Miller Electric Maxstar 200 STR User Manual

OM-2233 203 409Q

2007−04

Processes

TIG (GTAW) Welding

Stick (SMAW) Welding

Description

115/230/400/460 Volt Models W/Autoline

Arc Welding Power Source



Maxstar 200 STR

Visit our website at

www.MillerWelds.com

And Non-CE Models

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 9001:2000 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 4/05

TABLE OF CONTENTS

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

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

1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

1-4. California Proposition 65 Warnings 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Signification des symboles 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Dangers relatifs au soudage à l’arc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. 7 . . . . . . . . . . .

2-4. Principales normes de sécurité 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-5. Information sur les champs électromagnétiques 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − DEFINITIONS (CE Models) 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Warning Label Definitions 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Manufacturer’s Rating Label 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Symbols And Definitions 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − INSTALLATION 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Specifications 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Volt-Ampere Curves 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Duty Cycle And Overheating 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Selecting A Location 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Weld Output Terminals And Selecting Cable Sizes* 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Remote 14 Receptacle Information 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-7. TIG Lift-Arc DCEN (Direct Current Electrode Negative) Connections 17 . . . . . . . . . . . . . . . . . . . . . . . . . .

4-8. Stick DCEP (Direct Current Electrode Positive) Connections 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Electrical Service Guide 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Connecting Input Power 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − OPERATION 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Controls 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Process Control 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Lift-ArcE Start Procedure 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Stick Start Procedure − Scratch Start Technique 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Amperage Control 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. DIG Control 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Routine Maintenance 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Blowing Out Inside Of Unit 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-3. Troubleshooting Help Aids 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-4. Troubleshooting 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − ELECTRICAL DIAGRAMS 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − SELECTING AND PREPARING

TUNGSTEN ELECTRODE 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1. Selecting Tungsten Electrode 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-2. Safety Information About Tungsten 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-3. Preparing Tungsten For AC Or DC Electrode Negative (DCEN) Welding 29 . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − GUIDELINES FOR TIG WELDING (GTAW) 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1. Positioning The Torch 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-2. Torch Movement During Welding 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-3. Positioning Torch Tungsten For Various Weld Joints 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TABLE OF CONTENTS

SECTION 10 − STICK WELDING (SMAW) GUIDELINES 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-1. Stick Welding Procedure 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-2. Electrode and Amperage Selection Chart 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-3. Striking an Arc − Scratch Start Technique 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-4. Striking an Arc − Tapping Technique 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-5. Positioning Electrode Holder 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-6. Poor Weld Bead Characteristics 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-7. Good Weld Bead Characteristics 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-8. Conditions That Affect Weld Bead Shape 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-9. Electrode Movement During Welding 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-10. Butt Joints 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-11. Lap Joint 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-12. Tee Joint 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-13. Weld Test 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-14. Troubleshooting − Porosity 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-15. Troubleshooting − Excessive Spatter 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-16. Troubleshooting − Incomplete Fusion 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-17. Troubleshooting − Lack Of Penetration 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-18. Troubleshooting − Excessive Penetration 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-19. Troubleshooting − Burn-Through 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-20. Troubleshooting − Waviness Of Bead 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-21. Troubleshooting − Distortion 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 11 − PARTS LIST 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPTIONS AND ACCESSORIES
WARRANTY

Declaration of Conformity for

European Community (CE) Products

NOTE

Manufacturer: European Contact:

Miller Electric Mg. Co. Mr. Danilo Fedolfi,
1635 W. Spencer St. Managing Director
Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
Phone: [phone] Via Privata Iseo 6/E

European Contact Signature:

Declares that the product: Maxstar

This information is provided for units with CE certification (see rating label on unit).

20098 San Giuliano
Milanese, Italy
Phone: [phone]
Fax: [phone]



200 STR

conforms to the following Directives and Standards:

Low Voltage Directive: 73/23/EEC

Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC

Electromagnetic Capability Directives: 89/336, 92/31/EEC

Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990

Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1

(December 1996 − Draft revision)

Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989

Insulation coordination for equipment within low-voltage systems:

Part 1: Principles, requirements and tests: IEC 664-1: 1992

Electromagnetic compatibility (EMC) Product standard for arc welding equipment:

EN50199: August 1995

Directives

Standards

dec_stat_6/05

Notes

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

 Warning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

som _3/05

 Marks a special safety message.

 Means “Note”; not safety related.

1-2. Arc Welding Hazards

 The symbols shown below are used throughout this manual to

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

 Only qualified persons should install, operate, maintain, and

repair this unit.

 During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input

live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.

 Do not touch live electrical parts.
 Wear dry, hole-free insulating gloves and body protection.
 Insulate yourself from work and ground using dry insulating mats

or covers big enough to prevent any physical contact with the work
or ground.

 Do not use AC output in damp areas, if movement is confined, or if

there is a danger of falling.

 Use AC output ONLY if required for the welding process.
 If AC output is required, use remote output control if present on

unit.

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

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

 Disconnect input power or stop engine before installing or

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

 Properly install and ground this equipment according to its

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

 Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.

 When making input connections, attach proper grounding conduc-

tor first − double-check connections.

 Frequently inspect input power cord for damage or bare wiring −

replace cord immediately if damaged − bare wiring can kill.

power circuit and machine internal circuits are also

This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.

 Turn off all equipment when not in use.
 Do not use worn, damaged, undersized, or poorly spliced cables.
 Do not drape cables over your body.
 If earth grounding of the workpiece is required, ground it directly

with a separate cable.

 Do not touch electrode if you are in contact with the work, ground,

or another electrode from a different machine.

 Do not touch electrode holders connected to two welding ma-

chines at the same time since double open-circuit voltage will be
present.

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

parts at once. Maintain unit according to manual.

 Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 Clamp work cable with good metal-to-metal contact to workpiece

or worktable as near the weld as practical.

 Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

 Do not connect more than one electrode or work cable to any

single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.

 Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section
before touching any parts.

FUMES AND GASES can be hazardous.

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

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

arc to remove welding fumes and gases.

 If ventilation is poor, wear an approved air-supplied respirator.
 Read and understand the Material Safety Data Sheets (MSDSs)

and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.

 Work in a confined space only if it is well ventilated, or while

wearing an air-supplied respirator. Always have a trained watch­person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath­ing air is safe.

 Do not weld in locations near degreasing, cleaning, or spraying op-

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

 Do not weld on coated metals, such as galvanized, lead, or

cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

OM-2233 Page 1

ARC RAYS can burn eyes and skin.

BUILDUP OF GAS can injure or kill.

Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.

 Wear an approved welding helmet fitted with a proper shade of fil-

ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).

 Wear approved safety glasses with side shields under your

helmet.

 Use protective screens or barriers to protect others from flash,

glare and sparks; warn others not to watch the arc.

 Wear protective clothing made from durable, flame-resistant mate-

rial (leather, heavy cotton, or wool) and foot protection.

WELDING can cause fire or explosion.

Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot

burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.

 Remove all flammables within 35 ft (10.7 m) of the welding arc. If

this is not possible, tightly cover them with approved covers.

 Do not weld where flying sparks can strike flammable material.
 Protect yourself and others from flying sparks and hot metal.
 Be alert that welding sparks and hot materials from welding can

easily go through small cracks and openings to adjacent areas.

 Watch for fire, and keep a fire extinguisher nearby.
 Be aware that welding on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

 Do not weld on closed containers such as tanks, drums, or pipes,

unless they are properly prepared according to AWS F4.1 (see
Safety Standards).

 Connect work cable to the work as close to the welding area as

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

 Do not use welder to thaw frozen pipes.
 Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

 Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

 Remove any combustibles, such as a butane lighter or matches,

from your person before doing any welding.

 Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B

for hot work and have a fire watcher and extinguisher nearby.

workpiece, and hot equipment can cause fires and

FLYING METAL can injure eyes.

 Welding, chipping, wire brushing, and grinding

cause sparks and flying metal. As welds cool,
they can throw off slag.

 Wear approved safety glasses with side

shields even under your welding helmet.

 Shut off shielding gas supply when not in use.
 Always ventilate confined spaces or use

approved air-supplied respirator.

HOT PARTS can cause severe burns.

 Do not touch hot parts bare handed.
 Allow cooling period before working on gun or

torch.

 To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and
clothing to prevent burns.

MAGNETIC FIELDS can affect pacemakers.

 Pacemaker wearers keep away.
 Wearers should consult their doctor before

going near arc welding, gouging, or spot
welding operations.

NOISE can damage hearing.

Noise from some processes or equipment can
damage hearing.

 Wear approved ear protection if noise level is

high.

CYLINDERS can explode if damaged.

Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.

 Protect compressed gas cylinders from excessive heat, mechani-

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

 Install cylinders in an upright position by securing to a stationary

support or cylinder rack to prevent falling or tipping.

 Keep cylinders away from any welding or other electrical circuits.
 Never drape a welding torch over a gas cylinder.
 Never allow a welding electrode to touch any cylinder.
 Never weld on a pressurized cylinder − explosion will result.
 Use only correct shielding gas cylinders, regulators, hoses, and fit-

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

 Turn face away from valve outlet when opening cylinder valve.
 Keep protective cap in place over valve except when cylinder is in

use or connected for use.

 Use the right equipment, correct procedures, and sufficient num-

ber of persons to lift and move cylinders.

