cylinders away from any cutting or other electrical circuits.
D Never allow electrical contact between a plasma arc torch and a

cylinder.

D Never cut on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses, and

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

D Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the valve.

D Keep protective cap in place over valve except when cylinder is in

use or connected for use.

D Use the right equipment, correct procedures, and sufficient number

of persons to lift and move cylinders.

D Read and follow instructions on compressed gas cylinders, asso-

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

OM-264 267 Page 2

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

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, insulated welding gloves and
clothing to prevent burns.

MOVING PARTS can injure.

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

closed and securely in place.

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

guards for maintenance and troubleshooting as necessary.

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

finished and before reconnecting input power.

READ INSTRUCTIONS.

D Read and follow all labels and the Owner’s

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

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

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

FLYING METAL or DIRT can injure eyes.

D Wear safety glasses with side shields or wear

face shield.

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.

OVERUSE can cause OVERHEATING.

D Allow cooling period; follow rated duty cycle.
D Reduce amperage (thickness) or reduce duty

cycle before starting to cut again.

EXPLODING HYDROGEN hazard.

D When cutting aluminum underwater or with the

water touching the underside of the aluminum,
free hydrogen gas may collect under the work­piece.

D See your cutting engineer and water table instructions for help.

BATTERY EXPLOSION can injure.

D Do not use plasma cutter to charge batteries or

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

FALLING EQUIPMENT can injure.

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift unit.

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

tend 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.

FIRE OR EXPLOSION hazard.

D Do not locate 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.

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.

H.F. RADIATION can cause interference.

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

navigation, safety services, computers, and
communications equipment.

D Have only qualified persons familiar with elec-

tronic equipment perform this installation.

D The user is responsible for having a qualified electrician promptly

correct any interference problem resulting from the installation.

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

at once.

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

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

ARC CUTTING can cause interference.

D Electromagnetic energy can interfere with

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

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

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

D Locate cutting operation 100 meters from any sensitive electronic

equipment.

D Be sure this cutting power source is installed and grounded

according to this manual.

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

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

OM-264 267 Page 3

1-4. California Proposition 65 Warnings

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

1-5. Principal Safety Standards

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

Recommended Practices for Plasma Arc Cutting and Gouging, Ameri­can Welding Society Standard AWS C5.2, from Global Engineering
Documents (phone: [phone], website: www.global.ihs.com).

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

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

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

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

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

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

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

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).

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

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

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

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

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

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

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 may interfere with some medical implants, e.g. pace­makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con­duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:

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

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

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

4. Keep head and trunk as far away from the equipment in the weld­ing circuit as possible.

5. Connect work clamp to workpiece as close to the weld as
possible.

6. Do not work next to, sit or lean on the welding power source.

7. Do not weld whilst carrying the welding power source or wire
feeder.

About Implanted Medical Devices:

Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom­mended.

OM-264 267 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT

UTILISATION

pom_2013−09fre

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. Signification des symboles

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

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

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

. Indique des instructions spécifiques.

2-2. Dangers liés au coupage à l’arc au plasma

Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les
risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 1-5. Veuillez lire et respecter
toutes ces normes de sécurité.

L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.

Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.

LE COUPAGE présente un risque de
feu ou d’explosion.

Des particules de métal chaud et des étincelles
peuvent jaillir de la pièce au moment du coupage.
Les étincelles et le métal chaud, la pièce à couper

feu ou des brûlures. Avant de commencer à travailler, assurez-vous
que l’endroit est sécuritaire.

D Déplacez toute matière inflammable se trouvant à l’intérieur d’un

périmètre de 10,7 m (35 pi) de la pièce à couper. Si cela est
impossible, vous devez les couvrir avec des housses approuvées
et bien ajustées.

D Ne coupez pas dans un endroit où des étincelles pourraient

atteindre des matières inflammables.

D Protégez−vous, ainsi que toute autre personne travaillant sur les

lieux, contre les étincelles et le métal chaud.

D Assurez−vous qu’aucune étincelle ni particule de métal ne peut se

glisser dans de petites fissures ou tomber dans d’autres pièces.

D Afin d’éliminer tout risque de feu, soyez vigilant et gardez toujours

un extincteur à la portée de la main.

D Si vous coupez sur un plafond, un plancher ou une cloison, soyez

conscient que cela peut entraîner un feu de l’autre côté.

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

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

D Ne coupez pas sur un contenant fermé tel qu’un réservoir ou un

bidon.

D Fixez le câble de masse sur la pièce à couper, le plus près possible

de la zone à couper afin de prévenir que le courant de coupage ne
prenne une trajectoire inconnue ou longue et ne cause ainsi une
décharge électrique, d’étincelles ou un feu.

D Ne pas utiliser le coupeur plasma pour dégeler des conduites

gelées.

chauffée et l’équipement chaud peuvent causer un

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.

D Ne coupez jamais des contenants qui peuvent contenir des

matières inflammables. Vous devez en premier lieu les vider et les
nettoyer convenablement.

D Ne coupez pas quand l’atmosphère peut contenir des poussières,

gaz ou vapeurs (comme l’essence) inflammables.

D Ne coupez pas dans un endroit où l’atmosphère risque de contenir

de la poussière ou des vapeurs explosives.

D Ne coupez pas de bouteilles, de tuyaux ou de contenants

pressurisés.

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 Ne placez pas le poste sur une surface combustible ou au−dessus

de celle−ci.

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 Avant le coupage, retirez tout combustible de vos poches, par

exemple un briquet au butane ou des allumettes.

UN CHOC ÉLECTRIQUE peut tuer.

Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures
graves. Le chalumeau et le circuit de masse sont
automatiquement actifs lorsque le poste est sous
tension. L’alimentation d’entrée et les circuits
internes de l’appareil le sont également. Le coupage
plasma nécessite des tensions plus importantes
que le soudage pour amorcer et maintenir l’arc (200
à 400VDC est typique), mais peut être utilisé avec
des torches équipées de systèmes de verrouillage
de sécurité qui arrêtent la machine en cas de buse
desserrée ou si l’électrode touche la tuyère. Un
poste incorrectement installé ou inadéquatement
mis à la terre constitue un danger.

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

sans trous.

D Isolez−vous 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 touchez pas aux pièces du chalumeau si vous êtes en contact

avec la pièce à couper ou le sol.

D Mettez l’appareil hors tension avant d’effectuer la vérification, le

nettoyage ou le changement d’une pièce du chalumeau.

OM-264 267 Page 5

D Coupez l’alimentation d’entrée avant d’installer l’appareil ou

d’effectuer l’entretien. Verrouillez ou étiquetez la sortie
d’alimentation selon la norme OSHA 29 CFR 1910.147
(reportez−vous aux Principales normes de sécurité).

D Installer le poste correctement et le mettre à la terre

convenablement selon les consignes du manuel de l’opérateur et
les normes nationales, départementales et locales.

