OM265809B 2016−01

Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Description

Arc Welding Power Source And

Wire Feeder

Millermatic 211
R

Visit our website at File: MIG (GMAW)

[Link]

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 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 Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
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 parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard. particular model are also provided.

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
[Link] on the web.

Mil_Thank 2009−09

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 TABLE OF CONTENTS

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

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 7
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-3. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-4. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-5. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-2. Multi−Voltage Plug (MVP) Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-3. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-4. Connecting 120 Volt Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-5. Connecting 1-Phase Input Power For 240 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-6. Installing Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-7. Work Cable Routing Inside Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-8. Process/Polarity Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-9. Changing Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-10. Installing Welding Gun Or Spool Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-11. Changing Drive Roll Or Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-12. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-13. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5-14. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-15. Removing MIG Gun After Installation To Replace With A Spool Gun . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-16. Spool Gun Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-1. Manual Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-2. Using Auto-Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-3. Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-4. Weld Parameter Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6-5. Weld Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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 TABLE OF CONTENTS

SECTION 7 − MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-3. Drive Motor Protection And Tip Saver/Short Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7-4. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION 9 − GMAW WELDING (MIG) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SECTION 10 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
COMPLETE PARTS LIST − Available at [Link]
WARRANTY

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 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2015−09
7

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

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if . Indicates special instructions.

not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.

1-2. Arc Welding Hazards

D Always verify the supply ground − check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you
disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions
grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information D When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-5. Read and tor first − double-check connections.
follow all Safety Standards. D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and D Frequently inspect input power cord and ground conductor for
repair this unit. damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
During operation, keep everybody, especially children, away. D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
ELECTRIC SHOCK can kill.
D If earth grounding of the workpiece is required, ground it directly
Touching live electrical parts can cause fatal shocks with a separate cable.
or severe burns. The electrode and work circuit is D Do not touch electrode if you are in contact with the work, ground,
electrically live whenever the output is on. The input or another electrode from a different machine.
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic D Do not touch electrode holders connected to two welding ma-
wire welding, the wire, wire reel, drive roll housing, chines at the same time since double open-circuit voltage will be
and all metal parts touching the welding wire are present.
electrically live. Incorrectly installed or improperly D Use only well-maintained equipment. Repair or replace damaged
grounded equipment is a hazard.
parts at once. Maintain unit according to manual.
D Do not touch live electrical parts. D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats D Clamp work cable with good metal-to-metal contact to workpiece
or covers big enough to prevent any physical contact with the work or worktable as near the weld as practical.
or ground. D Insulate work clamp when not connected to workpiece to prevent
D Do not use AC output in damp areas, if movement is confined, or if contact with any metal object.
there is a danger of falling. D Do not connect more than one electrode or work cable to any
D Use AC output ONLY if required for the welding process. single weld output terminal. Disconnect cable for process not in
use.
D If AC output is required, use remote output control if present on
unit. D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
D Additional safety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
SIGNIFICANT DC VOLTAGE exists in inverter weld-
as floors, gratings, or scaffolds; when in cramped positions such ing power sources AFTER removal of input power.
as sitting, kneeling, or lying; or when there is a high risk of unavoid- D Turn Off inverter, disconnect input power, and discharge input
able or accidental contact with the workpiece or ground. For these capacitors according to instructions in Maintenance Section
conditions, use the following equipment in order presented: 1) a before touching any parts.
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder HOT PARTS can burn.
is recommended. And, do not work alone!
D Do not touch hot parts bare handed.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to D Allow cooling period before working on
OSHA 29 CFR 1910.147 (see Safety Standards). equipment.
D Properly install, ground, and operate this equipment according to D To handle hot parts, use proper tools and/or wear heavy, insu-
its Owner’s Manual and national, state, and local codes. lated welding gloves and clothing to prevent burns.

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 D Remove stick electrode from holder or cut off welding wire at
FUMES AND GASES can be hazardous. contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free
these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high
health.
shoes, and a cap.
D Keep your head out of the fumes. Do not breathe the fumes. D Remove any combustibles, such as a butane lighter or matches,
D If inside, ventilate the area and/or use local forced ventilation at the from your person before doing any welding.
arc to remove welding fumes and gases. The recommended way D After completion of work, inspect area to ensure it is free of sparks,
to determine adequate ventilation is to sample for the composition glowing embers, and flames.
and quantity of fumes and gases to which personnel are exposed. D Use only correct fuses or circuit breakers. Do not oversize or by-
D If ventilation is poor, wear an approved air-supplied respirator. pass them.
D Read and understand the Safety Data Sheets (SDSs) and the D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
manufacturer’s instructions for adhesives, coatings, cleaners, for hot work and have a fire watcher and extinguisher nearby.
consumables, coolants, degreasers, fluxes, and metals. D Read and understand the Safety Data Sheets (SDSs) and the
D Work in a confined space only if it is well ventilated, or while manufacturer’s instructions for adhesives, coatings, cleaners,
wearing an air-supplied respirator. Always have a trained watch- consumables, coolants, degreasers, fluxes, and metals.
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath- FLYING METAL or DIRT can injure eyes.
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op- D Welding, chipping, wire brushing, and grinding
erations. The heat and rays of the arc can react with vapors to form cause sparks and flying metal. As welds cool,
highly toxic and irritating gases. they can throw off slag.
D Do not weld on coated metals, such as galvanized, lead, or D Wear approved safety glasses with side
cadmium plated steel, unless the coating is removed from the weld shields even under your welding helmet.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements BUILDUP OF GAS can injure or kill.
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin. D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
Arc rays from the welding process produce intense approved air-supplied respirator.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the ELECTRIC AND MAGNETIC FIELDS (EMF)
weld. can affect Implanted Medical Devices.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and D Wearers of Pacemakers and other Implanted
sparks when welding or watching (see ANSI Z49.1 and Z87.1 Medical Devices should keep away.
listed in Safety Standards). D Implanted Medical Device wearers should consult their doctor
D Wear approved safety glasses with side shields under your and the device manufacturer before going near arc welding, spot
helmet. welding, gouging, plasma arc cutting, or induction heating
D Use protective screens or barriers to protect others from flash, operations.
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant mate- NOISE can damage hearing.
rial (leather, heavy cotton, wool). Body protection includes Noise from some processes or equipment can
oil-free clothing such as leather gloves, heavy shirt, cuffless damage hearing.
trousers, high shoes, and a cap.
D Wear approved ear protection if noise lev-
WELDING can cause fire or explosion. el is high.

Welding on closed containers, such as tanks, CYLINDERS can explode if damaged.

drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot Compressed gas cylinders contain gas under high
workpiece, and hot equipment can cause fires and pressure. If damaged, a cylinder can explode. Since
burns. Accidental contact of electrode to metal objects can cause gas cylinders are normally part of the welding
sparks, explosion, overheating, or fire. Check and be sure the area is process, be sure to treat them carefully.
safe before doing any welding.
D Protect compressed gas cylinders from excessive heat, mechani-
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If cal shocks, physical damage, slag, open flames, sparks, and arcs.
this is not possible, tightly cover them with approved covers. D Install cylinders in an upright position by securing to a stationary
D Do not weld where flying sparks can strike flammable material. support or cylinder rack to prevent falling or tipping.
D Protect yourself and others from flying sparks and hot metal. D Keep cylinders away from any welding or other electrical circuits.
D Be alert that welding sparks and hot materials from welding can D Never drape a welding torch over a gas cylinder.
easily go through small cracks and openings to adjacent areas.
D Never allow a welding electrode to touch any cylinder.
D Watch for fire, and keep a fire extinguisher nearby.
D Never weld on a pressurized cylinder − explosion will result.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side. D Use only correct compressed gas cylinders, regulators, hoses,
D Do not weld on containers that have held combustibles, or on and fittings designed for the specific application; maintain them
closed containers such as tanks, drums, or pipes unless they are and associated parts in good condition.
properly prepared according to AWS F4.1 and AWS A6.0 (see D Turn face away from valve outlet when opening cylinder valve. Do
Safety Standards). not stand in front of or behind the regulator when opening the valve.
D Do not weld where the atmosphere can contain flammable dust, D Keep protective cap in place over valve except when cylinder is in
gas, or liquid vapors (such as gasoline). use or connected for use.
D Connect work cable to the work as close to the welding area as D Use the right equipment, correct procedures, and sufficient num-
practical to prevent welding current from traveling long, possibly ber of persons to lift and move cylinders.
unknown paths and causing electric shock, sparks, and fire D Read and follow instructions on compressed gas cylinders,
hazards. associated equipment, and Compressed Gas Association (CGA)
D Do not use welder to thaw frozen pipes. publication P-1 listed in Safety Standards.
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 1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard. MOVING PARTS can injure.