 Read and follow instructions on compressed gas cylinders,

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

OM-2233 Page 2

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

FIRE OR EXPLOSION hazard.

 Do not install or place unit on, over, or near

combustible surfaces.

 Do not install unit near flammables.

 Do not overload building wiring − be sure power supply system is

properly sized, rated, and protected to handle this unit.

FALLING UNIT can cause injury.

 Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

 Use equipment of adequate capacity to lift and

support unit.

 If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of
unit.

OVERUSE can cause OVERHEATING

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

starting to weld again.

 Do not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

 Put on grounded wrist strap BEFORE handling

boards or parts.

 Use proper static-proof bags and boxes to

store, move, or ship PC boards.

MOVING PARTS can cause injury.

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

closed and securely in place.

 Have only qualified persons remove doors,

panels, covers, or guards for maintenance as
necessary.

 Reinstall doors, panels, covers, or guards

when maintenance is finished and before re­connecting input power.

READ INSTRUCTIONS.

 Read Owner’s Manual before using or servic-

ing unit.

 Use only genuine Miller/Hobart replacement

parts.

H.F. RADIATION can cause interference.

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

navigation, safety services, computers, and
communications equipment.

 Have only qualified persons familiar with

electronic equipment perform this installation.

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

ly correct any interference problem resulting from the installa­tion.

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

equipment at once.

 Have the installation regularly checked and maintained.
 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.

MOVING PARTS can cause injury.

 Keep away from moving parts.
 Keep away from pinch points such as drive

rolls.

WELDING WIRE can cause injury.

 Do not press gun trigger until instructed to do

so.

 Do not point gun toward any part of the body,

other people, or any metal when threading
welding wire.

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.)

 Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

ARC WELDING can cause interference.

 Electromagnetic energy can interfere with

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

 Be sure all equipment in the welding area is

electromagnetically compatible.

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

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

 Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

 Be sure this welding machine is installed and grounded

according to this manual.

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

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

For Gasoline Engines:
 Engine exhaust contains chemicals known to the State of

California to cause cancer, birth defects, or other reproductive
harm.

For Diesel Engines:
 Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and
other reproductive harm.

OM-2233 Page 3

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, American Welding Society Standard

AWS F4.1 from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web­site: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale

1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields

Welding current, as it flows through welding cables, will cause electro­magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power­frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.

To reduce magnetic fields in the workplace, use the following
procedures:

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−in-
ternational.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (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,

P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000, 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 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220, website: www.osha.gov).

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

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

4. Keep welding power source and cables as far away from opera­tor as practical.

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

About Pacemakers:

Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.

OM-2233 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

fre_som _3/05

 Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.

2-1. Symboles utilisés

Symbole graphique d’avertissement ! Attention ! Cette pro­cédure comporte des risques possibles ! Les dangers éven­tuels sont représentés par les symboles graphiques joints.

 Indique un message de sécurité particulier

 Signifie NOTE ; n’est pas relatif à la sécurité.

2-2. Dangers relatifs au soudage à l’arc

 Les symboles représentés ci-dessous sont utilisés dans ce manuel

pour attirer l’attention et identifier les dangers possibles. En
présence de l’un de ces symboles, prendre garde et suivre les
instructions afférentes pour éviter tout risque. Les instructions en
matière de sécurité indiquées ci-dessous ne constituent qu’un
sommaire des instructions de sécurité plus complètes fournies
dans les normes de sécurité énumérées dans la Section 2-5. Lire et
observer toutes les normes de sécurité.

 Seul un personnel qualifié est autorisé à installer, faire fonction-

ner, entretenir et réparer cet appareil.

 Pendant le fonctionnement, maintenir à distance toutes les per-

sonnes, notamment les enfants de l’appareil.

UNE DÉCHARGE ÉLECTRIQUE peut
entraîner la mort.

Le contact d’organes électriques sous tension peut
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est

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

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

trous.

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

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

 Ne pas se servir de source électrique à courant électrique dans les zo-

nes humides, dans les endroits confinés ou là où on risque de tomber.

 Se servir d’une source électrique à courant électrique UNIQUEMENT si

le procédé de soudage le demande.

 Si l’utilisation d’une source électrique à courant électrique s’avère né-

cessaire, se servir de la fonction de télécommande si l’appareil en est
équipé.

 D’autres consignes de sécurité sont nécessaires dans les conditions

suivantes : risques électriques dans un environnement humide ou si l’on
porte des vêtements mouillés ; sur des structures métalliques telles que
sols, grilles ou échafaudages ; en position coincée comme assise, à ge­noux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou
accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser
les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC
à tension constante (à fil), 2) un poste à souder DC manuel (électrode)
ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des
situations, l’utilisation d’un poste à souder DC à fil à tension constante
est recommandée. En outre, ne pas travailler seul !

 Couper l’alimentation ou arrêter le moteur avant de procéder

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

 Installer le poste correctement et le mettre à la terre convenablement

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

 Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer

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

 En effectuant les raccordements d’entrée, fixer d’abord le conducteur

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

sous tension lorsque le courant est délivré à la

Ce groupe de symboles signifie Avertissement ! Attention ! Risques
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions afférentes
ci-dessous concernant les mesures à prendre pour supprimer
les dangers.

 Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il

n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu
peut entraîner la mort.

 L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
 Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante

ou mal épissés.

 Ne pas enrouler les câbles autour du corps.
 Si la pièce soudée doit être mise à la terre, le faire directement avec un

câble distinct.

 Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre

ou une électrode provenant d’une autre machine.

 Ne pas toucher des porte électrodes connectés à deux machines en

même temps à cause de la présence d’une tension à vide doublée.

 N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-

champ les pièces endommagées. Entretenir l’appareil conformément à
ce manuel.

 Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
 S’assurer que tous les panneaux et couvercles sont correctement en

place.

 Fixer le câble de retour de façon à obtenir un bon contact métal-métal

avec la pièce à souder ou la table de travail, le plus près possible de la
soudure.

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

avec tout objet métallique.

 Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à

une même borne de sortie de soudage.

Il reste une TENSION DC NON NÉGLIGEABLE dans
les sources de soudage onduleur quand on a coupé
l’alimentation.

 Arrêter les convertisseurs, débrancher le courant électrique et

décharger les condensateurs d’alimentation selon les instructions indi­quées dans la partie Entretien avant de toucher les pièces.

LES FUMÉES ET LES GAZ peuvent
être dangereux.

Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereuse pour la santé.

 Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces va-

peurs.

 À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de

l’arc pour l’évacuation des fumées et des gaz de soudage.

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

vé.

 Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et

les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.

 Travailler dans un espace fermé seulement s’il est bien ventilé ou en

portant un respirateur à alimentation d’air. Demander toujours à un sur­veillant dûment formé de se tenir à proximité. Des fumées et des gaz de
soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provo­quant des blessures ou des accidents mortels. S’assurer que l’air de
respiration ne présente aucun danger.

 Ne pas souder dans des endroits situés à proximité d’opérations de dé-

graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
l’arc peuvent réagir en présence de vapeurs et former des gaz haute­ment toxiques et irritants.

 Ne pas souder des métaux munis d’un revêtement, tels que l’acier gal-

vanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait
été enlevé dans la zone de soudure, que l’endroit soit bien ventilé et en
portant un respirateur à alimentation d’air. Les revêtements et tous les
métaux renfermant ces éléments peuvent dégager des fumées toxi­ques en cas de soudage.

OM-2233 Page 5

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

Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provo-

Des étincelles sont projetées pendant le soudage.
 Porter un casque de soudage approuvé muni de verres filtrants ap-

proprié pour protéger visage et yeux pendant le soudage (voir ANSI
Z49.1 et Z87.1 énuméré dans les normes de sécurité).

 Porter des lunettes de sécurité avec écrans latéraux même sous vo-

tre casque.

 Avoir recours à des écrans protecteurs ou à des rideaux pour

protéger les autres contre les rayonnements les éblouissements et
les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.

 Porter des vêtements confectionnés avec des matières résistantes

et ignifuges (cuir, coton lourd ou laine) et des bottes de protection.

quer des brûlures dans les yeux et sur la peau.

LE SOUDAGE peut provoquer un
incendie ou une explosion.

Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent

d’étincelles, des pièces chaudes et des équipements chauds peuvent
provoquer des incendies et des brûlures. Le contact accidentel de
l’électrode avec des objets métalliques peut provoquer des étincelles,
une explosion, une surchauffe ou un incendie. Avant de commencer
le soudage, vérifier et s’assurer que l’endroit ne présente pas de
danger.

 Déplacer toutes les substances inflammables à une distance de

10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soi­gneusement avec des protections homologuées.

 Ne pas souder dans un endroit où des étincelles peuvent tomber sur

des substances inflammables.

 Se protéger, ainsi que toute autre personne travaillant sur les lieux,

contre les étincelles et le métal chaud.

 Des étincelles et des matériaux chauds du soudage peuvent

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

 Afin d’éliminer tout risque de feu, être vigilant et garder toujours un

extincteur à la portée de main.

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

peut déclencher un incendie de l’autre côté.

 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 (voir les normes de
sécurité).

 Brancher le câble de masse sur la pièce le plus près possible de la

zone de soudage pour éviter le transport du courant sur une longue
distance par des chemins inconnus éventuels en provoquant des
risques d’électrocution, d’étincelles et d’incendie.