D Assurez−vous que le fil de terre du cordon d’alimentation est

correctement relié à la borne de terre dans la boîte de coupure ou
que la fiche du cordon est branchée à une prise correctement mise
à la terre − vous devez toujours vérifier la mise à la terre.

D Avant d’effectuer les connexions d’alimentation, vous devez relier

le bon fil de terre.

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, sous dimensionnés

ou réparés.

D Vérifiez et remplacez les cosses du câble du chalumeau si elles

sont usées ou altérées.

D Le câble du chalumeau ne doit pas s’enrouler autour de votre

corps.

D Si les normes le stipulent, la pièce à couper doit être mise à la terre.
D Utilisez uniquement de l’équipement en bonne condition. Réparez

ou remplacez immédiatement toute pièce altérée.

D Portez un harnais de sécurité si vous devez travailler au−dessus

du sol.

D Assurez−vous que tous les panneaux et couvercles sont

correctement en place.

D N’essayez pas d’aller à l’encontre des systèmes de verrouillage de

sécurité ou de les contourner.

D Utilisez uniquement le ou les chalumeaux recommandés dans le

manuel de l’opérateur.

D N’approchez pas le tube du chalumeau et l’arc pilote lorsque la

gâchette est enfoncée.

D Le câble de masse doit être pincé correctement sur la pièce à

couper, métal contre métal (et non de telle sorte qu’il puisse se
détacher), ou sur la table de travail le plus près possible de la ligne
de coupage.

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

contact avec tout objet métallique.

DÉCHARGES ÉLECTRIQUES poten­tiellement mortelles.

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

D Mettre l’unité hors tension, mesurer la tension des

condensateurs d’entrée et s’assurer qu’elle est pratiquement
nulle avant de toucher à l’une quelconque des pièces. Mesurer
cette tension conformément aux directives énoncées à la
section Entretien du manuel de l’utilisateur ou du manuel
technique avant de toucher à l’une quelconque des pièces.

Risque de blessure en cas
D’EXPLOSION DES PIÈCES.

D Mise sous tension, toute pièce défectueuse

des sources d’alimentation de l’inverseur peut
exploser ou faire exploser d’autres pièces.
Pour entretenir les inverseurs, toujours porter
un masque protecteur et un vêtement à
manches longues.

LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.

Le coupage plasma produit des étincelles et
projections de métal à très haute température.
Lorsque la pièce refroidit, du laitier peut se former.

D Portez une visière ou des lunettes de sécurité avec des écrans

latéraux approuvées.

D Portez des vêtements de protection adéquats afin de protéger

votre peau.

D Ayez recours à des protège−tympans ou à un serre−tête ignifuges

afin d’éviter que les étincelles n’entrent dans vos oreilles.

LES RAYONS D’ARC peuvent
entraîner des brûlures aux yeux et à la
peau.

Les rayons d’arc provenant du procédé de coupage
produisent des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) qui peuvent entraîner
des brûlures aux yeux et à la peau.

D Une protection faciale (casque ou masque) avec des lunettes

filtrantes de teinte adéquate est indispensable pour protéger le
visage et les yeux des rayonnements de l’arc et des étincelles
pendant la découpe ou en regardant simplement ANSI Z49.1
(reportez−vous aux Principales normes de sécurité) suggère
d’utiliser un filtre de teinte nd 9 (nd 8 étant le minimum) pour tout
travail de coupage faisant appel à un courant de moins de 300 A.
On mentionne également dans la norme Z49.1 qu’un filtre plus
faible peut être utilisé lorsque l’arc est caché par la pièce à couper.
Comme cela est habituellement le cas pour les travaux de coupage
à faible courant, les teintes énumérées au tableau 1 sont fournies à
titre d’information pour l’opérateur.

D Porter des lunettes de sécurité à coques latérales sous votre

casque ou écran facial.

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

protéger les autres contre les rayonnements, les étincelles et les
éblouissements; prévenez 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.

Tableau 1. Protection des yeux pour le coupage au plasma d’arc

Intensité de courant en ampères Filtre de teinte (minimum)

Moins de 20 no. 4

20 − 40 no. 5
40 − 60 no. 6

60 − 100 no. 8

LE BRUIT peut endommager l’ouïe.

Certaines applications de coupage produisent un
bruit constant, ce qui peut endommager l’ouïe si le
niveau sonore dépasse les limites permises par
l’OSHA (reportez−vous aux Principales normes de
sécurité).

D Utilisez des protège−tympans ou un serre−tête antibruit si le

niveau sonore est élevé.

D Prévenez toute personne sur les lieux du danger relié au bruit.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le coupage produit des vapeurs et des gaz.
Respirer ces vapeurs et ces gaz peut être
dangereux pour la santé.

D Ne mettez pas votre tête au−dessus des vapeurs. Ne respirez pas

ces vapeurs.

OM-264 267 Page 6

D Si vous êtes à l’intérieur au moment du coupage, ventilez la pièce

ou ayez recours à une ventilation aspirante installée près de l’arc
pour évacuer les vapeurs et les gaz. Pour déterminer la bonne
ventilation, il est recommandé de procéder à un prélèvement pour
la composition et la quantité de fumées et de gaz auxquels est
exposé le personnel.

D Si la ventilation est médiocre, utilisez un respirateur anti−vapeurs

approuvé.

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

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

D Travaillez dans un espace restreint uniquement s’il est bien ventilé

ou si vous portez un respirateur anti−vapeurs. Les vapeurs
causées par le coupage et l’épuisement de l’oxygène peuvent
altérer la qualité de l’air et entraîner des blessures ou la mort.
Assurez−vous que l’air ambiant est sain pour la santé.

D Ne coupez pas dans un endroit près d’opérations de décapage, de

nettoyage ou de vaporisation. La chaleur et les rayons d’arc
peuvent réagir avec les vapeurs et former des gaz hautement
toxiques et irritants.

D Ne coupez pas des métaux enrobés tels que des métaux

galvanisés, contenant du plomb ou de l’acier plaqué au cadmium, à
moins que l’enrobage ne soit ôté de la surface du métal à couper,
que l’endroit où vous travaillez ne soit bien ventilé, ou que vous ne
portiez un respirateur anti−vapeurs. Les enrobages ou tous
métaux qui contiennent ces éléments peuvent créer des vapeurs
toxiques s’ils sont coupés.

D Ne coupez pas de contenants qui renferment ou ont renfermés des

matières toxiques ou réactives − vous devez en premier lieu les
vider et les nettoyer convenablement.

L’ARC PLASMA peut provoquer des
blessures.

La chaleur dégagée par le plasma d’arc peut
entraîner de sérieuses brûlures. La force de l’arc est
un facteur qui s’ajoute au danger de brûlures. La

rapidement passer au travers de gants et de tissus.

D N’approchez pas le tube du chalumeau.
D Ne saisissez pas la pièce à couper près de la ligne de coupage.
D L’arc pilote peut causer des brûlures − n’approchez pas le tube du

chalumeau lorsque vous avez appuyé sur le gâchette.