D Do not install or place unit on, over, or near D Keep away from moving parts such as fans.
combustible surfaces. D Keep all doors, panels, covers, and guards
D Do not install unit near flammables. closed and securely in place.
D Do not overload building wiring − be sure power supply system is D Have only qualified persons remove doors, panels, covers, or
properly sized, rated, and protected to handle this unit. guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
READ INSTRUCTIONS.
extend beyond opposite side of unit.
D Read and follow all labels and the Owner’s
D Keep equipment (cables and cords) away from moving vehicles Manual carefully before installing, operating, or
when working from an aerial location. servicing unit. Read the safety information at
D Follow the guidelines in the Applications Manual for the Revised the beginning of the manual and in each
NIOSH Lifting Equation (Publication No. 94−110) when manu- section.
ally lifting heavy parts or equipment. D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
OVERUSE can cause OVERHEATING local codes.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit. H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
FLYING SPARKS can injure. navigation, safety services, computers, and
communications equipment.
D Wear a face shield to protect eyes and face.
D Have only qualified persons familiar with
D Shape tungsten electrode only on grinder with electronic equipment perform this installation.
proper guards in a safe location wearing proper
face, hand, and body protection. D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
D Sparks can cause fires — keep flammables away. tion.
D If notified by the FCC about interference, stop using the
STATIC (ESD) can damage PC boards. equipment at once.
D Have the installation regularly checked and maintained.
D Put on grounded wrist strap BEFORE handling D Keep high-frequency source doors and panels tightly shut, keep
boards or parts. spark gaps at correct setting, and use grounding and shielding to
D Use proper static-proof bags and boxes to minimize the possibility of interference.
store, move, or ship PC boards.

MOVING PARTS can injure.

D Keep away from moving parts. ARC WELDING can cause interference.
D Keep away from pinch points such as drive D Electromagnetic energy can interfere with
rolls. sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
WELDING WIRE can injure. D Be sure all equipment in the welding area is
electromagnetically compatible.
D Do not press gun trigger until instructed to do
so. D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Do not point gun toward any part of the body,
other people, or any metal when threading D Locate welding operation 100 meters from any sensitive elec-
welding wire. tronic equipment.
D Be sure this welding machine is installed and grounded
BATTERY EXPLOSION can injure. according to this manual.
D If interference still occurs, the user must take extra measures
D Do not use welder to charge batteries or jump such as moving the welding machine, using shielded cables,
start vehicles unless it has a battery charging using line filters, or shielding the work area.
feature designed for this purpose.

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 1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Safety in Welding, Cutting, and Allied Processes, CSA Standard
is available as a free download from the American Welding Society at W117.2, from Canadian Standards Association, Standards Sales, 5060
[Link] or purchased from Global Engineering Documents Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 1-877-413-5184, website: [Link]). (phone: 800-463-6727, website: [Link]).
Safe Practice For Occupational And Educational Eye And Face Protec-
Safe Practices for the Preparation of Containers and Piping for Welding tion, ANSI Standard Z87.1, from American National Standards Institute,
and Cutting, American Welding Society Standard AWS F4.1, from Glob- 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
al Engineering Documents (phone: 1-877-413-5184, website: site: [Link]).
[Link]). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for Welding and Cutting Containers that have Held Com- Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: [Link]).
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: [Link]). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
National Electrical Code, NFPA Standard 70, from National Fire Protec- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
[Link] and www. [Link]). phone for Region 5, Chicago, is 312-353-2220, website:
[Link]).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, Applications Manual for the Revised NIOSH Lifting Equation, The Na-
from Compressed Gas Association, 14501 George Carter Way, Suite tional Institute for Occupational Safety and Health (NIOSH), 1600
103, Chantilly, VA 20151 (phone: 703-788-2700, website:[Link]- Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
[Link]). [Link]/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). The current from arc welding (and allied pro- welding circuit as possible.
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding 5. Connect work clamp to workpiece as close to the weld as
circuit. EMF fields can interfere with some medical implants, e.g. pace- possible.
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con- 6. Do not work next to, sit or lean on the welding power source.
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit: 7. Do not weld whilst carrying the welding power source or wire
feeder.
1. Keep cables close together by twisting or taping them, or using a
About Implanted Medical Devices:
cable cover.
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.

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 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7

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

2-1. Symboles utilisés

DANGER! − Indique une situation dangereuse qui si on . Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
AVIS − Indique des déclarations pas en relation avec des blessures afférant pour les actions nécessaires afin d’éviter le danger.
personnelles.