 Ne pas utiliser le poste de soudage pour dégeler des conduites

gelées.

 En cas de non-utilisation, enlever la baguette d’électrode du porte-

électrode ou couper le fil à la pointe de contact.

 Porter des vêtements de protection exempts d’huile tels que des

gants en cuir, une veste résistante, des pantalons sans revers, des
bottes et un casque.

 Avant de souder, retirer toute substance combustible de ses poches

telles qu’un allumeur au butane ou des allumettes.

 Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B

pour travaux de soudage et prévoir un détecteur d’incendie et un ex­tincteur à proximité.

être projetées de l’arc de soudure. La projection

DES PARTICULES VOLANTES
peuvent blesser les yeux.

 Le soudage, l’écaillement, le passage de la

pièce à la brosse en fil de fer, et le meulage
génèrent des étincelles et des particules
métalliques volantes. Pendant la période de
refroidissement des soudures, elles risquent

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

facial.

de projeter du laitier.

LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.

 Fermer l’alimentation du gaz protecteur en cas

de non-utilisation.

 Veiller toujours à bien aérer les espaces confi-

nés ou se servir d’un respirateur d’adduction
d’air homologué.

DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.

 Ne pas toucher des parties chaudes à mains

nues.

 Prévoir une période de refroidissement avant

 Ne pas toucher aux pièces chaudes, utiliser les outils recom-

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

d’utiliser le pistolet ou la torche.

LES CHAMPS MAGNÉTIQUES peuvent

affecter les stimulateurs cardiaques.

 Porteurs de stimulateur cardiaque, rester

à distance.

 Les porteurs d’un stimulateur cardiaque doi-

vent d’abord consulter leur médecin avant de
s’approcher des opérations de soudage à l’arc,
de gougeage ou de soudage par points.

LE BRUIT peut endommager l’ouïe.

Le bruit des processus et des équipements peut
affecter l’ouïe.

 Porter des protections approuvées pour les

oreilles si le niveau sonore est trop élevé.

LES BOUTEILLES peuvent exploser
si elles sont endommagées.

Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endomma­gée, elle peut exploser. Du fait que les bouteilles de
gaz font normalement partie du procédé de soudage,

les manipuler avec précaution.

 Protéger les bouteilles de gaz comprimé d’une chaleur excessi-

ve, des chocs mécaniques, des dommages physiques, du lai­tier, des flammes ouvertes, des étincelles et des arcs.

 Placer les bouteilles debout en les fixant dans un support sta-

tionnaire ou dans un porte-bouteilles pour les empêcher de tom­ber ou de se renverser.

 Tenir les bouteilles éloignées des circuits de soudage ou autres

circuits électriques.

 Ne jamais placer une torche de soudage sur une bouteille à gaz.
 Une électrode de soudage ne doit jamais entrer en contact avec

une bouteille.

 Ne jamais souder une bouteille pressurisée − risque d’explosion.
 Utiliser seulement des bouteilles de gaz protecteur, régulateurs,

tuyaux et raccords convenables pour cette application spécifi­que ; les maintenir ainsi que les éléments associés en bon état.

 Détourner votre visage du détendeur-régulateur lorsque vous

ouvrez la soupape de la bouteille.

 Le couvercle du détendeur doit toujours être en place, sauf lors-

que la bouteille est utilisée ou qu’elle est reliée pour usage ulté­rieur.

 Utiliser les équipements corrects, les bonnes procédures et suf-

fisamment de personnes pour soulever et déplacer les bouteil­les.

 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.

OM-2233 Page 6

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

Risque D’INCENDIE OU D’EXPLO­SION.

 Ne pas placer l’appareil sur, au-dessus ou

à proximité de surfaces inflammables.

 Ne pas installer l’appareil à proximité de

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

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

produits inflammables.

LA CHUTE DE L’APPAREIL peut
blesser.

 Utiliser l’anneau de levage uniquement pour

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

 Utiliser un équipement de levage de capacité

 En utilisant des fourches de levage pour déplacer l’unité, s’assu-

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

suffisante pour lever l’appareil.

L’EMPLOI EXCESSIF peut SUR­CHAUFFER L’ÉQUIPEMENT.

 Prévoir une période de refroidissement ;

respecter le cycle opératoire nominal.

 Réduire le courant ou le facteur de marche

avant de poursuivre le soudage.

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

LES CHARGES ÉLECTROSTATIQUES
peuvent endommager les circuits
imprimés.

 Établir la connexion avec la barrette de terre

avant de manipuler des cartes ou des pièces.

 Utiliser des pochettes et des boîtes antistati-

ques pour stocker, déplacer ou expédier des
cartes PC.

DES ORGANES MOBILES peuvent
provoquer des blessures.

 Ne pas s’approcher des organes mobiles.
 Ne pas s’approcher des points de coincement

tels que des rouleaux de commande.

LES FILS DE SOUDAGE peuvent
provoquer des blessures.

 Ne pas appuyer sur la gâchette avant d’en

avoir reçu l’instruction.

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

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

DES ORGANES MOBILES peuvent
provoquer des blessures.

 S’abstenir de toucher des organes mobiles tels

que des ventilateurs.

 Maintenir fermés et verrouillés les portes,

panneaux, recouvrements et dispositifs de

 Seules des personnes qualifiées sont autorisées à enlever les

portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.

 Remettre les portes, panneaux, recouvrements ou dispositifs de

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

protection.

LIRE LES INSTRUCTIONS.

 Lire le manuel d’utilisation avant d’utiliser ou

d’intervenir sur l’appareil.

 Utiliser uniquement des pièces de rechange

Miller/Hobart.

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

 Le rayonnement haute fréquence (HF) peut

provoquer des interférences avec les équipe­ments de radio-navigation et de communica-

 Demander seulement à des personnes qualifiées familiarisées

avec des équipements électroniques de faire fonctionner l’instal­lation.

 L’utilisateur est tenu de faire corriger rapidement par un électri-

cien qualifié les interférences résultant de l’installation.

 Si le FCC signale des interférences, arrêter immédiatement

l’appareil.

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

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

tion, les services de sécurité et les ordinateurs.

LE SOUDAGE À L’ARC risque de
provoquer des interférences.

 L’énergie électromagnétique peut gêner le

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

 Veiller à ce que tout l’équipement de la zone de

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

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

 Veiller à souder à une distance de 100 mètres de tout équipe-

ment électronique sensible.

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

conformément à ce mode d’emploi.

 En cas d’interférences après avoir pris les mesures précéden-

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

soudage soit compatible électromagnétiquement.

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)

 Les batteries, les bornes et autres accessoires contiennent du

plomb et des composés à base de plomb, produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des can­cers et des malformations congénitales ou autres problèmes de
procréation. Se laver les mains après manipulation.

Pour les moteurs à essence :
 Les gaz d’échappement des moteurs contiennent des produits

chimiques dont l’État de Californie reconnaît qu’ils provoquent
des cancers et des malformations congénitales ou autres pro­blèmes de procréation.

Pour les moteurs diesel :
 Les gaz d’échappement des moteurs diesel et certains de leurs

composants sont reconnus par l’État de Californie comme
provoquant des cancers et des malformations congénitales ou au­tres problèmes de procréation.

OM-2233 Page 7

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
de Global Engineering Documents (téléphone : 1-877-413-5184, site In­ternet : www.global.ihs.com).

Recommended Safe Practices for the Preparation for Welding and Cut­ting of Containers and Piping, American Welding Society Standard AWS

F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site
Internet : www.global.ihs.com).

National Electrical Code, NFPA Standard 70, de National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet
: www.cganet.com).

Code for Safety in Welding and Cutting, CSA Standard W117.2, de
Canadian Standards Association, Standards Sales, 178 Rexdale

2-6. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des
champs magnétiques et électriques.

Le courant de soudage, pendant son passage dans les câbles de souda­ge, causera des champs électromagnétiques. Il y a eu et il y a encore un
certain souci à propos de tels champs. Cependant, après avoir examiné
plus de 500 études qui ont été faites pendant une période de recherche
de 17 ans, un comité spécial ruban bleu du National Research Council a
conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a
pas démontré que l’exposition aux champs magnétiques et champs élec­triques à haute fréquence représente un risque à la santé humaine ».
Toutefois, des études sont toujours en cours et les preuves continuent à
être examinées. En attendant que les conclusions finales de la recherche
soient établies, il vous serait souhaitable de réduire votre exposition aux
champs électromagnétiques pendant le soudage ou le coupage.

Pour réduire les champs magnétiques sur le poste de travail, appliquer
les procédures suivantes :

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone :
800-463-6727 ou à Toronto 416-747-4044, site Internet :
www.csa-international.org).

Practice For Occupational And Educational Eye And Face Protection,

ANSI Standard Z87.1, de American National Standards Institute, 11 West
42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, de National Fire Protection Association, P.O.

Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : 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, de U.S. Government Printing Office, Superinten­dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10
bureaux régionaux−−le téléphone de la région 5, Chicago, est
312-353-2220, site Internet : www.osha.gov).

1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.

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

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

4. Garder le poste de soudage et les câbles le plus loin possible de
vous.

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

En ce qui concerne les stimulateurs cardiaques

Les porteurs de stimulateur cardiaque doivent consulter leur médecin
avant de souder ou d’approcher des opérations de soudage. Si le méde­cin approuve, il est recommandé de suivre les procédures précédentes.