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.

chaleur intense et la puissance de l’arc peuvent

D Ne pointez pas le chalumeau en direction de votre corps ni de la

pièce à couper lorsque vous appuyez sur la gâchette − l’arc pilote
s’allume automatiquement.

D Mettez l’alimentation hors tension et débranchez le cordon

d’alimentation avant de démonter le chalumeau ou de changer une
pièce du chalumeau.

D Utilisez uniquement le ou les chalumeaux recommandés dans le

manuel de l’opérateur.

LES BOUTEILLES peuvent exploser
si elles sont endommagées.

Les bouteilles de gaz comprimé contiennent du gaz
sous haute pression. Si une bouteille est
endommagée, elle peut exploser. Puisque les

processus de travail des métaux, assurez−vous de les manipuler
correctement.

D Protégez les bouteilles de gaz comprimé contre la chaleur

excessive, les chocs mécaniques, des dommages physiques, le
laitier, la flamme, les étincelles et l’arc.

D Installez et attachez les bouteilles dans la position verticale à l’aide

d’une chaîne, sur un support stationnaire ou un châssis
porte−bouteille afin de prévenir qu’elles ne tombent ou ne
basculent.

D Les bouteilles ne doivent pas être près de la zone de coupage ni de

tout autre circuit électrique.

D Un contact électrique ne doit jamais se produire entre un

chalumeau de plasma d’arc et une bouteille.

D Ne coupez jamais sur une bouteille pressurisée − une explosion en

résulterait.

D Utilisez uniquement des bouteilles de gaz comprimé , des

détendeurs, des boyaux et des raccords conçus pour l’application
déterminée. Gardez−les, ainsi que toute autre pièce associée, en
bonne condition.

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

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

D Utiliser les équipements corrects, les bonnes procédures et

suffisamment de personnes pour soulever et déplacer les
bouteilles.

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

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

bouteilles de gaz font habituellement partie d’un

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

maintenance

LES PIÈCES CHAUDES peuvent
provoquer des brûlures.

D Ne pas toucher des parties chaudes à mains

nues.

D Prévoir une période de refroidissement avant

d’utiliser l’équipement.

D Ne pas toucher aux pièces chaudes, utiliser les

outils recommandés et porter des gants de
soudage et des vêtements épais pour éviter les
brûlures.

Les PIÈCES MOBILES peuvent
provoquer des blessures.

D S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

D Maintenir fermés et verrouillés les portes,

panneaux, recouvrements et dispositifs de
protection.

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

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

D Remettre les portes, panneaux, recouvrements ou dispositifs de

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

OM-264 267 Page 7

LIRE LES INSTRUCTIONS.

t

D Lire et appliquer les instructions sur les

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

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

constructeur.

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

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

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

D Porter des lunettes de sécurité avec écrans

latéraux ou un écran facial.

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.

L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.

D Prévoir une période de refroidissement;

respecter le cycle opératoire nominal.

D Réduire l’ampérage (épaisseur) avant de

continuer à couper ou réduire le facteur de
marche.

Danger D’EXPLOSION
D’HYDROGÈNE.

D Lors du coupage d’aluminium partiellement ou

totalement immergé dans l’eau, de l’hydrogène
libre peut s’accumuler sous la pièce.

D Consultez votre ingénieur de coupage et les instructions de la

table de coupage.

L’EXPLOSION DE LA BATTERIE peu
provoquer des blessures.

D Ne pas utiliser le découpeur plasma 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.

LA CHUTE DE L’ÉQUIPEMENT peut
provoquer des blessures.

D Utiliser l’anneau de levage uniquement pour

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

D Utiliser un engin d’une capacité appropriée pour soulever

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.

Risque D’INCENDIE OU
D’EXPLOSION.

D Ne pas installer l’appareil à proximité de

produits inflammables

D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces

infllammables.

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

l’alimentation est correctement dimensionné et protégé avant de
mettre l’appareil en service.

LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits im­primés.

D Etablir 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,

déplacer ou expédier des cartes PC.

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

D Le Rayonnement haute frequence (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

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

LE COUPAGE Ã L’ARC peut causer
des interférence.

D L’énergie électromagnétique peut gêner le

fonctionnement d’appareils électroniques
comme des ordinateurs et des robots.

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

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

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

électronique sensible.

D S’assurer que la source de coupage est correctement branchée et

mise à la terre.

D Si l’interférence persiste, l’utilisateur doit prendre des mesures

supplémentaires comme écarter la machine, utiliser des câbles
blindés de des filtres, ou boucler la zone de travail.

OM-264 267 Page 8

2-4. Proposition californienne 65 Avertissements

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

25249.5 et suivants)

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).

Recommended Practices for Plasma Arc Cutting and Gouging,
American Welding Society Standard AWS C5.2, 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 02269 (phone: [phone],
website: www.nfpa.org and www. sparky.org).

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

Ce produit contient des éléments chimiques, dont le plomb,
reconnus par l’État de Californie pour leur caractère
cancérogène ainsi que provoquant des malformations
congénitales ou autres problèmes de procréation. Se laver les

mains après toute manipulation.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).

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

Institute, 25 West 43rd Street, New York, NY 10036 (phone:
212-642-4900, website: www.ansi.org).

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

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

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

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

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 CEM peuvent créer des interférences
avec certains implants médicaux comme des stimulateurs cardiaques.
Des mesures de protection pour les porteurs d’implants médicaux
doivent être prises: Limiter par exemple tout accès aux passants ou
procéder à une évaluation des risques individuels pour les soudeurs.
Tous les soudeurs doivent appliquer les procédures suivantes pour
minimiser l’exposition aux CEM provenant du circuit de soudage:

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

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

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

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

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

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

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

En ce qui concerne les implants médicaux :

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

OM-264 267 Page 9

SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

. Some symbols are found only on CE products.

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

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

3-2. Miscellaneous Symbols And Definitions

. Some symbols are found only on CE products.

Safe1 2012−05

Safe26 2012−05

A

V

U

I

1max

IP

I

1eff

Amperes

Volts Increase

Protective Earth

(Ground)

On Off Percent Direct Current

Rated No Load

0

Voltage (OCV) U

Rated Maximum

Supply Current

Degree Of
Protection

Maximum Effective

Supply Current

I

pf

Plasma Arc Cutting

1

2

(PAC)

Single Phase Constant Current Voltage Input

Primary Voltage

Rated Welding

Current X

Loose Shield Cup Input

power factor

U

S

2

Adjust Air/Gas

Pressure

No − Do Not Do

This

Conventional Load

Voltage

Duty Cycle

Suitable for Some

Hazardous

Locations

Hz

S

1

Low Air Pressure

Light

Temperature

Line Connection

Single Phase

Static Frequency

Converter-

Transformer-

Rectifier

Hertz

Power Rating,
Product Of Voltage
And Current (KVA)

OM-264 267 Page 10

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

SECTION 4 − SPECIFICATIONS

4-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the bottom. 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