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

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-
Les symboles représentés ci-dessous sont utilisés dans ce ma- stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
nuel pour attirer l’attention et identifier les dangers possibles. En l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor-
présence de l’un de ces symboles, prendre garde et suivre les mes de sécurité).
instructions afférentes pour éviter tout risque. Les instructions
D Installez, mettez à la terre et utilisez correctement cet équipement
en matière de sécurité indiquées ci-dessous ne constituent
conformément à son Manuel d’Utilisation et aux réglementations
qu’un sommaire des instructions de sécurité plus complètes
nationales, gouvernementales et locales.
fournies dans les normes de sécurité énumérées dans la Sec-
tion 2-5. Lire et observer toutes les normes de sécurité. D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
Seul un personnel qualifié est autorisé à installer, faire fonc-
cordon est raccordée à une prise correctement mise à la terre.
tionner, entretenir et réparer cet appareil.
D En effectuant les raccordements d’entrée, fixer d’abord le conduc-
teur de mise à la terre approprié et contre-vérifier les connexions.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil. D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
UNE DÉCHARGE ÉLECTRIQUE peut D Vérifier fréquemment le cordon d’alimentation et le conducteur de
entraîner la mort. mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
Le contact d’organes électriques sous tension peut le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraî-
provoquer des accidents mortels ou des brûlures ner la mort.
graves. Le circuit de l’électrode et de la pièce est sous D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
machine sont également sous tension lorsque l’alimen- sante ou mal épissés.
tation est sur Marche. Dans le mode de soudage avec D Ne pas enrouler les câbles autour du corps.
du fil, le fil, le dérouleur, le bloc de commande du D Si la pièce soudée doit être mise à la terre, le faire directement
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement avec un câble distinct.
installé ou mis à la terre de manière incorrecte ou D Ne pas toucher l’électrode quand on est en contact avec la pièce,
impropre constitue un danger. la terre ou une électrode provenant d’une autre machine.
D Ne pas toucher des porte électrodes connectés à deux machines
D Ne pas toucher aux pièces électriques sous tension. en même temps à cause de la présence d’une tension à vide dou-
D Porter des gants isolants et des vêtements de protection secs et blée.
sans trous. D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
D S’isoler de la pièce à couper et du sol en utilisant des housses ou champ les pièces endommagées. Entretenir l’appareil conformé-
des tapis assez grands afin d’éviter tout contact physique avec la ment à ce manuel.
pièce à couper ou le sol. D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D Ne pas se servir de source électrique à courant électrique dans les D S’assurer que tous les panneaux et couvercles sont correctement
zones humides, dans les endroits confinés ou là où on risque de en place.
tomber.
D Fixer le câble de retour de façon à obtenir un bon contact métal-
D Se servir d’une source électrique à courant électrique UNIQUE- métal avec la pièce à souder ou la table de travail, le plus près pos-
MENT si le procédé de soudage le demande. sible de la soudure.
D Si l’utilisation d’une source électrique à courant électrique s’avère D Isoler la pince de masse quand pas mis à la pièce pour éviter le
nécessaire, se servir de la fonction de télécommande si l’appareil contact avec tout objet métallique.
en est équipé. D Ne pas raccorder plus d’une électrode ou plus d’un câble de
D D’autres consignes de sécurité sont nécessaires dans les condi- masse à une même borne de sortie de soudage. Débrancher le
tions suivantes : risques électriques dans un environnement câble pour le procédé non utilisé.
humide ou si l’on porte des vêtements mouillés ; sur des structures D Utiliser une protection différentielle lors de l’utilisation d’un équi-
métalliques telles que sols, grilles ou échafaudages ; en position
pement auxiliaire dans des endroits humides ou mouillés.
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 Il reste une TENSION DC NON NÉGLIGEABLE dans
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
les sources de soudage onduleur UNE FOIS
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à l’alimentation coupée.
souder AC à tension à vide réduite. Dans la plupart des situations, D Arrêter les convertisseurs, débrancher le courant électrique et
l’utilisation d’un poste à souder DC à fil à tension constante est re- décharger les condensateurs d’alimentation selon les instructions
commandée. En outre, ne pas travailler seul ! indiquées dans la partie Entretien avant de toucher les pièces.
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 chauffement ou un incendie. Avant de commencer le soudage, vérifier
LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger.
provoquer des brûlures. D Déplacer toutes les substances inflammables à une distance de
D Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
D Prévoir une période de refroidissement avant soigneusement avec des protections homologués.
de travailler à l’équipement. D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Ne pas toucher aux pièces chaudes, utiliser les outils recomman- D Se protéger et d’autres personnes de la projection d’étincelles et
dés et porter des gants de soudage et des vêtements épais pour de métal chaud.
éviter les brûlures. D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
LES FUMÉES ET LES GAZ peuvent fissures et des ouvertures.
être dangereux. D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
Le soudage génère des fumées et des gaz. Leur
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
inhalation peut être dangereux pour votre santé. peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
D Eloigner votre tête des fumées. Ne pas respirer les fumées. des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au préparés correctement conformément à AWS F4.1 et AWS A6.0
niveau de l’arc pour l’évacuation des fumées et des gaz de (voir les Normes de Sécurité).
soudage. Pour déterminer la bonne ventilation, il est recommandé D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
de procéder à un prélèvement pour la composition et la quantité gaz ou émanations inflammables (vapeur d’essence, par exemple).
de fumées et de gaz auxquels est exposé le personnel. D Brancher le câble de masse sur la pièce le plus près possible de la
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs zone de soudage pour éviter le transport du courant sur une
approuvé. longue distance par des chemins inconnus éventuels en provo-
D Lire et comprendre les fiches de données de sécurité et les instruc- quant des risques d’électrocution, d’étincelles et d’incendie.
tions du fabricant concernant les adhésifs, les revêtements, les D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
nettoyants, les consommables, les produits de refroidissement, les lées.
dégraisseurs, les flux et les métaux. D En cas de non utilisation, enlever la baguette d’électrode du porte-
D Travailler dans un espace fermé seulement s’il est bien ventilé ou électrode ou couper le fil à la pointe de contact.
en portant un respirateur à alimentation d’air. Demander toujours à D Porter un équipement de protection pour le corps fait d’un matériau
un surveillant dûment formé de se tenir à proximité. Des fumées et résistant et ignifuge (cuir, coton robuste, laine). La protection du
des gaz de soudage peuvent déplacer l’air et abaisser le niveau corps comporte des vêtements sans huile comme par ex. des
d’oxygène provoquant des blessures ou des accidents mortels. gants de cuir, une chemise solide, des pantalons sans revers, des
S’assurer que l’air de respiration ne présente aucun danger. chaussures hautes et une casquette.
D Ne pas souder dans des endroits situés à proximité d’opérations D Avant de souder, retirer toute substance combustible de vos po-
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et ches telles qu’un allumeur au butane ou des allumettes.
les rayons de l’arc peuvent réagir en présence de vapeurs et for- D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
mer des gaz hautement toxiques et irritants. trace d’étincelles incandescentes ni de flammes.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
galvanisé, plaqué en plomb ou au cadmium à moins que le revête- Ne pas augmenter leur puissance; ne pas les ponter.
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
bien ventilé, et en portant un respirateur à alimentation d’air. Les NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
revêtements et tous les métaux renfermant ces éléments peuvent extincteur à proximité.
dégager des fumées toxiques en cas de soudage. D Lire et comprendre les fiches de données de sécurité et les instruc-
tions du fabricant concernant les adhésifs, les revêtements, les
LES RAYONS DE L’ARC peuvent nettoyants, les consommables, les produits de refroidissement,
provoquer des brûlures dans les les dégraisseurs, les flux et les métaux.
yeux et sur la peau. DES PIECES DE METAL ou DES
Le rayonnement de l’arc du procédé de soudage génère SALETES peuvent provoquer des
des rayons visibles et invisibles intenses (ultraviolets e blessures dans les yeux.
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la
peau. Des étincelles sont projetées pendant le soudage. D Le soudage, l’écaillement, le passage de la pièce à
D Porter un casque de soudage approuvé muni de verres filtrants la brosse en fil de fer, et le meulage génèrent des étincelles et des
approprié pour protéger visage et yeux pour protéger votre visage particules métalliques volantes. Pendant la période de ref-
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 roidissement des soudures, elles risquent de projeter du laitier.
et Z87.1 énuméré dans les normes de sécurité). D Porter des lunettes de sécurité avec écrans latéraux ou un écran
D Porter des lunettes de sécurité avec écrans latéraux même sous facial.
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour LES ACCUMULATIONS DE GAZ
protéger les autres contre les rayonnements les éblouissements risquent de provoquer des blessures
et les étincelles ; prévenir toute personne sur les lieux de ne pas ou même la mort.
regarder l’arc.
D Porter un équipement de protection pour le corps fait d’un matériau D Fermer l’alimentation du gaz comprimé en cas
résistant et ignifuge (cuir, coton robuste, laine). La protection du de non utilisation.
corps comporte des vêtements sans huile comme par ex. des D Veiller toujours à bien aérer les espaces confinés ou se servir d’un
gants de cuir, une chemise solide, des pantalons sans revers, des respirateur d’adduction d’air homologué.
chaussures hautes et une casquette.
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
LE SOUDAGE peut provoquer un peuvent affecter les implants médicaux.
incendie ou une explosion.
D Les porteurs de stimulateurs cardiaques et
Le soudage effectué sur des conteneurs fermés tels autres implants médicaux doivent rester à
que des réservoirs, tambours ou des conduites peut distance.
provoquer leur éclatement. Des étincelles peuvent
D Les porteurs d’implants médicaux doivent consulter leur médecin
être projetées de l’arc de soudure. La projection d’étincelles, des
et le fabricant du dispositif avant de s’approcher de la zone où se
pièces chaudes et des équipements chauds peut provoquer des incen- déroule du soudage à l’arc, du soudage par points, du gougeage,
dies et des brûlures. Le contact accidentel de l’électrode avec des de la découpe plasma ou une opération de chauffage par
objets métalliques peut provoquer des étincelles, une explosion, un sur- induction.
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 D Tenir les bouteilles éloignées des circuits de soudage ou autres
LE BRUIT peut endommager l’ouïe. circuits électriques.
Le bruit des processus et des équipements peut D Ne jamais placer une torche de soudage sur une bouteille à gaz.
affecter l’ouïe. D Une électrode de soudage ne doit jamais entrer en contact avec
D Porter des protections approuvées pour les une bouteille.
oreilles si le niveau sonore est trop élevé. D Ne jamais souder une bouteille pressurisée − risque d’explosion.
LES BOUTEILLES peuvent exploser D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
si elles sont endommagées.
les maintenir ainsi que les éléments associés en bon état.
Les bouteilles de gaz comprimé contiennent du D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
gaz sous haute pression. Si une bouteille est de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
endommagée, elle peut exploser. Du fait que de l’ouverture de la vanne.
les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution. D Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des D Utiliser les équipements corrects, les bonnes procédures et suffi-
flammes ouvertes, des étincelles et des arcs. samment de personnes pour soulever et déplacer les bouteilles.
D Placer les bouteilles debout en les fixant dans un support station- D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
naire ou dans un porte-bouteilles pour les empêcher de tomber ou l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
de se renverser. Association) mentionné dans les principales normes de sécurité.