OM-2233 Page 8

SECTION 3 − DEFINITIONS (CE Models)

3-1. Warning Label Definitions

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

1 Electric shock from welding electrode

or wiring can kill.

1.1 Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.

1.2 Protect yourself from electric shock by
insulating yourself from work and
ground.

1.3 Disconnect input plug or power before
working on machine.

2 Breathing welding fumes can be

2.1 Keep your head out of the fumes.

2.2 Use forced ventilation or local exhaust

2.3 Use ventilating fan to remove fumes.
3 Welding sparks can cause explosion

3.1 Keep flammables away from welding.

3.2 Welding sparks can cause fires. Have

1 1.1 1.2 1.3

hazardous to your health.

to remove the fumes.

or fire.

Do not weld near flammables.

a fire extinguisher nearby, and have a
watchperson ready to use it.

4 4.1

3.3 Do not weld on drums or any closed
containers.

4 Arc rays can burn eyes and injure

skin.

4.1 Wear hat and safety glasses. Use ear
protection and button shirt collar. Use
welding helmet with correct shade of
filter. Wear complete body protection.

5 Become trained and read the

instructions before working on the
machine or welding.

6 Do not remove or paint over (cover)

the label.

2 2.1 2.2 2.3

3 3.1 3.2 3.3

5

6

179 310-A

OM-2233 Page 9

1

6 7

2

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

1 Electric shock from wiring can

kill.

2 Disconnect input plug or

power before working on

3

V

> 60 s

8

45

V

V

S-185 836

9

machine.

3 Hazardous voltage remains

on input capacitors after
power is turned off. Do not
touch fully charged
capacitors.

4 Always wait 60 seconds after

power is turned off before
working on unit, OR

5 Check input capacitor voltage,

and be sure it is near 0 before
touching any parts.

6 When power is applied failed

parts can explode or cause
other parts to explode.

7 Flying pieces of parts can

cause injury. Always wear a
face shield when servicing
unit.

8 Always wear long sleeves and

button your collar when
servicing unit.

9 After taking proper

precautions as shown,
connect power to unit.

1

∠ = <60

∠

2

°

34

S-179 309-A

5

3-2. WEEE Label (For Products Sold Within The EU)

1 Warning! Watch Out! There

are possible hazards as
shown by the symbols.

2 Falling equipment can cause

injury and damage to unit.

3 Always lift and support unit

using both handles. Keep
angle of lifting device less
than 60 degrees.

4 Use a proper cart to move

unit.

5 Do not use one handle to lift

or support unit.

1/96

Do not discard product (where ap­plicable) with general waste.

Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collec­tion facility.

Contact your local recycling office
or your local distributor for further
information.

OM-2233 Page 10

3-3. Manufacturer’s Rating Label

S

S

f1

f2

1A 10V

40% 60%

X

I

2

80V

80V

U

2

X

I

2

U

2

U1=115V

U1=230V

U1=230V

U1=400V

U1=460V

IP23

175

27

U

o

1A 20V

U

o

50/60 Hz

1

50/60 Hz

1

50/60 Hz

3

50/60 Hz

3

50/60 Hz

3

EN 60974−1

150

125

U1=115V

100%

70%

125

150

16

25

16

U1=115V

50%

125

25

effmaxII

1731

1119

611

59

15

80%

100

24

200A 18V

100%

175200

1718

200A 28V

100%

60%40%

150

26

11

35 25

 See Section 4-4 for

location.

 Use rating label to de-

termine input power
requirements.

195 646-B

3-4. Symbols And Definitions

A
V

X

U

Amperes High Temperature

Volts Voltage Input

Percent Arc Force (DIG) Remote

Protective Earth

(Ground)

On Off Positive Negative

Duty Cycle Direct Current Line Connection

Primary Voltage

1

IP

Alternating

Current

Degree Of

Protection

I

2

I

1max

Gas Tungsten Arc

Welding (GTAW)

3 Phase Static Frequency

Converter-Transformer-Rectifier

Rated Welding

Current

Rated Maximum

Supply Current

S

U

I

1eff

Shielded Metal Arc

Welding (SMAW)

Lift-Arc Start

(GTAW)

Seconds

Conventional Load

2

Voltage

Maximum Effective

Supply Current

U

Rated No Load

Voltage (Average)

0

Hz

Output Adjust

Hertz

S

Suitable For Areas

Of Increased

Shock Hazard

Increase/Decrease

Of Quantity

OM-2233 Page 11

4-1. Specifications

I

R

d O

O

KVA

KW

SECTION 4 − INSTALLATION

nput Power

Three-Phase
Stick Process

Three-Phase
TIG Process

Three-Phase

Stick Process

Three-Phase
TIG Process

Single-Phase
Stick Process

Single-Phase

TIG Process

Single-Phase
Stick Process

Single-Phase

TIG Process

ate

utput

150 A @ 26 VDC,

60% Duty Cycle

175 A @ 17 VDC,

60% Duty Cycle

200 A @ 28 VDC,

30% Duty Cycle

200 A @ 18 VDC,

40% Duty Cycle

150 A @ 26 VDC,

60% Duty Cycle

175 A @ 17 VDC,

60% Duty Cycle

125 A @ 25 VDC,

50% Duty Cycle

150 A @ 16 VDC,

70% Duty Cycle

Welding

Amperage

Range

1 − 200

1 − 200

1 − 200

1 − 200

1 − 200

1 − 200

1 − 200

1 − 200

Max.

pen-Circuit

Voltage

80∇

9-14♦

80

9-14♦

80∇

9-14♦

80

9-14♦

80∇

9-14♦

80

9-14♦

80∇

9-14♦

80

9-14♦

Amperes Input At Rated Output, 50/60Hz

115 230 400 460

-−

-−

-−

-−

34.1

0.42*

29.7

0.42*

13.1

0.16*

10.5

0.16*

18.4

0.16*

12.7

0.16*

21.7

0.23*

17.4

0.23*

-−

-−

7.4

0.24*

6.0

0.24*

10.3

0.24*

7.2

0.24*

-−

-−

-− -−

-− -−

0.25*

0.25*

0.25*

0.25*

10.6
.25*

.25*

6.4

5.2

8.9

6.2

8.5

5.2

0.06*

4.2

0.06*

7.3

0.06*

5.1

0.06*

5.0

0.05*

4.0

0.05*

4.0

0.05*

3.4

0.05*

5.0

0.03*

4.0

0.03*

7.0

0.03*

4.9

0.03*

5.0

0.02*

4.0

0.02*

3.8

0.03*

3.4

0.03*

Single-Phase
Stick Process

Single-Phase

TIG Process

*While idling

100 A @ 24 VDC,

80% Duty Cycle

125 A @ 15 VDC,

100% Duty Cycle

1 − 200

1 − 200

80∇

9-14♦

80

9-14♦

28.1

0.42*

23.0

0.42*

-− -− -−

-− -− -−

3.2

0.05*

2.6

0.05*

0.03*

0.03*

♦Low open-circuit voltage while in Lift-Arc on all models, and Stick on models with stock numbers 907 036 and 907 037.

∇Normal open-circuit voltage (80 volts) is present while in the Stick process for models with stock number 907 220.

NOTE: Duty cycle limitations on units with 115 volt input power are due to the input power cord supplied with the unit.

NOTE: This unit is equipped with Auto-Line. The Auto-Line circuitry automatically connects to 120−460 VAC, single- or three-phase power without
removing the cover to relink the power source.

3.2

2.6

OM-2233 Page 12

4-2. Volt-Ampere Curves

140

Volt-ampere curves show minimum
and maximum voltage and amper­age output capabilities of welding
power source. Curves of other set­tings fall between curves shown.

115VAC Input

120

100

80

Volts

60

40

Stick/TIG Min

20

0

0 50 100 150 200 250

140

120

100

80

Stick Max

TIG Max

DIG Max

Amperes

Other Input Voltages

Stick Max

TIG Max

Volts

60

40

Stick/TIG Min

20

0

0 50 100 150 200 250

*Amperage setting must be reduced to obtain currents less than highlighted data* point.

DIG Max

.

Amperes

189 767-A

OM-2233 Page 13

4-3. Duty Cycle And Overheating

90 A @ 100% Duty Cycle For 115 Volt Single-Phase Stick Process
125 A @ 100% Duty Cycle For 115 Volt Single-Phase TIG Process

150 A @ 60% Duty Cycle For Stick Process (Other Voltages)
175 A @ 60% Duty Cycle For TIG Process (Other Voltages)

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

If unit overheats, output stops, and
cooling fan runs. Wait fifteen min­utes for unit to cool. Reduce amper­age or duty cycle before welding.

 Exceeding duty cycle can

damage unit and void
warranty.

Overheating

6 Minutes Welding 4 Minutes Resting

0

15

Minutes

Reduce Duty Cycle

A or V

OR

189 770-A

OM-2233 Page 14

4-4. Selecting A Location

Dimensions And Weight

34.7 lb (15.7 kg) - without power cord

37.3 lb (16.9 kg) - with power cord
17-1/4 in

(438 mm)

1 Identification Plate
2 Rating Label
3 Line Disconnect Device
Locate unit near correct input

power supply.