Power Supply
Input

Rated AC Phase and line frequency (Hz) 1 − Phase 60 Hz
Rated Input Voltage (U1) and rated Input Cur-

rent (I1) and I1 eff at rated output. I1 eff used to
determine power cord rating

Power Factor/kVA/kW at Rated Output Volts AC RMS − (U1) Power Factor kVA/kW

Peak kW at Arc Stretch kW 10.1

Volts AC RMS − (U1) Amps RMS − (I1) I1 eff

120 VAC, 1−Phase (20 A) 25.1 11.2
120 VAC, 1−Phase (15 A) 18.1 10.7

240 VAC, 1−Phase 26.7 18.9

120 VAC, 1−Phase (20 A) 0.969 3.02 / 2.93
120 VAC, 1−Phase (15 A) 0.970 2.17 / 2.11

240 VAC, 1−Phase 0.995 6.41 / 6.30

Output

Rated Open Circuit Voltage (U0) Type 400 Volts DC/Electrode Negative
Output Characteristic Constant Current

Volts AC RMS - (U1) Amps DC - (I2)

Rated Output Current and Voltage (I2, U2) at
rated Input Voltage (U1)

Output Current Range 15 − 40 A
Duty Cycle at 104°F (405C) and Rated Condi-

tions
(U1, I1, U2, I2) based on a 10 minute period

120 VAC, 1−Phase (20A) 27 A 91 V

120 VAC, 1−Phase (15 A) 20 A 88 V

240 VAC, 1−Phase 40 A 140 V

Volts AC RMS - (U1) Amps DC − (I2)

120 VAC, 1−Phase (20A) 27 A 20%

120 VAC, 1−Phase (15 A) 20 A 35%

240 VAC, 1−Phase 40 A 50%

−− −−

−− −−

−− −−

−−

−−

Volts DC -

(U2)

Duty Cycle

%

OM-264 267 Page 11

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

General

Toppling or tilting Up to 15° incline − − − −
Machine Weight 21 lb (9.5 kg) including 12 ft (3.7 m) torch

23 lb (10.4 kg) including 20 ft (6.1 m) torch

Torch − The XT40 torch is intended for handheld use only. The torch conforms to IEC 60974-7 when used with the Spectrum 625

X-TREME. Do not use this torch in combination with any other machines.
Gas Type Air or Nitrogen

Gas Quality

Gas Inlet Flow and Pressure 6.0 SCFM (170 L/min)

Gas Filtering Particulates to 5 microns
Mild Steel capacities (see Section 6-2 for cutting speeds vs material type and thickness)

Cooling Method Air
Duty Cycle of Torch 100% at 40 Amps
Rating of Electrical Controls (Trigger) 30 VDC at .1 Amps − − − −

Rating of Electrical Controls (Cup) 30 VDC at 1 Amp − − − −
Approved Systems Spectrum 625 X-TREME w/XT40 torch
Trigger Protection Safety trigger guard
Safety Devices Safety interlock devices shut down power source
Rated Capacity (edge start) 5/8 in. at 13 ipm (330 mm/min)*

Sever Cut Capacity (edge start) 7/8 in. at 4 ipm (102 mm/min)*
Pierce Capacity 5/16 in.

Gouge Mode Capacity**

*Travel speeds are approximately 80% of maximum.
** Working air pressure must be at or above 90 PSI (621kPa).

Requirements for the torch connection

S Use only compressed air which is free from dirt, oil, and water.
S Ensure that the connections are properly assigned and tightened.
S For torch replacement, see Miller torch manual Part No. OM-254449
S Ensure correct air pressure (flow pressure) and airflow (volume) are set. Insufficient airflow can lead to the torch overheating.

Clean, moisture−free,

oil−free

240V Input 15A Min 40A Max
120V (20A) Input 15A Min 27A Max
120V (15A) Input 15A Min 25A Max

− − − −

−− −−

−− −−

90 PSI (621 kPa)

Min

−− −−

−− −−

−− −−

−− −−

−− −−

−− −−

120 PSI (827

kPa) Max

4-3. Torch Dimensions And Weight

1-3/16 in.

(30 mm)

2.2 lb (1.0 kg)

OM-264 267 Page 12

8-3/4 in.

(222 mm)

1-1/2 in.
(38 mm)

Ref. 253 554-A

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

4-4. Duty Cycle And Overheating

Overheating

20% duty cycle

2 Minutes Cutting 8 Minutes Resting

35% duty cycle

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

50% duty cycle

5 Minutes Cutting 5 Minutes Resting

Duty Cycle is percentage of 10
minutes that unit can cut at rated
load without overheating.

If unit overheats, thermostat(s)
opens, output stops, Temperature
trouble light goes On, and cooling
fan runs. Wait fifteen minutes for
unit to cool or temperature light to
go off. Reduce amperage or duty
cycle before cutting or gouging.

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

A

0

15

Minutes

4-5. Power Source Dimensions And Weight

Dimensions And Weight

21 lb (9.5 kg)
including 12 ft (3.7 m) torch

4-6. Environmental Specifications

A. IP Rating

OR

Reduce Duty Cycle

sduty1 5/95 / Ref. 264 954-B

5-1/2 in.

(140 mm)

9 in.

(229 mm)

13-1/8 in.
(333 mm)

loc_2 3/96 - Ref. 264 954-B

IP Rating Operating Temperature Range

IP23CS

This equipment is designed for outdoor use. It may be stored, but is

not intended to be used for cutting outside during precipitation unless

sheltered.

5° to 104° F (−15° to 40° C)

IP23CS 2014−09

OM-264 267 Page 13

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

SECTION 5 − INSTALLATION

5-1. Selecting A Location

Location

! Do not move or operate

unit where it could tip.

1 Line Disconnect Device
Locate unit near correct input

power supply.
Locate unit at least 18 in. (460 mm)

away from a wall or other
obstruction to allow adequate
clearance for cooling air flow.

! Special installation may be

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

1

18 in.

(460 mm)

5-2. Connecting Gas/Air Supply

18 in.

(460 mm)

loc_2 3/96 - Ref. ST-151 556 / Ref. 264 254-B

. Use only clean, dry air with 90

1

2

to 120 psi (621 to 827 kPa)
pressure.

1 Gas/Air Inlet Opening
2 Hose
3 Teflon Tape
Obtain hose with 1/4 NPT right-

hand thread fitting. Wrap threads
with teflon tape (optional) or apply
pipe sealant, and install fitting in
opening. Route hose to gas/air
supply.

Tools Needed:

9/16 in.

OM-264 267 Page 14

3

From Gas/Air

Supply

Ref. 805 326-A

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

5-3. Connecting And Disconnecting Torch

3

1

2

! Turn off power source and

disconnect input power.

1 Torch Connector
2 Quick Connect Collar
3 Receptacle
To connect torch:

Align torch connector key with
receptacle keyway, and insert into
receptacle. Rotate collar until it
firmly snaps into the locked
position.

To disconnect torch:
Rotate collar to release torch

connector from receptacle and pull
torch connector away from unit.