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

D Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-
Risque D’INCENDIE OU D’EXPLOSION. placer ou expédier des cartes de circuits imprimes.
D Ne pas placer l’appareil sur, au-dessus ou Les PIÈCES MOBILES peuvent
à proximité de surfaces inflammables. causer des blessures.
D Ne pas installer l’appareil à proximité de pro-
duits inflammables. D Ne pas s’approcher des organes mobiles.
D Ne pas surcharger l’installation électrique − s’assurer que D Ne pas s’approcher des points de coincement
l’alimentation est correctement dimensionnée et protégée avant tels que des rouleaux de commande.
de mettre l’appareil en service.
LES FILS DE SOUDAGE peuvent
LA CHUTE DE L’ÉQUIPEMENT peut provoquer des blessures.
provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en
D Utiliser l’anneau de levage uniquement pour avoir reçu l’instruction.
soulever l’appareil, NON PAS les chariots, les D Ne pas diriger le pistolet vers soi, d’autres
bouteilles de gaz ou tout autre accessoire. personnes ou toute pièce mécanique en engageant le fil de
D Utiliser un équipement de levage de capacité suffisante pour lever soudage.
l’appareil.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer L’EXPLOSION DE LA BATTERIE
que les fourches sont suffisamment longues pour dépasser du peut provoquer des blessures.
côté opposé de l’appareil.
D Tenir l’équipement (câbles et cordons) à distance des véhicules D Ne pas utiliser l’appareil de soudage pour
mobiles lors de toute opération en hauteur. charger des batteries ou faire démarrer des
D Suivre les consignes du Manuel des applications pour l’équation véhicules à l’aide de câbles de démarrage,
de levage NIOSH révisée (Publication Nº94–110) lors du levage sauf si l’appareil dispose d’une fonctionnalité
manuelle de pièces ou équipements lourds. de charge de batterie destinée à cet usage.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT. Les PIÈCES MOBILES peuvent
causer des blessures.
D Prévoir une période de refroidissement ; res-
pecter le cycle opératoire nominal. D S’abstenir de toucher des organes mobiles tels
D Réduire le courant ou le facteur de marche que des ventilateurs.
avant de poursuivre le soudage. D Maintenir fermés et verrouillés les portes,
D Ne pas obstruer les passages d’air du poste. panneaux, recouvrements et dispositifs de protection.
D Lorsque cela est nécessaire pour des travaux d’entretien et de dé-
LES ÉTINCELLES PROJETÉES pannage, faire retirer les portes, panneaux, recouvrements ou
peuvent provoquer des blessures. dispositifs de protection uniquement par du personnel qualifié.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
D Porter un écran facial pour protéger le visage et protection quand l’entretien est terminé et avant de rebrancher
les yeux. l’alimentation électrique.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exé- LIRE LES INSTRUCTIONS.
cuter dans un endroit sûr lorsque l’on porte l’équipement ho-
mologué de protection du visage, des mains et du corps. D Lire et appliquer les instructions sur les
D Les étincelles risquent de causer un incendie − éloigner toute étiquettes et le Mode d’emploi avant l’instal-
substance inflammable. lation, l’utilisation ou l’entretien de l’appareil.
Lire les informations de sécurité au début du
manuel et dans chaque section.
LES CHARGES ÉLECTROSTATI-
QUES peuvent endommager les cir- D N’utiliser que les pièces de rechange recommandées par le
constructeur.
cuits imprimés.
D Effectuer l’installation, l’entretien et toute intervention selon les
D Établir la connexion avec la barrette de terre manuels d’utilisateurs, les normes nationales, provinciales et de
avant de manipuler des cartes ou des pièces.
l’industrie, ainsi que les codes municipaux.
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 LE RAYONNEMENT HAUTE LE SOUDAGE À L’ARC risque de
FRÉQUENCE (H.F.) risque de provoquer des interférences.
provoquer des interférences.
D L’énergie électromagnétique risque de
D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences pour l’équipement
provoquer des interférences avec les équi- électronique sensible tel que les ordinateurs et
pements de radio−navigation et de communication, les services l’équipement commandé par ordinateur tel que
de sécurité et les ordinateurs. les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit com-
patible électromagnétiquement.
D Demander seulement à des personnes qualifiées familiarisées avec D Pour réduire la possibilité d’interférence, maintenir les câbles de
des équipements électroniques de faire fonctionner l’installation. soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
D L’utilisateur est tenu de faire corriger rapidement par un électricien
D Veiller à souder à une distance de 100 mètres de tout équipement
qualifié les interférences résultant de l’installation. électronique sensible.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil. D Veiller à ce que ce poste de soudage soit posé et mis à la terre
D Effectuer régulièrement le contrôle et l’entretien de l’installation. conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes,
D Maintenir soigneusement fermés les portes et les panneaux des il incombe à l’utilisateur de prendre des mesures supplémentaires
sources de haute fréquence, maintenir les éclateurs à une distan- telles que le déplacement du poste, l’utilisation de câbles blindés,
ce correcte et utiliser une terre et un blindage pour réduire les l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
interférences éventuelles. de travail.

2-4. Proposition californienne 65 Avertissements

Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du
fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent
dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres
formations congénitales et, dans certains cas, des cancers. problèmes de procréation. Se laver les mains après
(Code de santé et de sécurité de Californie, chapitre 25249.5 utilisation.
et suivants)

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
is available as a free download from the American Welding Society at (phone: 800-463-6727, website: [Link]).
[Link] or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec-
(phone: 1-877-413-5184, website: [Link]). tion, ANSI Standard Z87.1, from American National Standards Institute,
Safe Practices for the Preparation of Containers and Piping for Welding 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
and Cutting, American Welding Society Standard AWS F4.1, from Glob- site: [Link]).
al Engineering Documents (phone: 1-877-413-5184, website:
[Link]). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Safe Practices for Welding and Cutting Containers that have Held Com-
Quincy, MA 02269 (phone: 1-800-344-3555, website: [Link]).
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: [Link]). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
National Electrical Code, NFPA Standard 70, from National Fire Protec- and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
[Link] and www. [Link]). (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, phone for Region 5, Chicago, is 312-353-2220, website:
from Compressed Gas Association, 14501 George Carter Way, Suite [Link]).
103, Chantilly, VA 20151 (phone: 703-788-2700, website:[Link]- Applications Manual for the Revised NIOSH Lifting Equation, The Na-
[Link]). tional Institute for Occupational Safety and Health (NIOSH), 1600
Safety in Welding, Cutting, and Allied Processes, CSA Standard Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
W117.2, from Canadian Standards Association, Standards Sales, 5060 [Link]/NIOSH).

2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs câbles d’un côté et à distance de l’opérateur.
électromagnétiques (CEM) à certains endroits. Le courant issu d’un 3. Ne pas courber et ne pas entourer les câbles autour de votre
soudage à l’arc (et de procédés connexes, y compris le soudage par corps.
points, le gougeage, le découpage plasma et les opérations de 4. Maintenir la tête et le torse aussi loin que possible du matériel du
chauffage par induction) crée un champ électromagnétique (CEM) circuit de soudage.
autour du circuit de soudage. Les champs électromagnétiques produits 5. Connecter la pince sur la pièce aussi près que possible de la
peuvent causer interférence à certains implants médicaux, p. ex. les soudure.
stimulateurs cardiaques. Des mesures de protection pour les porteurs 6. Ne pas travailler à proximité d’une source de soudage, ni
d’implants médicaux doivent être prises: Limiter par exemple tout accès s’asseoir ou se pencher dessus.
aux passants ou procéder à une évaluation des risques individuels pour 7. Ne pas souder tout en portant la source de soudage ou le
les soudeurs. Tous les soudeurs doivent appliquer les procédures dévidoir.
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
En ce qui concerne les implants médicaux :
soudage:
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
1. Rassembler les câbles en les torsadant ou en les attachant avec
points, de gougeage, du coupage plasma ou de chauffage par induc-
du ruban adhésif ou avec une housse.
tion. Si le médecin approuve, il est recommandé de suivre les
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les procédures précédentes.
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 SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.

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

Safe1 2012−05

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

Safe95 2012−05

Become trained and read the instructions before working on the

machine or welding.

Safe40 2012−05

3-2. Miscellaneous Symbols And Definitions

. Some symbols are found only on CE products.

A Amperage
Direct Current
(DC)
Alternating
Current (AC) V Voltage

Gas Input Circuit Breaker I2 Rated Welding

Current I1max Rated Maximum
Supply Current

U1 Primary Voltage Positive Negative

Hz Hertz

U0 Rated No Load
Voltage (OCV) U2 Conventional
Load Voltage
Line Connection
Gas Metal Arc
Welding (GMAW)

Single Phase

IP X I1eff
Static Frequency
Internal Protection Maximum Effective
Duty Cycle Converter-
Rating Supply Current
Transformer-
Rectifier

Single Phase

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 . A complete Parts List is available on-line at [Link]

SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output.
For future reference, write serial number in space provided on back cover of this manual.

4-2. Unit Specifications

. Do not use information in unit specifications table to determine electrical service requirements. See Sections 5-3, 5-4 and 5-5 for information on
connecting input power.

Maximum
Rated Amperes Input at Rated
Input Open Circuit Weight Overall
Welding Amperage Range Load Output, KVA KW
Voltage Voltage DC w/ Gun Dimensions
Output 50/60HZ, Single−Phase
(U0*)

115 A @ 19.8
Volts DC, 20% 30 − 130 54 24.3
Duty Cycle
120 VAC Solid/Stainless Flux Cored Wire Feed Speed Range 2.9 2.9
Wire Type Length: 20.5 in.
and Dia .023 − .035 in. .030 − .035 in. 60 − 600 IPM
(521 mm)
(0.6 − 0.9 mm) (0.8 − 0.9 mm) (1.5 − 15.24 m/min)
42 lb. Width: 11.25 in.
150 A @21.5 (19 kg) (286 mm)
Volts DC, 30 − 230 54 16.6 Height: 12.5 in.
40% Duty Cycle (318 mm)

240 VAC Solid/Stainless Flux Cored Wire Feed Speed Range 4.0 4.0
Wire Type
and Dia .023 − .035 in. .030 − .045 in. 60 − 600 IPM
(0.6 − 0.9 mm) (0.8 − 1.2 mm) (1.5 − 15.24 m/min)

*See unit rating label and Section 3-2.