 Special installation may be

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

13-3/8 in

(333 mm)

7-9/16 in

(192 mm)

Location And Airflow

1

3

2

18 in

(460 mm)

18 in

(460 mm)

802 886-A

OM-2233 Page 15

4-5. Weld Output Terminals And Selecting Cable Sizes*

+

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding

100 ft (30 m) Or Less

150 ft

(45 m)

200 ft

(60 m)

250 ft

(70 m)

300 ft

(90 m)

350 ft

(105 m)

400 ft

(120 m)

Weld Output

Terminals

 Turn off power before

connecting to weld out­put terminals.

 Do not use worn, dam-

aged, undersized, or
poorly spliced cables.

Welding

Amperes***

100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)

150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95 3/0 (95)

200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)

10 − 60%

Duty

Cycle

60 − 100%

Duty

Cycle

10 − 100% Duty Cycle

−

Output Receptacles

* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.

**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use

***Select weld cable size for pulsing application at peak amperage value. S-0007-E−

4-6. Remote 14 Receptacle Information

AJ

K

B

L

C

D

*The remaining sockets are not used.

I

NH

M

G

F

E

REMOTE

OUTPUT

CONTROL

ST-802 541

CHASSIS

Socket* Socket Information

C Output to remote control; 0 to +10 volts dc output

to remote control.

D Remote control circuit common.

E 0 to +10 volts dc input command signal from

remote control.

K Chassis common.

OM-2233 Page 16

4-7. TIG Lift-Arc DCEN (Direct Current Electrode Negative) Connections

 Turn off power before mak-

ing connections.

1 Positive (+) Weld Output

Terminal

Connect work lead to positive weld

4

5

6

3

1

output terminal.
2 Negative (−) Weld Output

Terminal

Connect TIG torch to negative weld
output terminal.

3 Gas Cylinder
4 Cylinder Valve
Open valve slightly so gas flow

blows dirt from valve. Close valve.
5 Regulator/Flowmeter
6 Flow Adjust
Typical flow rate is 15 cubic feet per

hour (7.1 liters per minute).
Connect torch gas hose to regula-

tor/flowmeter.
7 Gas Valve
Valve controls gas preflow and

postflow. Open valve on torch just
before welding.

2

7

Tools Needed:

11/16 in, 1-1/8 in, (21 mm)

Ref. 802 888-A

OM-2233 Page 17

4-8. Stick DCEP (Direct Current Electrode Positive) Connections

2

1

 Turn off power before mak-

ing connections.

1 Negative (−) Weld Output

Terminal

Connect work lead to negative weld
output terminal.

2 Positive (+) Weld Output

Terminal

Connect electrode holder to posi­tive weld output terminal.

Ref. 802 888-A

4-9. Electrical Service Guide

NOTE

Input Voltage

Input Amperes At Rated Output 25 22 13.1 7.4 6.4

Max Recommended Standard Fuse Rating In Amperes
Time Delay

Min Input Conductor Size In AWG

Max Recommended Input Conductor Length In Feet (Meters) 57 (17) 79 (24)

Min Grounding Conductor Size In AWG

Actual input voltage cannot exceed - 10% of minimum or +10% of maximum input
voltages indicated in table.

Normal Operating

4

4

Single-Phase,

100% Duty

Cycle

115 230 230 400 460

1

2

3

25 25 15 8 8

35 30 20 10 10

10 12 14 14 14

10 12 14 14 14

Single-Phase,

60% Duty

Cycle

Three-Phase, 60% Duty

102
(31)

Cycle

308
(94)

407

(124)

Reference: 2005 National Electrical Code (NEC)
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” .

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

310.16. 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.

OM-2233 Page 18

4-10. Connecting Input Power

A. Connecting Three-Phase Input Power

3

4

3

6

 Installation must meet all National

and Local Codes − have only quali­fied persons make this installation.

 Disconnect and lockout/tagout in-

put power before connecting input

= GND/PE Earth Ground

conductors from unit.

 Always connect green or green/

yellow conductor to supply
grounding terminal first, and never
to a line terminal.

 The Auto-Line circuitry in this unit au-

tomatically adapts the power source

7

2

L1

5

L2

L3

1

to the primary voltage being applied.
Check input voltage available at site.
This unit can be connected to any in­put power between 120 and 460 VAC
without removing cover to relink the
power source.

For Three-Phase Operation

1 Input Power Cord.
2 Disconnect Device (switch shown in

the OFF position)

3 Green Or Green/Yellow Grounding

Conductor

4 Disconnect Device Grounding

Terminal
5 Input Conductors (L1, L2 And L3)
6 Disconnect Device Line Terminals
Connect green or green/yellow grounding

conductor to disconnect device grounding
terminal first.

Connect input conductors L1, L2, and L3
to disconnect device line terminals.

7 Over-Current Protection
Select type and size of over-current

protection using Section 4-9 (fused dis­connect switch shown).

Close and secure door on disconnect de­vice. Remove lockout/tagout device, and
place switch in the On position.

Tools Needed:

2/04 - Ref. 802 136-A

OM-2233 Page 19

B. Connecting Single-Phase Input Power

1

8

10

7

9

L1

L2

3

6

=GND/PE Earth Ground

1

1

3

6

5

 Installation must meet all National

and Local Codes − have only quali-

fied persons make this installation.
 Disconnect and lockout/tagout in-

put power before connecting input

conductors from unit.
 Always connect green or green/

yellow conductor to supply

grounding terminal first, and never

to a line terminal.

 The Auto-Line circuitry in this unit au-

tomatically adapts the power source

to the primary voltage being applied.

Check input voltage available at site.

This unit can be connected to any in-

put power between 120 and 460 VAC

without removing cover to relink the

power source.

1 Black And White Input Conductor

(L1 And L2)
2 Red Input Conductor
3 Green Or Green/Yellow Grounding

Conductor
4 Insulation Sleeving
5 Electrical Tape
Insulate and isolate red conductor as

shown.
6 Input Power Cord.
7 Disconnect Device (switch shown in

2

4

the OFF position)
8 Disconnect Device Grounding

Terminal
9 Disconnect Device Line Terminals
Connect green or green/yellow grounding

conductor to disconnect device grounding
terminal first.

Connect input conductors L1 and L2 to
disconnect device line terminals.

10 Over-Current Protection
Select type and size of over-current

protection using Section 4-9 (fused dis­connect switch shown).

Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.

Tools Needed:

OM-2233 Page 20

2/04 - Ref. 802 136-A

5-1. Controls

A. Non CE Units

SECTION 5 − OPERATION

5

1

2

4

3

6

NOTE: Green on nameplate indicates a TIG
function, Gray indicates a Stick function.

1 Process Controls
See Section 5-2.
2 Amperage Control
See Section 5-5.

3 DIG Control

See Section 5-6.

4 High Temperature Shutdown Light

See Section 4-3.

5 Power On/Troubleshooting Help Aids

Light
See Section 6-3.
6 Power Switch
Use switch to turn unit and indicator light

On/Off.

202 323-B / 802 889

OM-2233 Page 21

B. For CE Units

5

1

2

4

3

6

NOTE: Green on nameplate indicates a TIG
function, Gray indicates a Stick function.

1 Process Controls
See Section 5-2.
2 Amperage Control
See Section 5-5.

3 DIG Control

See Section 5-6.

4 High Temperature Shutdown Light

See Section 4-3.

5 Power On/Troubleshooting Help Aids

Light
See Section 6-3.
6 Power Switch
Use switch to turn unit and indicator light

On/Off.

202 722-A / 802 889

OM-2233 Page 22

5-2. Process Control

1

5-3. Lift-Arc™ Start Procedure

Lift-Arc Start Method

“Touch”

1

CE Model

1

1 − 2

Seconds

1 Process Control
Rotate knob up to select the Stick

process. Rotate knob down to se­lect the TIG Lift Arc process.

Stick (SMAW) - This is a DCEP (di­rect current electrode positive) pro­cess. Make connections according
to Section 4-8.

TIG Lift-Arc - This is a DCEN (di-
rect current electrode negative)
process in which the electrode
must come in contact with the work
piece to initiate an arc (see Section
5-3). Make connections according
to Section 4-7.

Lift-Arc Start

With Lift-Arc selected, start arc
as follows:

1 TIG Electrode
2 Workpiece
Turn gas on. Touch tungsten elec-

trode to workpiece at weld start
point. Hold electrode to work-
piece for 1-2 seconds, and slowly

2

lift electrode. Arc is formed when
electrode is lifted.

Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece with­out overheating, sticking, or getting
contaminated.

Application:

Lift-Arc is used for the DCEN
GTAW process when HF Start
method is not permitted, or to re­place the scratch method.

Do NOT Strike Like A Match!

OM-2233 Page 23

5-4. Stick Start Procedure − Scratch Start Technique

1

2

3

5-5. Amperage Control

With Stick selected, start arc as follows:
1 Electrode
2 Workpiece
3 Arc
Drag electrode across workpiece like strik-

ing a match; lift electrode slightly after touch­ing work. If arc goes out electrode was lifted
to high. If electrode sticks to workpiece, use
a quick twist to free it.

 For models with stock number 907

220, normal open-circuit voltage (80
volts) is present before electrode
touches workpiece.

For models with stock numbers 907 036 and
907 037, normal open-circuit voltage is not
present before electrode touches work­piece; only a low sensing voltage is present
between electrode and workpiece.

Min

5-6. DIG Control

CE Model

1

1

1 A (Amperage Control)
Rotate knob clockwise to increase

amperage (Min-200 amps).