5-4. Connecting And Disconnecting Work Cable

2

1

Ref. 264 954-B

! Turn off power source and

disconnect input power.

1 Work Cable Plug
2 Work Cable Receptacle
To connect plug, align key with

receptacle keyway and insert into
receptacle. Rotate plug clockwise
(hand tight only) 1/4 turn to secure in
receptacle.

To disconnect plug, rotate counter­clockwise until key aligns with key­way and pull plug from receptacle.

Ref. 264 954-B / Ref. 803 475-G

OM-264 267 Page 15

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

5-5. Connecting Work Clamp

1

2

5-6. 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.

NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be be available.

Input Voltage (V) 120 240
Input Amperes (A) At Rated Output
Max Recommended Standard Fuse Rating In Amperes

Time-Delay Fuses

Normal Operating Fuses

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters)

Min Grounding Conductor Size In AWG

4

4

1

2

3

1 Work Clamp
2 Workpiece
Connect work clamp to a clean,

paint-free location on workpiece, as
close to cutting area as possible.

Ref. 803 640-A

Elec Serv 2014−01

60 Hz Single Phase

27

A 15 or 20

ampere individual

branch circuit

protected by

time-delay fuses

or circuit breaker

is required.

See Section 4-2

35
45
10

130
(40)

10

Reference: 2014 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.

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

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

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

requirements.

5-7. Extension Cord Data

. When calculating max. cord length, remember to include conductor length from line disconnect device to input power receptacle.

Conductor Size − AWG (mm2)*

Single Phase AC

Input Voltage

120 182 (55) 114 (35) 72 (22) 45 (14) 29 (9)

240 340 (104) 210 (64) 130 (40) − − − −

*Conductor size is based on maximum 3% voltage drop

OM-264 267 Page 16

6 (13.3) 8 (8.4) 10 (5.3) 12 (3.3) 14 (2.1)

Maximum Allowable Cord Length in ft (m)

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

5-8. Multi−Voltage Plug Adapter (MVP) Connection

Selecting Plug Adapter

2

3

4

5

6

7

1

1

! Do not cut off power cord

connector and rewire. The
power cord connector and
plugs adapters will work with
standard NEMA receptacles.
Modifying power cord,
connector, and plug adapter
will void product warranty.

8

Selecting Plug Adapter

1 Power Cord Connector From

Welding Power Source − NEMA
Type L6−30P

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

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

(Customer Supplied)

Connecting Plug Adapter To Power Cord

4 Plug Adapter − NEMA Type 5−20P

(Optional)

5 Receptacle − NEMA Type 5−20R

(Customer Supplied)

6 Plug Adapter − NEMA Type 6−50P

7 Receptacle − NEMA Type 6−50R

(Customer Supplied)

8 Receptacle − NEMA Type L6−30R

(Customer Supplied)

! Follow electrical service guide for

240 VAC in Section 5-6. Do not use
plug rating to size branch circuit
protection.

Connecting Plug Adapter To Power
Cord

Align plug adapter and power cord
contacts. Push together.

Turn plug adapter clockwise until
completely tight.

Connect plug to receptacle.

MVP Plug2 2011−09 / Ref. 254 665-A

OM-264 267 Page 17

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

5-9. 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 Sec-
tion 20.

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

. The Auto-Line circuitry in this unit

automatically links the power source to the
primary voltage being applied, either 120 or
240 VAC.

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 Adapter And Power

Cord Connector (NEMA Type 5−15P Plug
Shown)

For multi−voltage plug adapter connections, see
Section 5-8.

2 Receptacle − NEMA Type 5−15R

(Customer Supplied)

1

2

OM-264 267 Page 18

Input6 2011−03 Ref. 253 558-A / Ref. 254 665-A

Notes

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

OM-264 267 Page 19

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

5-10. Connecting 1-Phase Input Power For 240 VAC

1

L2

3

6

1

8

L1

L1

=GND/PE Earth Ground

7

2

4

5

L2

Tools Needed:

240 VAC, 1

9

OM-264 267 Page 20

Input10 2014−09 − 803 766-B / Ref. 254 665-A / Ref. 251 808-A

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

5-10. 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 adapts 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 protec-

tion using Section 5-6 (fused disconnect
switch shown).

8 Receptacle (NEMA 6-50R)

Customer Supplied

9 Multi-Voltage Plug And Power Cord

Connector (NEMA Type 6−50P Plug
Shown)

For multi−voltage plug connections, see Sec­tion 5-8.

Close and secure door on disconnect device.
Follow established lockout/tagout proced­ures to put unit in service.

Input10 2014−09

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-264 267 Page 21

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

SECTION 6 − OPERATION

6-1. Controls

A. Standard Front Panel Controls

2

V

POWER

PRESSURE

3

CUP

TEMP

20

1

25

15 40

A

30

35

30A

TIP

40A

TIP

120V

15A

120V

20A

50A

240V
30A

1 Output Control
Use control to set cutting output.

OM-264 267 Page 22

4

2 Power Light
3 Trouble Lights (See Section 8-6)

Ref. 253 015-A / Ref. 264 954-B / Ref. 805 326-A

4 Power Switch
Use switch to turn unit On or Off.

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

B. Automation Front Panel Controls

2

V

POWER

PRESSURE

20

3

CUP

TEMP

1

25

15 40

A

30

35

30A

TIP

40A

TIP

120V

15A

120V

20A

50A

240V
30A

1 Output Control
Use control to set cutting output.
2 Power Light

4

5

3 Trouble Lights (See Section 8-6)

4 Automation Receptacle

Ref. 253 015-A / Ref. 264 954-B / Ref. 805 326-A

5 Power Switch

Use switch to turn unit On or Off.

OM-264 267 Page 23

6-2. Cutting Speed

Mild Steel

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

Arc Current

Stainless

Arc Current

30

40

30

40

Material Thickness Recommended Cut Speeds

Inches mm IPM mm/min

22ga (0.03) 0.79 461 11,704
18ga (0.05) 1.22 303 7.701
16ga (0.06) 1.52 279 7,092
14ga (0.08) 2.01 201 5,100
22ga (0.03) 0.79 822 20,889
18ga (0.05) 1.22 466 11,847
16ga (0.06) 1.52 441 11,196
14ga (0.08) 2.01 358 9,103

1/8 in. (0.13) 3.18 218 5,547

1/4 (0.25) 6.35 64 1.626

3/8 ((0.38) 9.53 36 914

1/2 (0.50) 12.70 22 559
5/8 (0.63) 15.88 13 330

Material Thickness Recommended Cut Speeds

Inches mm IPM mm/min

16ga (0.06) 1.52 174 4,419
12ga (0.11) 2.67 86 2,184
12ga (0.11) 2.67 154 3,911

1/8 (0.13) 3.18 137 3,480
1/4 (0.25) 6.35 52 1,321
3/8 (0.38) 9.53
1/2 (0.50) 12.70 18 457

Aluminum

Arc Current

30

40

16ga (0.06) 1.52 329 8,357
12ga (0.11) 2.67 198 5,029

Material Thickness Recommended Cut Speeds

Inches mm IPM mm/min

3/32 (0.09) 2.36 281 7,137

1/8 (0.13) 3.18 241 6,121
1/4 (0.25) 6.35 78 1,981
3/8 (0.38) 9.53 34 864

. Recommended cut speed is approximately 80% of maximum.
. Aluminum and Stainless Steel cut speeds at these thicknesses may be reduced as much as 20%.