4-3. Environmental Specifications

A. IP Rating
IP Rating
IP21
This equipment is designed for indoor use and is not intended to be used or stored outside.
IP21 2014−06

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4-4. Duty Cycle And Overheating

Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
250
duty cycle before welding.
NOTICE − Exceeding duty cycle
200 can damage unit and void warranty.
Weld Amperes

240V
150

100

120V,20A
50

0
10 20 30 40 50 60 70 80 90 100

% Duty Cycle

120V Input

20% duty cycle at 115 amps 100% duty cycle at 90 amps

2 Minutes Welding 8 Minutes Resting Continuous Welding

240V Input

40% duty cycle at 150 amps 100% duty cycle at 100 amps

Continuous Welding
4 Minutes Welding 6 Minutes Resting

Overheating

0
A or V

15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 272269A

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4-5. Volt-Ampere Curves

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

100

80

60
Volts

240V MAX
40 .

20
120/240V MIN. 120V MAX.

0
0 25 50 75 100 125 150 175 200 225

Amperes

272270A

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SECTION 5 − INSTALLATION
5-1. Selecting A Location

Movement ! Do not move or operate

unit where it could tip.
1

Location And Airflow

! Special installation may be
required where gasoline or
2 volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1 Lifting Handles
Use handles to lift unit.
2 Line Disconnect Device
Locate unit near correct input
power supply.

18 in.
(460 mm)

18 in.
(460 mm)

loc_smallmig 2015-12

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

Selecting Plug

2
1
3

! Do not cut off power cord con-

nector and rewire. The power
cord connector and plugs will
work with standard NEMA re-
ceptacles. Modifying power
cord, connector, and plugs will
6 void product warranty.

Connecting Plug To Power Cord

MVP Plug1 2010−10 / Ref. 803812C

Selecting Plug 4 Plug − NEMA Type 5−20P (Optional) Connecting Plug To Power Cord
1 Power Cord Connector From 5 Receptacle − NEMA Type 5−20R
Welding Power Source (Customer Supplied) Align arrow on plug with arrow on power
6 Plug − NEMA Type 6−50P cord connector. Push together.
Select plug for power supply receptacle
7 Receptacle − NEMA Type 6−50R
available at site. Not all plugs shown are
(Customer Supplied) Tighten threaded collar. As threaded collar
provided as standard with unit.
2 Plug − NEMA Type 5−15P
! Follow electrical service guide for is tightened, push plug onto adapter until
collar is completely tight.
240 VAC in Section 5-3. Do not use
3 Receptacle − NEMA Type 5−15R plug rating to size branch circuit
(Customer Supplied) protection. Connect plug to receptacle.

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5-3. Electrical Service Guide Elec Serv 2014−01

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

In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.

60 Hz 240 60 Hz 120
Single Phase Volts AC
Input Voltage (V) 240
A 15 or 20
Input Amperes (A) At Rated Output 16.6 ampere
individual
Max Recommended Standard Fuse Rating In Amperes 1 branch circuit
protected by
Time-Delay Fuses 2 25 time-delay
Normal Operating Fuses 3 30 fuses or
circuit breaker
Min Input Conductor Size In AWG 4 14 is required.

Max Recommended Input Conductor Length In Feet (Meters) 72 (22) See Section
4 5-4
Min Grounding Conductor Size In AWG 14

Reference: 2014 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.

5-4. Connecting 120 Volt Input Power

! Installation must meet all
National and Local Codes − have
1 2 only qualified persons make this
installation.

! Special installation may be

required where gasoline or volatile
liquids are present − see NEC
Article 511 or CEC Section 20.
NOTICE − The Auto-Line circuitry in this
unit automatically links the power source
to the primary voltage being applied, either
120 or 240 VAC.
See rating label on unit and check input
voltage available at site.
For 120 volts AC input power, a 15 or 20
ampere individual branch circuit protected
by time-delay fuses or circuit breaker is
required.
1 Multi-Voltage Plug And Power Cord
Connector (NEMA Type 5−15P Plug
Shown)
For multi−voltage plug connections, see
Section 5-2.
2 Receptacle − NEMA Type 5−15R
(Customer Supplied)

Input6 2011−03 271714A / Ref. 805474A

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

3 =GND/PE Earth Ground

L1
5
L2
6

L2 L1

240 VAC, 1

Tools Needed:

input4 2012-05 − 271714A / 803766C / Ref. 802443A

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5-5. Connecting 1-Phase Input Power For 240 VAC (Continued)

! Installation must meet all National and automatically links the power source to the
primary voltage being applied, either 120 or
Connect green or green/yellow grounding
conductor to disconnect device grounding
Local Codes − have only qualified per-
240 VAC. terminal first.
sons make this installation.
See rating label on unit and check input volt- Connect input conductors L1 and L2 to dis-
! Disconnect and lockout/tagout input age available at site. connect device line terminals.
power before connecting input con- 1 Input Power Cord 7 Over-Current Protection
ductors from unit. Follow established
2 Disconnect Device (switch shown in the Select type and size of over-current
procedures regarding the installation
OFF position) protection using Section 5-3 (fused
and removal of lockout/tagout
devices. 3 Disconnect Device Grounding Terminal disconnect switch shown).
4 Disconnect Device Line Terminals 8 Receptacle (NEMA 6-50R)
! Always connect green or green/yellow 5 Black And White Input Conductor (L1 Customer Supplied
conductor to supply grounding termi- And L2)
nal first, and never to a line terminal. Close and secure door on disconnect device.
6 Green Or Green/Yellow Grounding Remove lockout/tagout device, and place
NOTICE − The Auto-Line circuitry in this unit Conductor switch in the On position.

input4 2012−05 − 803766C

Notes

Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

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5-6. Installing Work Clamp

. Tighten connection hardware
with proper tools. Do not just
hand tighten hardware. A loose
electrical connection will cause
poor weld performance and ex-
cessive heating of the work
6 clamp.
1 Work Clamp
5 2 Work Cable From Unit
3 Screw
2 4
4 Flat Washer
5 Lock Washer
6 Nut
3
Route work cable through hole in
clamp handle. Secure cable with
hardware as shown.

Tools Needed:

805460A

5-7. Work Cable Routing Inside Unit

1 Work Cable
2 Output Terminal Block
Work cable is routed through the
small hole in front panel and routed
along base of unit to output terminal
block.

Ref. 267805A

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5-8. Process/Polarity Table

Cable Connections
Process Polarity
Cable To Gun Cable To Work
GMAW − Solid wire with shield- DCEP − Reverse polarity Connect to positive (+) out- Connect to negative (−) output
ing gas put terminal terminal
FCAW − Self-shielding wire − DCEN − Straight Polarity Connect to negative (−) Connect to positive (+) output
no shielding gas output terminal terminal

5-9. Changing Polarity

Always read and follow wire
manufacturer’s recommended
polarity, and see Section 5-8.

Tools Needed:

7/16 in.

. Connection hardware must be tightened with proper tools. Do

not just hand tighten hardware. A loose electrical connection
will cause poor weld performance and excessive heating at the
terminal block.

DCEP DCEN
Electrode Positive Electrode Negative
FOR SOLID WIRE FOR FLUX CORE WIRE

Ref. 267805A / Ref. 267825A

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5-10. Installing Welding Gun Or Spool Gun

1 Drive Assembly
2 Gun Trigger Plug
3 Gun Trigger Receptacle
Route gun trigger plug through front
panel.
Insert plug into receptacle, and
tighten threaded collar.
4 Gun Securing Knob
5 Gun End
Loosen knob. Insert end of gun
through opening in front panel
until it bottoms against drive
assembly. Tighten knob.
Close door.

3 4 2

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

Incorrect installation will have adverse effects on gas flow.

5 5

Correct Incorrect

Ref. 267805A / 267807A

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5-11. Changing Drive Roll Or Wire Inlet Guide

1 Inlet Wire Guide
Remove guide by pressing on
barbed area or cutting off one end
near housing and pulling it out of
hole. Push new guide into hole from
rear until it snaps in place.
2 Drive Roll
The drive roll includes three
different sized grooves. The text
aligned with the drive roll retaining
pin indicates the selected groove
(see Section 5-13).
3 Retaining Pin
To secure drive roll, locate open slot
and push drive roll completely over
retaining pin, then rotate drive roll to
desired slot.