Min

1

CE Model

1

1 DIG Control
Control increases SMAW short-cir-

cuit amperage at low arc voltage.
This allows the operator to use a
very short arc length without stick­ing the electrode.

Set control at 0 for normal welding
amperage. Turn clockwise to in­crease short-circuit amperage.

OM-2233 Page 24

SECTION 6 − MAINTENANCE AND TROUBLESHOOTING

6-1. Routine Maintenance

 Disconnect power before maintaining.

 Maintain more often during severe conditions.

3 Months

Replace
unreadable
labels.

Clean and tighten
weld terminals.

3 Months

Repair Or Replace
Cracked Cables
And Cords

6 Months

 Do not remove case when

blowing out inside of unit
(see Section 6-2) .

Blow out inside. During
heavy service clean
monthly.

6-2. Blowing Out Inside Of Unit

Replace Damaged
Gas Hose

 Do not remove case when

blowing out inside of unit.

To blow out unit, direct airflow
through front and back louvers as
shown.

802 886-A

OM-2233 Page 25

6-3. Troubleshooting Help Aids

1

2

 All directions are in reference to the

front of the unit. All circuitry referred to
is located inside the unit.

1 Output LED
2 High Temperature LED
The Output LED turns on when power is

turned on. The LED is also used to indicate
several machine malfunctions. When one
of the malfunctions listed below occurs, the
LED will first turn off for 1.5 seconds, and
then it will begin to blink. The number of
blinks corresponds to a Help message re­lating to that malfunction. After the LED
blinks the appropriate number of times, the
LED will again turn off for 1.5 seconds, and
the sequence will start again.

The malfunctions that correspond to Help
2, 3, 4, 5, and 9 are thermal related. The
High Temperature LED turns on along with
the blinking Output LED.

A malfunction relating to Help 0 will cause
the the Output LED to turn off and stay off,
but the High Temperature LED turns on and

stays on.
Help 0 Display
Indicates a short in the thermal protection

circuitry located on the bottom heat sink.
Contact a Factory Authorized Service
Agent if this happens.

Help 1 Display
Indicates a malfunction in the primary pow-

er circuit caused by an overcurrent condi­tion in the primary IGBT switching circuit.
Contact a Factory Authorized Service
Agent if this happens.

Help 2 Display
Indicates an open in the thermal protection

circuitry located on the bottom heat sink.
Contact a Factory Authorized Service
Agent if this happens.

Help 3 Display
Indicates the bottom heat sink has over-

heated. The unit has shut down to allow the

fan to cool it (see Section 4-3). Operation
will continue when the unit has cooled.

Help 4 Display
Indicates an open in the thermal protection

circuitry located on the top heat sink. Con­tact a Factory Authorized Service Agent if
this happens.

Help 5 Display
Indicates the top heat sink has overheated.

The unit has shut down to allow the fan to
cool it (see Section 4-3). Operation will con­tinue when the unit has cooled.

Help 8 Display
Indicates a malfunction in the secondary

power circuit of the unit. There is a high
open circuit condition. Contact a Factory
Authorized Service Agent if this happens.

Help 9 Display
Indicates a short in the thermal protection

circuitry located on the top heat sink. Con­tact a factory Authorized Service Agent if
this happens.

OM-2233 Page 26

6-4. Troubleshooting

Trouble Remedy

No weld output; unit completely
inoperative.

No weld output; Output LED on. Input voltage outside acceptable range of variation (see Section 4-9).

No weld output; Overtemp LED on. Unit overheated. Allow unit to cool with fan On (see Sections 4-3 and 6-3).

Erratic or improper weld output. Use proper size and type of weld cable (see Section 4-5).

Fan not operating. Check for and remove anything blocking fan movement.

Place line disconnect switch in On position (see Section 4-10).

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-10).

Check for proper input power connections (see Section 4-10).

See Section 6-3, Troubleshooting Help Aids.

Clean and tighten all weld connections (see Section 4-5).

Have Factory Authorized Service Agent check fan motor.

Wandering arc

Tungsten electrode oxidizing and not re­maining bright after conclusion of weld.

Use proper size tungsten (see Section 8).

Use properly prepared tungsten (see Section 8).

Reduce gas flow rate (see Section 4-7).

Shield weld zone from drafts.

Allow adequate postflow time to shield tungsten while it cools, after welding stops.

Check and tighten all gas fittings (see Section 4-7).

Water in torch. Refer to torch manual.

OM-2233 Page 27

SECTION 7 − ELECTRICAL DIAGRAMS

OM-2233 Page 28

Figure 7-1. Circuit Diagram

202 314-B

SECTION 8 − SELECTING AND PREPARING A TUNGSTEN

FOR DC OR AC WELDING WITH INVERTER MACHINES

gtaw_Inverter_7/2006

 Whenever possible and practical, use DC weld output instead of AC weld output.

8-1. Selecting Tungsten Electrode (Wear Clean gloves To Prevent Contamination Of Tungsten)

Amperage Range - Gas Type♦ - Polarity

Electrode Diameter (DCEN) − Argon

Direct Current Electrode Negative

(For Use With Mild Or Stainless Steel)

2% Ceria (Orange Band), 1.5% Lanthanum (Gray Band), Or 2% Thorium (Red Band) Alloy Tungstens

.010” (1 mm) Up to 25 Up to 20
.020” (1 mm) 15-40 15-35

.040” (1 mm) 25-85 20-80
1/16” (1.6 mm) 50-160 50-150
3/32” (2.4 mm) 135-235 130-250

1/8” (3.2 mm) 250-400 225-360
5/32” (4.0 mm) 400-500 300-450
3/16” (4.8 mm) 500-750 400-500

1/4” (6.4 mm) 750-1000 600-800

Balance Control @ 65% Electrode Negative

♦Typical argon shielding gas flow rates are 11 to 35 cfh (cubic feet per hour).

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

AC − Argon

(For Use With Aluminum)

8-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC

Welding With Inverter Machines

 Grinding the tungsten electrode produces dust and flying sparks which can cause injury and start fires. Use

local exhaust (forced ventilation) at the grinder or wear an approved respirator. Read MSDS for safety infor­mation. Consider using tungsten containing ceria, lanthana, or yttria instead of thoria. Grinding dust from
thoriated electrodes contains low-level radioactive material. Properly dispose of grinder dust in an environ­mentally safe way. Wear proper face, hand, and body protection. Keep flammables away.

Radial Grinding

Causes Wandering Arc

Wrong Tungsten Preparation

2-1/2 Times

Electrode Diameter

2

4

Ideal Tungsten Preparation − Stable Arc

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

3

abrasive wheel before welding. Do not use
wheel for other jobs or tungsten can become
contaminated causing lower weld quality.

1

2 Tungsten Electrode
A 2% ceriated tungsten is recommended.
3 Flat
Diameter of this flat determines amperage

capacity.
4 Straight Ground
Grind lengthwise, not radial.

OM-2233 Page 29

SECTION 9 − GUIDELINES FOR (GTAW) TIG WELDING

9-1. Positioning The Torch

 Grinding the tungsten elec-

trode produces dust and fly­ing sparks which can cause
injury and start fires. Use lo­cal exhaust (forced ventila­tion) at the grinder or wear an
approved respirator. Read
MSDS for safety information.
Consider using cerium or
lanthanum based tungsten
instead of thoriated. Tho­rium dust contains low-level
radioactive material. Proper­ly dispose of grinder dust in
an environmentally safe way.
Wear proper face, hand, and
body protection. Keep flam­mables away.

1 Workpiece
Make sure workpiece is clean

before welding.
2 Work Clamp
Place as close to the weld as

possible.
3 Torch
4 Filler Rod (If Applicable)
5 Gas Cup
6 Tungsten Electrode
Select and prepare tungsten

according to Section 8.

Guidelines:

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

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

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

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

10−25°

2

1

10−15°

4

3/16 in

Bottom View Of Gas Cup

90°

5

3

4

5

6

6

1/16 in

gtaw 7/2006

Om-2233 Page 30

Ref. ST-161 892

9-2. Torch Movement During Welding

Tungsten Without Filler Rod

Welding direction

Form pool Tilt torch Move torch to front

Tungsten With Filler Rod

Welding direction

Form pool Tilt torch Add filler metal

Remove rod

75°

75°

15°

Move torch to front

of pool. Repeat process.

9-3. Positioning Torch Tungsten For Various Weld Joints

Butt Weld And Stringer Bead

of pool. Repeat process.

ST-162 002-B

“T” Joint

90°

20-40°

30°

20°

15°

Lap Joint

70°

75°

90°

10°

15°

20°

75°

15°

Corner Joint

75°

ST-162 003 / S-0792

OM-2233 Page 31

SECTION 10 − STICK WELDING (SMAW) GUIDELINES

10-1. Stick Welding Procedure

 Weld current starts when

electrode touches work­piece.

 Weld current can damage

electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.

1 Workpiece
Make sure workpiece is clean be-

5

4

2

3

6

1

7

fore welding.
2 Work Clamp
3 Electrode
A small diameter electrode requires

less current than a large one. Fol­low electrode manufacturer’s
instructions when setting weld am­perage (see Section 10-2).

4 Insulated Electrode Holder
5 Electrode Holder Position
6 Arc Length
Arc length is the distance from the

electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound.