OM-264 267 Page 24

6-3. Trigger Safety Lock

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

1 Trigger

Trigger Locked

6-4. Plasma Cutting System Practices

Always connect work clamp to a clean,

paint-free location on workpiece, as close to

cutting area as possible.

1

Trigger Unlocked

DO NOT start pilot arc without cutting or

gouging as this shortens the service life

Ref. 253 554-A

! The pilot arc starts immediately

when trigger is pressed.

of the nozzle and electrode.

90°

Maintain approximately a 90° angle to the

workpiece surface for proper cutting results.

1/16 in.

(1.6 mm)

When doing extended (non-shielded)

cutting, maintain approximately 1/16 in.

standoff between electrode and surface.

Sparks should pass through the workpiece

and out the bottom when cutting.

Wt

DO NOT put pressure on shield when

drag cutting; instead, slide shield along

the surface for proper cutting results.

If sparks flare back from surface, this

usually is an indication that either travel

speed is too fast or amperage is set too low.

Pulling rather than pushing the torch

makes cutting easier. Use a proper guide

or template for accurate cutting operations.

Ref. 254 087-A

OM-264 267 Page 25

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

6-5. Sequence Of Cutting Operation

90°

Connect work clamp to a clean, paint-free

location on workpiece, as close to cutting

area as possible.

! The pilot arc starts immediately

when trigger is pressed.

Raise trigger lock and press

trigger. Pilot arc starts.

For standard (shielded) cutting, place drag shield on edge

of metal. For extended (non-shielded) cutting, use 1/8 in.

(3.2 mm) standoff distance (dragging tip will reduce tip life).

After cutting arc starts, slowly

start moving torch across metal.

Adjust torch speed so

sparks go thru metal and

out bottom of cut.

OM-264 267 Page 26

Pause briefly at end of

cut before releasing trigger.

Postflow continues for approx. 20 seconds

after releasing trigger; cutting arc can be

instantly restarted during postflow by raising

trigger lock and pressing trigger.

Ref. 254 087-A

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

6-6. Sequence Of Gouging Operation

Connect work clamp to a clean, paint-free

location on workpiece, as close to cutting

45°

Hold torch at approximately

45° angle to workpiece.

area as possible.

Trigger pilot arc once before starting to gouge.

! The pilot arc starts immediately

when trigger is pressed.

Raise trigger lock and press trigger. Pilot

arc starts. Move tip to within approxi-

mately 3/16 in. (4.8 mm). Start gouging

across workpiece surface. Maintain

approximately a 45° angle to surface.

Release trigger. Postflow continues for

approx. 20 seconds after releasing trigger;

arc can be instantly restarted during postflow

by raising trigger lock and pressing trigger.

Ref. 254 087-A

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-264 267 Page 27

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

6-7. Sequence Of Piercing Operation

! The pilot arc starts immediately

when trigger is pressed.

45°

Connect work clamp to a clean, paint-free

location on workpiece, as close to cutting

Rotate torch to upright position

approximately 90° to surface.

When arc has pierced through

workpiece, start cutting.

area as possible.

90°

Hold torch at approximately 45°

to the workpiece. Raise trigger

lock and press trigger. Pilot arc

90°

Maintain approximately 90° torch

position to surface, and continue

cutting.

starts.

Release trigger. Postflow continues for

approx. 20 seconds after releasing trigger;

arc can be instantly restarted during postflow

by raising trigger lock and pressing trigger.

Ref. 254 087-A

Notes

OM-264 267 Page 28

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

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

SECTION 7 − MECHANIZED OPERATION

7-1. XT40M Mounting Position

1 XT40M Machine Torch
2 Square
Use a square to align torch perpen-

dicular to the work surface.

7-2. Remote Control Receptacle

1

1

90°

2

. Remote trigger will only

operate with a machine torch
installed. Remote trigger is
disabled when a handheld
torch is installed.

1 Remote Control Receptacle
This receptacle provides remote

arc start inputs when using the
XT40M machine torch. Connect
supplied remote control cable to
receptacle on front panel. See
Section 7-3 for remote control cable
input and output functions.

7-3. Remote Control Cable Functions

Function Twisted Lead Set Lead Information

Blue/Blue White Blue/Blue White twisted lead set connects to a customer supplied set of remote contacts

Remote Start

Orange/Orange White Orange/Orange White twisted lead set connects to a customer supplied drive device.

Okay To Move

Voltage Sense Brown/Brown White Brown/Brown White twisted lead set provides a 50:1 scaling arc voltage output signal for

Ref. 264 954-B

to provide a remote trigger input signal for the remote start function. Remote trigger is
functional with handheld torch if unit is powered up with handheld trigger closed.

Normally open contacts close following arc start to provide an output signal to begin torch
movement. Relay contacts rating: 3 amps/28 VDC or 3 amps/120 VAC.

automatic torch height adjustment. Output voltage range at 50:1 scale, 0 to 8 VDC. Max
current is 1 mA. Polarity of leads: Brown − Positive, Brown/White − Negative.

OM-264 267 Page 29

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

7-4. Remote Control Cable Connection

2

! Turn off power source.

1 Remote Control Cable Plug
2 Remote Control Receptacle
Connect plug to receptacle on unit

front panel.

1

Remote Control Cable

Blue
Blue/White

Orange
Orange/White

Brown
Brown/White

Remote Start*

Okay To Move

Relay Contacts: 3 amps/28 VDC or

3 amps/120 VAC

Voltage Sense (Scaled 50:1)

Output voltage range at 50:1

0 −8 VDC, max current 1 mA

Brown − Positive, Brown/White − Negative

*Remote trigger is functional with
handheld torch if unit is powered up
with handheld trigger closed.

OM-264 267 Page 30

Ref. 264 954-B / 804 041-A

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

SECTION 8 − MAINTENANCE & TROUBLESHOOTING

8-1. Routine Maintenance

Each
Use

Every
Week

Every
3
Months

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

n Gas/Air Pressure n Torch Tip, Electrode,

n Shield Cup Shutdown

System

l Damaged Or Unreadable
Labels

And Shield Cup

~ Air Filter/Regulator l Cracked Parts n l Gas/Air Hose

! Disconnect power

before maintaining.

. Maintain more often

during severe conditions.