. See Section 10-2 for optional

1 drive rolls.

.024 Groove .030−.035 Groove

.030-.035 V-Knurled Groove

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

Groove Compatible Wire

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

267893A

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5-12. Installing Wire Spool And Adjusting Hub Tension

Installing 4 in. (102 mm) Wire Spool

When a slight force is needed

to turn spool, tension is set.

Installing 8 in. (203 mm) Wire Spool

Adapter and
retaining ring

When a slight force is

needed to turn spool, ten-
sion is set.

Align locking hole in

spool with locking
pin on spool hub.

Tools Needed:

1/2 in.
803012 / 267865A

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5-13. Threading Welding Wire

1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4 Pressure Adjustment Knob
5 Drive Roll
4
6 Gun Conduit Cable
Lay gun cable out straight.

Tools Needed:

1 2 3 5

1 2 . Hold wire tightly to keep 3

it from unraveling.

6 in.
(150 mm)

4 in.
(102 mm)

Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;
continue to hold wire.

. Use pressure indicator to set a desired

drive roll pressure. Begin with a setting of 2.
If necessary, make additional adjustments
4 after trying this initial setting.
Tighten
5 6
2 Pressure
3
4
Indicator

Be sure that wire is seated

in proper drive roll groove.
Close and tighten pressure Remove gun nozzle and contact tip. Turn power on.
assembly, and let go of wire.

7 8 9
Tighten

2
3
WOOD 4

Press gun trigger until wire comes out of gun.

(Keep gun cable as straight as possible.) Be sure that tip matches wire diameter. Feed wire to check drive roll pressure.
Reinstall contact tip and nozzle. Tighten knob enough to prevent slipping.
. Unit will enter Jog mode after trigger is Cut off wire. Close door.
held for 3 seconds (see Section 6-3).
Ref. 267805A / Ref. 267871A / Ref. 800924D

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5-14. Installing Gas Supply

Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.
. DO NOT use Argon/Mixed gas regulator/flowmeter 1 Cap
with CO2 shielding gas. See Parts List for optional 2 Cylinder Valve
CO2 gas regulator/flowmeter and hose.
Remove cap, stand to side of valve,
Tools Needed: and open valve slightly. Gas flow
5/8, 1-1/8 in. blows dust and dirt from valve.
1 Close valve.
3 Cylinder
4 Regulator/Flowmeter

2 Install so face is vertical.

5 Regulator/Flowmeter Gas
Hose Connection

3 6 Welding Power Source Gas

Hose Connection
4 Connect supplied gas hose
between regulator/flowmeter gas
hose connection, and fitting on rear
of welding power source.
7
Argon Gas Or 7 Flow Adjust
Mixed Gas
Flow rate should be set when gas is
flowing through welding power
source and welding gun. Open
feedhead pressure assembly so
5 that wire will not feed. Press gun
trigger to start gas flow.
Typical flow rate is 20 to 25 cfh
(cubic feet per hour). Check wire
manufacturer’s recommended
flow rate.
8 CO2 Adapter (Customer
6 Supplied)
8 9 9 O-Ring (Customer Supplied)
Install adapter with O-ring between
regulator/flowmeter and CO2
CO2 Gas cylinder.
After flow is set, close feedhead
pressure assembly.

Feedhead Pressure Assembly Open

Feedhead Pressure Assembly Closed

270208A / Ref. 247832A / Ref. 267807A / Ref. 267805A

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

Cut Off End Of Wire Open Pressure Assembly

Turn Off Power

Knob
. Hold wire tightly to keep it
from unraveling.

Rewind Wire Onto Spool, Fasten Loosen Knob, Disconnect Gun Trigger
End Of Wire To Spool Plug, And Remove Gun From Unit
(See Section 5-10 for gun installation)

270208A / Ref. 802982A / Ref. 267805A / Ref. 267807A

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5-16. Spool Gun Calibration Procedure

. To optimize performance, spool guns
must be calibrated before being used with
the Auto-Set feature.
Installing Spool Gun
Turn off power to Millermatic.
Install welding wire in spool gun (See Spool
Gun Owner’s Manual).
Install spool gun in Millermatic (See Section
5-10).
Pull and hold spool gun trigger while turning
Millermatic power on.

. Yellow over temperature LED will begin

flashing to indicate machine is in setup
mode.
Release spool gun trigger.
Rotate right control knob counterclockwise to
Turn Off Power Load And Install Spool Gun minimum setting. Then rotate knob clockwise
to 100.

. Blue Auto-Set LED will begin flashing to

indicate spool gun calibration is active.
Low Speed Calibration
Set left control knob to 2.
Set right control knob to 70.
Pull spool gun trigger and hold until wire stops
feeding. Spool gun should feed 24 in. of wire.
Measure the length of wire.
If wire length is greater than 24 in., turn right
control knob counterclockwise 10.
If wire length is less than 24 in., turn left control
knob clockwise 10.
Pull And Hold Trigger Turn On Power Pull trigger and feed wire again. Measure and
repeat adjustment until 24 in. of wire is fed.
When Low Speed Calibration is complete,
perform High Speed Calibration.
High Speed Calibration
Set left control knob to 8.
Set right control knob to 70.
Pull spool gun trigger and hold until wire stops.
Repeat above adjustment procedure until wire
length measures 24 in..
When wire length measures 24 in. turn left
Rotate Right Control Knob Rotate Right Control Knob control knob to 2.
Counterclockwise To Minimum Clockwise To 100
Turn off Millermatic and wait five seconds be-
fore powering on.
Calibration is complete.

2 70 8 70

Low Speed Calibration High Speed Calibration

Starting Settings Starting Settings

270208A / Ref. 802982A / Ref. 267805A / Ref. 267807A

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 . A complete Parts List is available on-line at [Link]

SECTION 6 − OPERATION
6-1. Manual Setup

1 2 3

3
6

Rear View

265381A / 270208A

1 Voltage/Material Thickness Control 3 Wire Speed/Wire Diameter Control 5 Power Light

Turn control clockwise inside white scale Turn control clockwise inside white scale Power light illuminates when the unit is
(1-10) to increase voltage (see weld (10-100) to increase wire feed speed. (see turned on and powered up.
parameter chart in welding power source weld parameter chart in welding power
source or Section 6-4). 6 Power Switch
or Section 6-4).
4 Over Temperature Light Use switch to turn unit On or Off.
2 Process Select Control
If unit overheats, light turns on and output
Turn control to select desired weld stops. Allow unit to cool before resuming
process. operation. This light will also communicate
additional unit errors.

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 . A complete Parts List is available on-line at [Link]

6-2. Using Auto-Set

4 1 2

265381A

1 Process Select Control 3 Auto-Set LED 4 Voltage/Material Thickness Control

Turn control to select process, material, Adjust the Voltage/Material Thickness
and type of shielding gas. The Auto-Set light illuminates indicating
control knob to the desired steel material
2 Wire Speed/Wire Diameter Control Auto-Set is on.
thickness to weld.
To turn Auto-Set on, turn the Wire Speed/
Wire Diameter control knob to the desired . A blinking Auto-Set LED indicates pa- . There is no adjustment within the
wire diameter setting. rameter is not recommended. material thickness band.

6-3. Jog Mode

If gun trigger is held for longer than 3 seconds without initiating a weld arc, unit will enter Jog mode and disable weld output.

S Jog mode is used to quickly feed wire through the wire drive assembly and MIG gun.

S While in Jog mode, wire feed speed is adjustable using the Wire Speed/Wire Diameter control knob.

S To exit Jog mode, release gun trigger.

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 . A complete Parts List is available on-line at [Link]

6-4. Weld Parameter Chart

267705A

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 . A complete Parts List is available on-line at [Link]

6-5. Weld Parameters

Ref. 267705A

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 . A complete Parts List is available on-line at [Link]

SECTION 7 − MAINTENANCE &TROUBLESHOOTING

7-1. Routine Maintenance

! Disconnect power . Maintain more often

before maintaining. during severe conditions.

n = Check Z = Change ~ = Clean l = Replace Reference

* To be done by Factory Authorized Service Agent

Every
3
Months

l Unreadable Labels ~ Weld Terminals nl Weld Cables

Every
6 OR
Months
~ Inside Unit

7-2. Overload Protection

1 Supplementary Protector CB1
CB1 protects unit from overload. If
CB1 opens, unit shuts down.
Reset supplementary protector.