7 Slag
Use a chipping hammer and wire

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

Tools Needed:

OM-2233 Page 32

stick 12/96 − ST-151 593

10-2. Electrode and Amperage Selection Chart

RANGE

AMPERAGE

ELECTRODE

6010

&

6011

6013

7014

7018

7024

Ni-Cl

308L

DIAMETER

3/32

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

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

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

1/4
3/32

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

1/4
3/32

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

1/4
3/32

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

1/4
3/32

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

1/8
5/32

50

100

150

200

250

300

350

400

450

AC

DC*

ELECTRODE

EP

6010

EP

6011

EP,EN

6013

EP,EN

7014

EP

7018

EP,EN

7024

EP

NI-CL

EP

308L

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

POSITION

ALL
ALL
ALL

ALL

ALL

FLAT

HORIZ

FILLET

ALL
ALL

PENETRATION

DEEP
DEEP

LOW

MED

LOW

LOW

LOW
LOW

USAGE

MIN. PREP, ROUGH

HIGH SPATTER

GENERAL

SMOOTH, EASY,

FAST

LOW HYDROGEN,

STRONG

SMOOTH, EASY,

FASTER

CAST IRON
STAINLESS

Ref. S-087 985-A

10-3. Striking an Arc − Scratch Start Technique

1

3

10-4. Striking an Arc − Tapping Technique

1

3

1 Electrode
2 Workpiece
3 Arc
Drag electrode across workpiece

2

like striking a match; lift electrode
slightly after touching work. If arc
goes out electrode was lifted to
high. If electrode sticks to work­piece, use a quick twist to free it.

S-0049

1 Electrode
2 Workpiece
3 Arc
Bring electrode straight down to

workpiece; then lift slightly to start

2

arc. If arc goes out, electrode was
lifted too high. If electrode sticks to
workpiece, use a quick twist to free it.

S-0050

OM-2233 Page 33

10-5. Positioning Electrode Holder

90° 90°

End View of Work Angle Side View of Electrode Angle

10°-30°

GROOVE WELDS

45°

45°

End View of Work Angle Side View of Electrode Angle

10-6. Poor Weld Bead Characteristics

FILLET WELDS

2

3

10°-30°

S-0060

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

1

4

10-7. Good Weld Bead Characteristics

OM-2233 Page 34

5

1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During

Welding

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

1

5234

4 No Overlap
5 Good Penetration into Base

Metal

S-0053-A

S-0052-B

10-8. Conditions That Affect Weld Bead Shape

NOTE

Weld bead shape is affected by electrode angle, arc length, travel speed, and
thickness of base metal.

Angle Too Small

Too Short

Slow

Correct Angle

10° - 30°

Drag

ELECTRODE ANGLE

Normal Too Long

ARC LENGTH

Normal Fast

TRAVEL SPEED

Angle Too Large

Spatter

S-0061

10-9. Electrode Movement During Welding

NOTE

1

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

3

1 Stringer Bead − Steady

Movement Along Seam

2

2 Weave Bead − Side to Side

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

area in one pass of the electrode.
Do not let weave width exceed
2-1/2 times diameter of electrode.

S-0054-A

OM-2233 Page 35

10-10. Butt Joints

1

10-11. Lap Joint

2

Single-Layer Fillet Weld

1 Tack Welds

2

1/16 in

(1.6 mm)

3

30°
Or Less

11

30°

4

30°
Or Less

3

Multi-Layer Fillet Weld

Prevent edges of joint from drawing
together ahead of electrode by tack
welding the materials in position be­fore final weld.

2 Square Groove Weld
Good for materials up to 3/16 in (5

mm) thick.
3 Single V-Groove Weld
Good for materials 3/16 − 3/4 in

(5-19 mm) thick. Cut bevel with oxy­acetylene or plasma cutting equip­ment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.

Create 30 degree angle of bevel on
materials in V-groove welding.

4 Double V-Groove Weld
Good for materials thicker than 3/16

in (5 mm).

S-0662

1 Electrode
2 Single-Layer Fillet Weld
Move electrode in circular motion.
3 Multi-Layer Fillet Weld
Weld a second layer when a heavi-

er fillet is needed. Remove slag be­fore making another weld pass.
Weld both sides of joint for maxi­mum strength.

S-0063 / S-0064

10-12. Tee Joint

OM-2233 Page 36

2

1

45°

Or Less

1 Electrode
2 Fillet Weld
Keep arc short and move at definite

rate of speed. Hold electrode as
shown to provide fusion into the
corner. Square edge of the weld
surface.

For maximum strength weld both

2

1

3

sides of upright section.
3 Multi-Layer Deposits
Weld a second layer when a heavi-

er fillet is needed. Use any of the
weaving patterns shown in Section
10-9. Remove slag before making
another weld pass.

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

10-13. Weld Test

3

2 To 3 in

(51-76 mm)

2 To 3 in

(51-76 mm)

1/4 in

(6.4 mm)

2
1

2

10-14. Troubleshooting − Porosity

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

Possible Causes Corrective Actions

Arc length too long. Reduce arc length.

1 Vise
2 Weld Joint
3 Hammer

3

1

Strike weld joint in direction shown.
A good weld bends over but does
not break.

S-0057-B

Damp electrode. Use dry electrode.

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

welding.

10-15. Troubleshooting − Excessive Spatter

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

Possible Causes Corrective Actions

Amperage too high for electrode. Decrease amperage or select larger electrode.

Arc length too long or voltage too high. Reduce arc length or voltage.

OM-2233 Page 37

10-16. Troubleshooting − Incomplete Fusion

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

Possible Causes Corrective Actions

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

Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

Adjust work angle or widen groove to access bottom during welding.

Momentarily hold arc on groove side walls when using weaving technique.

Keep arc on leading edge of weld puddle.

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

welding.

10-17. Troubleshooting − Lack Of Penetration

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

Lack of Penetration Good Penetration

Possible Causes Corrective Actions

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

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

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

Reduce travel speed.

10-18. Troubleshooting − Excessive Penetration

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

Excessive Penetration

Possible Causes Corrective Actions

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

OM-2233 Page 38

Good Penetration

Increase and/or maintain steady travel speed.

10-19. Troubleshooting − Burn-Through

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

Possible Causes Corrective Actions

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

Increase and/or maintain steady travel speed.

10-20. Troubleshooting − Waviness Of Bead

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

Possible Causes Corrective Actions

Unsteady hand. Use two hands. Practice technique.

10-21. Troubleshooting − Distortion

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

Base metal moves

in the direction of

the weld bead.

Possible Causes Corrective Actions

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

Make tack welds along joint before starting welding operation.

Select lower amperage for electrode.

Increase travel speed.

Weld in small segments and allow cooling between welds.

OM-2233 Page 39

28

SECTION 11 − PARTS LIST

 Hardware is common and not available unless listed.

12

27

13

26

25

614

15

28

26

615

27

11

19

18

16

401

400

402

14

3

34

8

6

10

32

2

29

4

1

OM-2233 Page 40

600

33

5

Figure 11-1. Main Assembly

9

803 107-E

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 11-1. Main Assembly

1 Fig11-2 Panel, Front W/Cmpnt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Fig11-3 Panel, Rear W/Cmpnt 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Fig11-4 Magnetics Subassembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Fig11-5 Windtunnel, W/Components 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Fig11-7 Base Assy, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 S1 128756 Switch, Tgl 3pst 40a 600vac Scr Term Wide Tgl 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 PM1 204821 Kit, Input/Pre-Regulator Inverter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 049611 Tubing, Cop .540 Od X .123 Wall X .687 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 196727 Cable, Power 10 Ft 12ga 4c Blk/Red/Wht/Grnyel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 +195643 Wrapper, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 206108 Handle, Rubberized Carrying 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 195663 Strap, Shoulder 6 Ft 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 189782 Insulator, Interconnect Board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 C7 213974 Capacitor Assy, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 189778 Plug, W/Leads Vfb 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 202400 Plug, W/Leads Boost Relay 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 189779 Cable, Lem W/Plugs 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 189784 Insulator, Wrapper 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 198147 Label, Side Maxstar 200 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 199478 Label, Miller 6.000 X 2.500 Horizontal 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 203990 Label, Warning General Precautionary (Non CE Models) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 179310 Label, Warning General Precautionary (CE Models) 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 185835 Label, Warning Electric Shock/Exploding Parts (Non CE Models) 1. . . . . . . . . . . . . . . . . . . . . . . . . .

29 185836 Label, Warning Electric Shock/Exploding Parts (CE Models) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 208998 Label, Rating Card Code 122 Serial & Stock Number 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 182826 Label, Warning Electric Shock Power Cord 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 207310 Core, Toroidal (CE Models Only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 215002 Clip, Support PC Mtg 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400 PC2 200851 Circuit Card Assy, Power Interconnect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400 PC2 230162 Circuit Card Assy, Power Interconnect (CE ROHS) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

401 PC1 206129 Circuit Card Assy, Inverter Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

401 PC1 230166 Circuit Card Assy, Inverter Control (CE ROHS) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

402 PC10 200841 Circuit Card Assy, Boost Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

402 PC10 230170 Circuit Card Assy, Boost Control (CE ROHS) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

403 PC9 199506 Circuit Card Assy, Input Filter (CE Models Only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

403 PC9 230207 Circuit Card Assy, Input Filter (CE ROHS) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 229333 Screw, M10−1.5 x 20 Hex Hd−pln 8.8 Pld Sems 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 083883 Washer, Lock .402 id x 0.709 od x.087t Stl Split10mm 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

614 136343 Screw, K50 x 20 Pan Hd−phl Stl Pld Pt Thread Forming 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

615 229334 Screw, M 5−.8 x 35 pan hd phl stl pld sems 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

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-2233 Page 41

 Hardware is common and not available unless listed.