Reference

Section 4-2,
8-5

Section 8-4

Section 8-3,
10

n l Torch Body, Cable

Every
6
Months

~ Inside Unit

OR

8-2. Wrapper Removal

Tools Needed:

Torx 25

! Turn off power, and

disconnect input power plug
from receptacle before
working on unit. Check to see
that all diagnostic LEDs have
stopped flashing before

2

1

removing wrapper from unit.

1 Wrapper
2 Torx Screws (Fine Thread)
Remove Torx screws and slide

wrapper off.

Ref. 805 326-A

OM-264 267 Page 31

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

8-3. Checking Or Replacing Filter Element

Tools Needed:

Torx 25

1

2

3

Ref. 805 327-A / Ref. 264 954-B

! Turn power Off, and disconnect in-

put power plug from receptacle.
Check to see that all diagnostic
LEDs have stopped flashing before
removing wrapper from unit.

Remove wrapper from unit (see Section
8-2).

1 Filter Base
2 Filter
3 Filter Cup
Unscrew filter cup from base.
Remove cup.
Unscrew filter element from base.

8-4. Checking Shield Cup Shutdown System

. Power must be reset whenever the cup shutdown

system is activated. Always turn Off power when
changing or checking consumables. Do NOT
overtighten torch shield cup. Gently finger tight­en cup onto torch.

1

Check filter element for dirt and moisture,
and replace if necessary.

Be sure that all parts are clean and dry.

Reinstall filter element, and secure filter
cup.

Reinstall wrapper.

1 Torch Shield Cup
Turn Power On and loosen shield

cup. If shutdown system works
properly, Cup light comes on. If not,
immediately turn Off power and
have Factory Authorized Service
Agent check unit.

If system works properly, retighten
cup and reset power.

OM-264 267 Page 32

Ref. 253 554-A

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

8-5. Checking/Replacing Retaining Cup, Tip, And Electrode

! Overtightening will strip threads. Do not overtighten retaining

cup during assembly. Do not cross-thread parts causing
stripping. Use care during torch assembly and parts
replacement.

! Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been signifi-

cantly reduced. Do not operate torch without a tip or electrode in place. Be sure to use genuine replacement
parts.

. A good practice is to replace both the tip and electrode at the same time.

! Turn Off power source before checking torch

parts.

Make sure this area is
clean of any debris.

6

4

Make sure swirl ring is clean of any
debris and no holes are obstructed.

3

2

New

Worn

Turn Off power source.

1 Shield Cup

Remove shield cup. Check cup for cracks,
and replace if necessary.

2Tip

3 Opening

5

1

Remove tip. Check tip, and replace if open­ing is deformed or 50% oversize. If inside of
tip is not clean and bright, clean with steel
wool. Be sure to remove any pieces of steel
wool afterwards.

4 Electrode
Check electrode. If center has a pit more

than a 1/16 in. (2 mm) deep, remove and re­place electrode.

New

1/32 in. (1 mm) to 1/16
in. (2 mm) maximum pit
depth depending on
acceptable cut quality

Worn

Ref. 253554-A

5 Swirl Ring

Remove swirl ring. Check ring, and replace
if side holes are plugged.

6 O-Ring
Check O-ring for cracks or worn spots, and

replace if necessary.

Carefully reassemble parts in reverse order.

OM-264 267 Page 33

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

8-6. Status/Trouble Lights

. Difficulty establishing a pilot arc may indicate consumables need to be cleaned or replaced.

V

REWOP

ERUSSERP

PUC

PMET

Light Condition Status/Possible Cause

Power On Input power is okay.

Pressure/Cup/Temp

Power

Power

Pressure On No or low [below 40 psi (276 kPa)] input pressure.

Pressure

Pressure

Cup

Cup

Cup

Cup

Temperature

Temperature

Temperature

For system troubleshooting see Section 8-7 and Section 8-8.

Off When Power light is on, system is normal if these lights

Flashing rate is steady for 15 seconds or until torch trigger
is pressed again, whichever comes first.

Repetitive flashing rate of two quick cycles, then a one
second pause.

Flashing rate is steady for 15 seconds or until torch trigger
is pressed again, whichever comes first.

Repetitive flashing rate of two quick cycles, then a one
second pause for a 15 second period.

On Torch cup is loose or off. Once cup is tightened, unit

Flashing rate is steady for 15 seconds or until torch trigger
is pressed again, whichever comes first.

Repetitive flashing rate of two quick cycles, then a one
second pause for a 15 second period or until torch trigger
is pressed again, whichever comes first.

Repetitive flashing rate of three quick cycles, then a one
second pause for a 15 second period or until torch trigger
is pressed again, whichever comes first.

On Power source overheated (see Section 4-4). Stop cutting

On (indefinitely) Power source temperature sensors may have failed or

Flashing rate is steady (indefinitely). Power source temperature sensor provided inaccurate

are off.
Input power below 156 volts AC, but has returned to

normal.
Input power is below 156 volts AC.

Regulated pressure in the unit is low. Check torch for
leaks. Check input pressure to unit is between 90 to 120
psi (621 to 827 kPa).

Regulated pressure in the unit is high. Check input pressure
to unit is between 90 to 120 psi (621 to 827 kPa) or pressure
transducer has failed.

power must be cycled off and back on again.
No arc was established. Check consumables or torch.

No pilot arc established possibly due to a loss of current.
Check consumables.

Consumables in torch failed to separate during pilot arc
possibly due to being stuck. Check consumables.

and allow unit to cool down.

ambient temperature is below -22° F (-30° C).

readings, but returned to normal. Unit power must be
cycled off and back on again.

OM-264 267 Page 34

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

8-7. Troubleshooting Power Source

Trouble Remedy

No pilot arc; difficulty in establishing an
arc.

No cutting output; Power light off; status
lights off; fan motor FM does not run.

Pilot arc working; no cutting output;
Power light on; status lights off; fan
motor running.

No gas/air flow; Power light on; status
lights off; fan motor running.

Pressure status light On. Check for sufficient gas/air supply pressure (see Section 5-2).

Cup status light On. Check torch shield cup (see Section 8-4). Reset power switch.

Temperature status light On. Unit overheating. Allow fan to run; the Trouble light goes out when the unit has cooled.

Status lights not working. Have Factory Authorized Service Agent check unit.

Power light flashing, status lights off. Reset power switch. Have qualified technician check input line power.

Pressure status light flashes. Unit lost pressure (momentarily) while cutting. Check air line for leaks.

Cup status light flashes. Unit lost output while attempting to cut or pilot. Check consumables and torch for wear.

Short tip life.

Clean or replace worn consumables as necessary (see torch Owner’s Manual).

Check for damaged torch or torch cable (see torch Owner’s Manual).

Place Power switch in On position.

Place line disconnect device in On position (see Section 5-10).

Check line fuse(s) and replace if needed or reset circuit breakers (see Section 5-10).

Be sure work clamp is connected.

Clean or replace worn consumables as necessary (see torch Owner’s Manual).

Have Factory Authorized Service Agent check for proper torch connections. Check operation of gas
valve AS1, and check gas/air system for leaks. Check filter element (see Section 8-3).