270208A

7-3. Drive Motor Protection And Tip Saver/Short Circuit Protection

A. Drive Motor Protection
Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, cycle unit power off and back on again.
B. Tip Saver/Short Circuit Protection
The tip saver/short circuit protection extends contact tip life and protects internal components from damage. If contact tip is shorted to workpiece, the
unit shuts down the welding output. To resume operation, release gun trigger to reset unit. If the contact tip has stuck to the workpiece, release gun
trigger, turn off unit, and remove contact tip from workpiece. Check contact tip and replace if damaged. Turn on unit to continue operation.
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 . A complete Parts List is available on-line at [Link]

7-4. Troubleshooting Table

Trouble Remedy

No weld output; wire does not feed; fan Secure power cord plug in receptacle (see Section 5-4 and 5-5).
does not run; no power light.
Replace building line fuse or reset circuit breaker if open.
Place Power switch in On position (see Section 6-1).
Reset welding power source supplementary protector if open (see Section 7-2).

No weld output; wire does not feed; fan Thermostat TP1 open (overheating). Allow fan to run with gun trigger switch off; thermostat closes when
motor continues to run. unit has cooled (see Section 4-4).

Secure gun trigger plug (see Section 5-10).

Release gun trigger and cycle unit power off and back on again.

No weld output; wire feeds. Connect work clamp to get good metal to metal contact.

Check for loose connections.

Replace gun contact tip (see gun Owner’s Manual).

Check for proper polarity connections (see Section 5-9).
Check thumbscrew securing gun end to feed head adapter and tighten if necessary.

Low weld output. Connect unit to proper input voltage or check for low line voltage.

Place Power switch in On position (see Section 6-1).

Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts.
welding.
Adjust drive roll pressure (see Section 5-13).
Change to proper drive roll groove (see Section 5-11).
Readjust hub tension (see Section 5-12).
Be sure that wire is positioned in proper drive roll groove and wire is laying in the groove.
Replace contact tip if blocked (see gun Owner’s Manual). Oversized tip may be required for some wires.
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 5-11 or gun Owner’s Manual).
Replace drive roll or pressure bearing if worn or slipping (see Section 5-11).
Secure gun trigger plug (see Section 5-10).
Check and clear any restrictions at drive assembly and liner (see Section 5-11 or gun Owner’s Manual).
Release gun trigger and allow gun and motor protection circuitry to reset.
Have nearest Factory Authorized Service Agent check drive motor.
Over Temperature light is on steady. Thermostat TP1 open (overheating). Allow fan to run with gun trigger off; thermostat closes when unit has
cooled (see Section 4-4).
Over Temperature light blinking one Trigger error. Release trigger and check MIG gun for shorted trigger connection. Contact nearest Factory
time. Authorized Service Agent.

Over Temperature light blinking two Shorted output. Unit has determined welding gun has shorted to workpiece and turned off output. Release
times. trigger and check that gun is not in contact with workpiece. Contact nearest Factory Authorized Service
Agent.
Over Temperature light blinking three Motor error. Check for birds nesting at wire spool and drive assembly. Verify proper drive roll alignment
times. and tension, and that wire drive pressure assembly is closed. Contact nearest Factory Authorized
Service Agent.
Over Temperature light blinking four Unit has experienced an over-voltage condition. Contact nearest Factory Authorized Service Agent.
times.

Over Temperature light blinking five Fan tach error. Contact nearest Factory Authorized Service Agent.
times.

Over Temperature light blinking six Thermistor error. Contact nearest Factory Authorized Service Agent.
times.

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 Notes

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 SECTION 8 − ELECTRICAL DIAGRAM

Figure 8-1. Circuit Diagram

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 265 808-E

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 SECTION 9 − GMAW WELDING (MIG) GUIDELINES
9-1. Typical GMAW (MIG) Process Connections
! Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
Regulator/ close to the weld as possible.
Flowmeter

Wire Feeder/
Power Source

Gun
Shielding Gas

Gas
Workpiece

Work Clamp
GMAW1 2015−01 (GMAW Only) − Ref. 801 909-A

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

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

Material thickness determines weld

parameters. Convert Material
1/8 or 0.125 in.
Thickness to
Amperage (A)
(0.001 in. = 1 ampere)
0.125 in. = 125 A

Select Wire Size Select Wire Speed (Amperage)

Wire Size Amperage Range Wire Wire Speed

.035 in
Size Recommendation
(Approx.) 125 A based on 1/8 in.
0.023 in. 30 − 90 A
0.023 in. 3.5 in. per ampere 3.5 x 125 A = 437 ipm material thickness
0.030 in. 40 − 145 A ipm = inches per minute
0.035 in. 50 − 180 A 0.030 in. 2 in. per ampere 2 x 125 A = 250 ipm
0.035 in. 1.6 in. per ampere 1.6 x 125 A = 200 ipm

Voltage controls height and Wire speed (amperage) controls weld

width of weld bead. penetration (wire speed = burn-off rate)
Select Voltage

Low voltage: wire stubs into work

High voltage: arc is unstable (spatter)
Set voltage midway between high/low voltage

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 9-3. Holding And Positioning Welding Gun
. Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in. (13 mm)
past end of nozzle, and tip of wire is positioned correctly on seam.

1 1 Hold Gun and Control Gun

Trigger
2 Workpiece
3 3 Work Clamp
2 4 Electrode Extension (Stickout)
Solid Wire − 3/8 to 1/2 in.
(9 to 13 mm)
5 5 Cradle Gun and Rest Hand on
Workpiece
4

0°-15° 45° 0°-15°

90° 90°
45°

End View of Work Angle Side View of Gun Angle End View of Work Angle Side View of Gun Angle
GROOVE WELDS FILLET WELDS
S-0421-A

9-4. Conditions That Affect Weld Bead Shape

. Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed
(weld current), and voltage.

10° 10°

Push Perpendicular Drag

GUN ANGLES AND WELD BEAD PROFILES

Short Normal Long Short Normal Long

ELECTRODE EXTENSIONS (STICKOUT) FILLET WELD ELECTODE EXTENSIONS (STICKOUT)

Slow Normal Fast

GUN TRAVEL SPEED S-0634

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 9-5. Gun Movement During Welding
. Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps,
a weave bead or multiple stringer beads works better.

1 Stringer Bead − Steady

Movement Along Seam
2 Weave Bead − Side To Side
Movement Along Seam
1 2 3 Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.

S-0054-A

9-6. Poor Weld Bead Characteristics

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

2 3 4

S-0053-A
5

9-7. Good Weld Bead Characteristics

1 Fine Spatter
2 Uniform Bead
3 Moderate Crater During
Welding
Weld a new bead or layer for each
1 1/8 in. (3.2 mm) thickness in metals
being welded.
4 No Overlap
5 Good Penetration into Base
Metal

2 3 4

5 S-0052-B

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 9-8. Troubleshooting − Excessive Spatter

Excessive Spatter − scattering of molten metal particles that

cool to solid form near weld bead.

S-0636

Possible Causes Corrective Actions

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

Voltage too high. Select lower voltage range.

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

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

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

Dirty welding wire. Use clean, dry welding wire.

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

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

9-9. Troubleshooting − Porosity

Porosity − small cavities or holes resulting from gas pockets

in weld metal.

S-0635

Possible Causes Corrective Actions

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

Remove spatter from gun nozzle.

Check gas hoses for leaks.

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

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

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

Dirty welding wire. Use clean, dry welding wire.

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

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

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

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

9-10. Troubleshooting − Excessive Penetration

Excessive Penetration − weld metal melting through base metal

and hanging underneath weld.

Excessive Penetration Good Penetration

S-0639

Possible Causes Corrective Actions

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

Increase travel speed.

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 9-11. Troubleshooting − Lack Of Penetration

Lack Of Penetration − shallow

fusion between weld metal and
base metal.
Lack of Penetration Good Penetration
S-0638

Possible Causes Corrective Actions

Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.

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

Keep arc on leading edge of weld puddle.

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

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

Reduce travel speed.

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

9-12. Troubleshooting − Incomplete Fusion

Incomplete Fusion − failure of weld metal to fuse completely with

base metal or a preceeding weld bead.

S-0637

Possible Causes Corrective Actions

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

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

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

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

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

Keep arc on leading edge of weld puddle.

Use correct gun angle of 0 to 15 degrees.

9-13. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal

resulting in holes where no metal remains.

S-0640

Possible Causes Corrective Actions

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

Increase and/or maintain steady travel speed.

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 9-14. Troubleshooting − Waviness Of Bead

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

S-0641

Possible Causes Corrective Actions

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

Unsteady hand. Support hand on solid surface or use two hands.