1

601

10

602

400

603

4

5

Item

No.

7

6

Dia.

Mkgs.

3

13

12

605

2

9

15

11

16

8

Figure 11-2. Panel, Front w/Components

17

14

202 508-E

Part

No.

Description

Quantity

11-2. Panel, Front w/Components (Figure 11-1 Item 1)

1 194242 Panel, Front/Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 195647 Panel, Front Lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 202325 Panel, Front Upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 174992 Knob, Pointer .840 Dia X .250 ID w/Spring Clip−.21 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 174991 Knob, Pointer 1.250 Dia X .250 ID w/Spring Clip−.21 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 202323 Nameplate, Miller Maxstar 200STR 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 202722 Nameplate, Miller Maxstar 200STR (CE Models Only) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 178355 Nut, 375−32 .54hex .25h Nyl Flange .62d 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 202553 Rcpt, Tw Lk Insul Fem(Dinse Type)50/70 Series Wsl 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 207253 Plug, Gas Fitting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 200659 Lead List, Small 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 185712 Insulator, Bulkhead Front 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 185713 Insulator, Bulkhead Rear 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 185714 Washer, Tooth 20MM ID X 32MM OD 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 185717 Nut, M20 X 1.5 1.0625 Hex .19 H Locking 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 185718 O-Ring 0.989 ID X 0.070 Wall 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 186228 O-Ring 0.739 ID X 0.070 Wall 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 202326 Recpt w/leads and plug 14-pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400 PC3 217272 Circuit Card Assy, Front Panel Interface W/Program 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400 PC3 *213922 Circuit Card Assy, Front Panel Interface W/Program 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400 PC3 **231249 Circuit Card Assy, Front Panel Interface W/Program (CE ROHS) 1. . . . . . . . . . . . . . . . . . .

602 231383 Washer, Tooth.377 ID X 0.507 OD X .022T STL PLD INT.375 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

603 178548 Terminal, Connector Friction 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

* For models with stock number 907036 or 907037.
** For models with stock number 907355.

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-2233 Page 42

 Hardware is common and not available unless listed.

3

5

4

1

202 397-E

Quantity

Item

No.

600

Dia.

Mkgs.

2

Part

No.

Figure 11-3.Panel, Rear w/Components

Description

Figure 11-3. Panel, Rear w/Components (Figure 11-1 Item 2)

1 194242 Panel, Front/Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 206053 Panel, Rear Lower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 195646 Panel, Rear Upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 201155 Bushing, Strain Relief .450/.709 Id X1.068 Mtg Hole 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 207253 Plug, Gas Fitting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 198245 Nut, Conduit .750 Npt Pld 1.388 Od X .150 Thk 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

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-2233 Page 43

603

613

17

603

617

12

9

604

613

3

605

13

14

10

12

14

13

605

Item

No.

614

8

Dia.

Mkgs.

1

611

604

 Hardware is common and

not available unless listed.

11

6

Figure 11-4. Magnetics Assembly w/Components

Part

No.

Description

617

202 398-H

Quantity

Figure 11-4. Magnetics Assembly w/Components (Figure 11-1 Item 3)

1 195649 Panel, Plenum 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 FM1 230808 Fan, Muffin 24vdc 4200 RPM 140 CFM 4.125 MTG HOLES 1. . . . . . . . . . . . . . . . . . . . . . . .

6 CR1 198549 Relay, Encl 24vdc Spst 35a/300vac 4pin Flange Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 189790 Inductor, Output 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 L2 210599 Coil, Inductor 9t 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 L3 206020 Coil, Inductor 14t 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 T1 212268 Xfmr, HF Litz/Litz w/Boost 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 109056 Core, Ferrite E 2.164 Lg X 1.094 High X .826 Wide 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 196512 Bracket, Inductor Mounting 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 196514 Gasket, Inductor Mounting 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-2233 Page 44

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 11-4. Magnetics Assembly w/Components
(Figure 11-1 Item 3) (Continued)

17 213208 Connector, Faston Male 1/4 Ring W/75deg Bend 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

603 057357 Bushing, Snap−in Nyl .937 Id X 1.125 Mtg Hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

604 182737 Screw, 010−32x2.00 Rnd Hd−slt Brs Pln 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

605 229323 Nut, 010−32 .31hex .13h Stl Pld Sem Cone Wshr.38d 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

611 136343 Screw, K50x 20 Pan Hd−phl Stl Pld Pt Thread Forming 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

613 083147 Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

614 010381 Connector, Rectifier 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

617 170647 Bushing, Snap−in nyl 1.312 ID X 1.500 Mtg Hole 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OM-2233 Page 45

1

2

8

 Hardware is common and

not available unless listed.

4

602

6

7

10

3

5

199 494-F

Figure 11-5. Windtunnel w/Components

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 11-5. Windtunnel w/Components (Figure 11-1 Item 4)

1 195645 Panel, Midplain Horizontal 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 198634 Bracket, Front Heatsink Mtg 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 198633 Wind Tunnel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 232856 Rail, Heat Sink 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 198652 Bracket, Windtunnel Insulator 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 +209949 Heat Sink, Module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 199497 Heat Sink, Secondary Assembly 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 L1 189787 Choke, Input 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 C9 151328 Capacitor, Polyp Met Film .0047Uf 1000 Vdc W/T (CE Models Only) 1. . . . . . . . . . . . . . . . . . .

083147 Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High (CE Models Only) 4. . . . . . . . . . . . . . . . . . . . . . . .

602 154408 Bushing, Snap−in Nyl .562 Id X .875 Mtg Hole Cent 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

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-2233 Page 46

606

2

 Hardware is common and

not available unless listed.

604

604

6

601

3

1

5

600

7

602

4

199 497-H

Figure 11-6. Heat Sink, Secondary Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 11-6. Heat Sink, Secondary Assembly (Figure 11-5 Item 7)

1 210783 Heat Sink, Diode 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 D1 204820 Kit, Diode, Ultra Fast 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 HD1 198028 Transducer, Current 100a Module Supply V+/− 15v 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 RT1 211124 Thermistor, Ntc 30k Ohm @ 25 Deg C 18 in Lead 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 R2, C6 206021 Resistor/Capacitor, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 R1, C5 199138 Resistor/Capacitor, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 SR1 199952 Diode, Power Module 50 Amp 600V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

600 207451 Screw, 008−32 x .50 Pan Hd−Phl Stl Pld 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

601 231214 Screw, 008−32 x 1.00 Pan Hd−phl Stl Pld 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

602 207451 Screw, 008−32 x .50 Pan Hd Phl Stl Pld Sems 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

604 207450 Screw, 004−40 x .37 Pan Hd−torx Stl Pld Cone Sems 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

606 229331 Screw, M 6−1.0 x 16 Pan Hd−phl Stl Pld Sems 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

OM-2233 Page 47

 Hardware is common and

not available unless listed.

199 493-B

Figure 11-7. Base Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Quantity

Figure 11-7. Base Assembly (Figure 11-1 Item 5)

1 195644 Base, 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 019663 Mount, Nprn 15/16odx3/8rec 3/16x3/8 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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-2233 Page 48

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, 2007

(Equipment with a serial number preface of “LH” or newer)

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

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

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

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

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Sources (Unless Otherwise Stated)
* Water Coolant Systems (Integrated)
* Intellitig
* Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the
engine manufacturer.)

3. 1 Year — Parts and Labor Unless Specified

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns)
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources, Coolers, and

Electronic

Controls/Recorders
* Water Coolant Systems (Non-Integrated)
* Flowgauge and Flowmeter Regulators (No Labor)
* HF Units
* Grids
* Spot Welders
* Load Banks
* Arc Stud Power Sources & Arc Stud Guns
* Racks
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF

Models)
* Field Options

(NOTE: Field options are covered under True Blue®

for the remaining warranty period of the product they

are installed in, or for a minimum of one year —

whichever is greater.)
* Bernard-Branded Mig Guns (No Labor)
* Weldcraft-Branded TIG Torches (No Labor)
* Subarc Wire Drive Assemblies

4. 6 Months — Batteries

5. 90 Days — Parts

* MIG Guns/TIG Torches and Subarc (SAW) Guns

guarantees or warranties expressed or implied.

* Induction Heating Coils and Blankets, Cables, and

Non-Electronic Controls
* APT & SAF Model Plasma Cutting Torches
* Remote Controls
* Accessory (Kits)
* Replacement Parts (No labor)
* Spoolmate Spoolguns
* Canvas Covers

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

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)

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 2007−01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

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

Distributor

Address

City

State Zip

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

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

and Parts)
Circuit Diagrams
Welding Process Handbooks

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

Miller Electric Mfg. 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]

European Headquarters −
United Kingdom

Phone: [phone]
FAX: [phone]

www.MillerWelds.com

Contact the Delivering Carrier to:

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.

PRINTED IN USA © 2007 Miller Electric Mfg. Co.2007−01