Check for dirty air filter and replace, if necessary (see manufacturer’s instructions).

Check air lines for leaks.

Have Factory Authorized Service Agent check pressure switch and control board.

Have Factory Authorized Service Agent check torch.

Have Factory Authorized Service Agent check control board.

Check and clean drag shield of any slag, particles, and debris.

Check input air pressure.

8-8. Troubleshooting Torch

Trouble Remedy

Arc goes on and off while cutting. Torch travel speed too slow; increase travel speed (see Section 6-5). Clean or replace torch consumables

Arc goes out while cutting. Be sure work clamp is securely attached to workpiece. Make sure tip is on or near [1/16 in. (1.6 mm) to

Sparks come out top of cut or cut is not
clean.

Trouble lights are on; unit has no cutting
output.

as necessary (see Section 8-5). Be sure work clamp is securely attached to workpiece.

1/8 in. (3.2 mm)] workpiece (see Section 6-4). Clean or replace torch consumables as necessary (see
Section 8-5).

Torch travel speed too fast; reduce travel speed (see Section 6-4). Clean or replace torch consumables
as necessary (see Section 8-5). Be sure work clamp is securely attached to workpiece. Unit not capable
of cutting metals thicker than rating (see Section 6-2).

Check torch consumables. Check for gas/air flow at torch. Check air supply connection and pressure to
unit and torch. Reset unit Power switch. Have Factory Authorized Service Agent check torch and
connections inside unit.

OM-264 267 Page 35

SECTION 9 − ELECTRICAL DIAGRAM

Figure 9-1. Circuit Diagram For Spectrum 625 X-TREME

OM-264 267 Page 36

264 143-A

OM-264 267 Page 37

Figure 9-2. Circuit Diagram For Spectrum 625 X-TREME CNC

OM-264 267 Page 38

265 480-A

OM-264 267 Page 39

SECTION 10 − PARTS LIST

10-1. Recommended Spare Parts

Item

No.

Dia.

Mkgs.

Part

No.

253008 Cord Set, 250V 6-30P 10ga 3/C 12 ft St Jkt Locking 1................ .. .....................

254330 Adapter, 5-15PXL630R 1................ .. ..............................................

254328 Adapter, 6-50PXL630R 1................ .. ..............................................

238486 Element, Filter Air 1................ .. ...................................................

260633 XT40, 12 ft Hand Held Torch (Replacement) w/Quick Connect 1................ .. ............

260635 XT40, 20 ft Hand Held Torch (Replacement) w/Quick Connect 1................ .. ............

263799 Cable, Work 12 ft 12 ga w/200A Clamp & Plug 1................ .. ..........................

254655 Label, XT40 Consumables 1................ .. ...........................................

254331 Adapter, 5-20PXL630R 1................ .. ..............................................

Description

Recommended Spare Parts

Quantity

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

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.

. For extended tip use, set Amperage control to 40.

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

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.

OM-264 267 Page 40

254 655-B

Figure 10-1. Consumable Parts For XT40

Item
No.

1

5

4

3

2

1

Part
No. Description

1 249 970 Torch Handle Kit (1)
2 249 971 Torch Trigger

Microswitch (1)...............

3 260 637 Leads, XT40 12ft Hand Held

Torch w/Disconnect (1)

3 260 638 Leads, XT40 20ft Hand Held

Torch w/Disconnect (1)
4 252 938 Torch Body Kit (1)
5 249 972 Torch Trigger Assembly

w/Spring (1)

252 951 Grease, Silicone (1)
260 633 XT40, 12ft Hand Held Torch

w/Disconnect Replacement (1)

260 635 XT40, 20ft Hand Held Torch

w/Disconnect Replacement (1)

See Figure 10-1 for

additional consumable parts.

Figure 10-2. Torch, XT40

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

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.

OM-264 267 Page 41

Part

Item

No.

No. Description

1 259 363 Mounting Screw (3)
2 259 361 Mounting Sleeve (1)
3 259 333 Kit, Torch Body W/Switch (1)
4 263 389 Positioning Sleeve Short Body (1)
5 259 357 Positioning Sleeve Long Body (1)
6 259 359 Strain Relief (1)
7 259 330 Torch Replacement Leads 25 ft (1)

3

1

2

7

See Figure 10-1 for

additional consumable parts.

4

6

5

Ref. 264 954-A

Figure 10-3. Torch, XT40M

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

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.

OM-264 267 Page 42

Part

Item

No.

No. Description

1 249 930 30 Amp Drag Shield (1)
2 249 937 40 Amp Machine Shield (1)
3 263 310 XT-Mach Torch, Shield Sense

4 249 932 30/40 Amp Retaining Cup (1)
5 249 927 30 Amp Tip (1)
6 249 928 40 Amp Tip (1)
7 249 931 30/40 Amp Swirl Ring (1)
8 249 926 30/40 Amp Electrode (1)
9 249 969 O-Ring (1)

Terminal w/Instruction (1)

1

2

See Figure 10-1 for

additional consumable parts.

5

8

6

4

3

7

9

Ref. 264 954-A

Figure 10-4. Consumable Parts For XT40M

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

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.

OM-264 267 Page 43

Notes

Notes

MATERIAL THICKNESS REFERENCE CHART

24 Gauge (.025 in.)
22 Gauge (.031 in.)
20 Gauge (.037 in.)

18 Gauge (.050 in.)
16 Gauge (.063 in.)
14 Gauge (.078 in.)

1/8 in. (.125 in.)

3/16 in. (.188 in.)

1/4 in. (.25 in.)

5/16 in. (.313 in.)

3/8 in. (.375 in.)

1/2 in. (.5 in.)

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

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, 2014

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

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

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

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

Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time periods.
All warranty time periods start on the delivery date of the equipment
to the original end-user purchaser, and not to exceed 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 Welding Generators

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

* Inverter Power Sources (Unless Otherwise Stated)
* 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)

* Fume Extractors − Capture 5, Filtair 400 and Industrial

Collector Series

4. 1 Year — Parts and Labor Unless Specified
* Automatic Motion Devices
* CoolBelt and CoolBand Blower Unit (No Labor)
* External Monitoring Equipment and Sensors

* Field Options

(NOTE: Field options are covered for the remaining
warranty period of the product they are installed in, or

for a minimum of one year — whichever is greater.)
* 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.)

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

guarantees or warranties expressed or implied.

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

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

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

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, relays, work
station table tops and welding curtains, or parts that
fail due to normal wear. (Exception: brushes and
relays are covered on all engine-driven products.)

2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable
and necessary maintenance, or equipment which has
been used for operation outside of the specifications for
the equipment.

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

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

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

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

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

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

miller_warr 2014-04-14

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

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

and Parts)
Circuit Diagrams
Welding Process Handbooks

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

Miller Electric Mfg. Co.

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

International Headquarters−USA

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

For International Locations Visit

www.MillerWelds.com

Contact the Delivering Carrier to:

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2014 Miller Electric Mfg. Co. 2014−01

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.