9-15. Troubleshooting − Distortion

Distortion − contraction of weld metal during welding that forces

base metal to move.
Base metal moves
in the direction of
the weld bead.
S-0642

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 voltage range and/or reduce wire feed speed.

Increase travel speed.

Weld in small segments and allow cooling between welds.

Notes

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 9-16. Common GMAW (MIG) Shielding Gases
This is a general chart for common gases and where they are used. Many different combinations (mixtures) of
shielding gases have been developed over the years. The most commonly used shielding gases are listed in the
following table.

Application

Gas Short Circuiting Spray Arc Short Circuiting Spray Arc Short Circuiting
Spray Arc Steel
Steel Stainless Steel Stainless Steel Aluminum Aluminum

Argon All Positions5 All Positions

Flat & Horizontal5 Flat & Horizontal5

Argon + 1% O2
Fillet Fillet

Flat & Horizontal5 Flat & Horizontal5

Argon + 2% O2
Fillet Fillet

Flat & Horizontal5

Argon + 5% O2
Fillet

Flat & Horizontal5

Argon + 8% CO2 All Positions
Fillet

Argon + 25% Flat & Horizontal1

All Positions All Positions4
CO2 Fillet

Argon + 50%
All Positions
CO2

Flat & Horizontal1

CO2 All Positions
Fillet

Helium All Positions2

Argon + Helium All Positions2

Tri-Mix4 All Positions

1 Globular Transfer
2 Heavy Thicknesses
3 Single Pass Welding Only
4 90% HE + 7-1/2% AR + 2-1/2% CO2
5 Also for GMAW-P, All Positions

9-17. Troubleshooting Guide For Semiautomatic Welding Equipment

Problem Probable Cause Remedy
Wire feed motor operates, but Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls.
wire does not feed.
Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to match
wire size and type if necessary.

Wire spool brake pressure too high. Decrease brake pressure on wire spool.

Restriction in the gun and/or assembly. Check and replace cable, gun, and contact tip if
damaged. Check size of contact tip and cable liner,
replace if necessary.

Wire curling up in front of the Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.
wire feed rolls (bird nesting).
Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner length
and diameter, replace if necessary.

Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push gun
end into housing just enough so it does not touch wire
feed rolls.

Dirty or damaged (kinked) liner. Replace liner.

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 Problem Probable Cause Remedy
Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder.

Gas nozzle plugged. Clean or replace gas nozzle.

Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.

Restriction in gas line. Check gas hose between flowmeter and wire feeder, and
gas hose in gun and cable assembly.

Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wiring.

Gas solenoid valve not operating. Have Factory Authorized Service Agent replace gas
solenoid valve.

Incorrect primary voltage connected to welding power Check primary voltage and relink welding power source
source. for correct voltage.

Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn
drive rolls if necessary.

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

Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
welding power source.

Loose connections at the gun weld cable or work cable. Check and tighten all connections.

Gun in poor shape or loose connection inside gun. Repair or replace gun as necessary.

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 SECTION 10 − PARTS LIST
. A complete Parts List is available on-line at [Link]
10-1. Recommended Spare Parts

Item Part
No. No. Description Quantity

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

. . . . . . . . . . . . . . . . . . . . ♦087299 . . TIP, contact scr .023 wire x 1.125
. . . . . . . . . . . . . . . . . . . . ♦000067 . . TIP, contact scr .030 wire x 1.125
. . . . . . . . . . . . . . . . . . . . ♦000068 . . TIP, contact scr .035 wire x 1.125
. . . . . . . . . . . . . . . . . . . . ♦000069 . . TIP, contact scr .045 wire x 1.125
. . . . . . . . . . . . . . . . . . . . ♦194010 . . LINER, monocoil .023/.025 wire x 15ft (consisting of) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . ♦194011 . . LINER, monocoil .030/.035 wire x 15ft (consisting of) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . ♦194012 . . LINER, monocoil .035/.045 wire x 15ft (consisting of) . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 079975 . . . . O-RING, .187 ID x .103CS rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

10-2. Optional Drive Rolls

For All Feed Head Assemblies
PART NO. WIRE DIAMETER INCHES (mm)
261157 .024 (.6) and .030/.035 (.8 and .9) and .030/.035 (.8 and .9) (VK Groove)
♦220179 .024 (.6) and .030/.035 (.8 and .9) (Standard)
♦202926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove)
♦Optional

10-3. Options
PART NO. DESCRIPTION REMARKS
249040 M-150 Replacement Gun 12 ft length/.030-.035 (.8 and .9) wire size
249041 M-150 Replacement Gun 15 ft length/.030-.035 (.8 and .9) wire size

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 Notes

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 Notes

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 Effective January 1, 2016
(Equipment with a serial number preface of MG or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Call Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original * Batteries
retail purchaser that new Miller equipment sold after the effective * Bernard Guns (No Labor)
1-800-4-A-MILLER date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
for your local workmanship at the time it is shipped by Miller. THIS WARRANTY IS
EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
Miller distributor. OR IMPLIED, INCLUDING THE WARRANTIES OF * Accessory (Kits)
MERCHANTABILITY AND FITNESS. * Canvas Covers
Within the warranty periods listed below, Miller will repair or replace * Induction Heating Coils and Blankets, Cables, and
any warranted parts or components that fail due to such defects in Non-Electronic Controls
Your distributor also gives material or workmanship. Miller must be notified in writing within * M-Guns
you ... thirty (30) days of such defect or failure, at which time Miller will * MIG Guns and Subarc (SAW) Torches
provide instructions on the warranty claim procedures to be * Remote Controls and RFCS-RJ45
Service followed. If notification is submitted as an online warranty claim, the
You always get the fast, * Replacement Parts (No labor)
claim must include a detailed description of the fault and the
reliable response you * Roughneck Guns
troubleshooting steps taken to identify failed components and the
need. Most replacement cause of their failure. * Spoolmate Spoolguns
parts can be in your Miller’s True Blue® Limited Warranty shall not apply to:
Miller shall honor warranty claims on warranted equipment listed
hands in 24 hours. below in the event of such a failure within the warranty time periods. 1. Consumable components; such as contact tips,
All warranty time periods start on the delivery date of the equipment cutting nozzles, contactors, brushes, relays, work
Support to the original end-user purchaser, and not to exceed twelve months station table tops and welding curtains, or parts that
Need fast answers to the after the equipment is shipped to a North American distributor or fail due to normal wear. (Exception: brushes and
tough welding questions? eighteen months after the equipment is shipped to an International relays are covered on all engine-driven products.)
Contact your distributor. distributor. 2. Items furnished by Miller, but manufactured by others,
The expertise of the 1. 5 Years Parts — 3 Years Labor such as engines or trade accessories. These items are
distributor and Miller is * Original Main Power Rectifiers Only to Include SCRs, covered by the manufacturer’s warranty, if any.
there to help you, every Diodes, and Discrete Rectifier Modules 3. Equipment that has been modified by any party other than
step of the way. 2. 3 Years — Parts and Labor Miller, or equipment that has been improperly installed,
* Auto-Darkening Helmet Lenses (Except Classic improperly operated or misused based upon industry
Series) (No Labor) standards, or equipment which has not had reasonable
* Engine Driven Welder/Generators and necessary maintenance, or equipment which has
(NOTE: Engines are Warranted Separately by the been used for operation outside of the specifications for
Engine Manufacturer.) the equipment.
* Inverter Power Sources (Unless Otherwise Stated) MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Plasma Arc Cutting Power Sources USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Process Controllers MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Transformer/Rectifier Power Sources exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
3. 2 Years — Parts and Labor replacement; or, where authorized in writing by Miller in appropriate
* Auto-Darkening Helmet Lenses − Classic Series Only cases, (3) the reasonable cost of repair or replacement at an
(No Labor) authorized Miller service station; or (4) payment of or credit for the
* Fume Extractors − Capture 5, Filtair 400 and Industrial purchase price (less reasonable depreciation based upon actual
Collector Series 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
4. 1 Year — Parts and Labor Unless Specified Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
* Automatic Motion Devices as determined by Miller. Therefore no compensation or
* CoolBelt and CoolBand Blower Unit (No Labor) reimbursement for transportation costs of any kind will be allowed.
* Desiccant Air Dryer System TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* External Monitoring Equipment and Sensors PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Field Options REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
(NOTE: Field options are covered for the remaining DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
warranty period of the product they are installed in, CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
or for a minimum of one year — whichever is
LEGAL THEORY.
greater.)
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
* RFCS Foot Controls (Except RFCS-RJ45) IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
* Fume Extractors − Filtair 130, MWX and SWX Series TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
* HF Units CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
* ICE/XT Plasma Cutting Torches (No Labor) BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
* Induction Heating Power Sources, Coolers OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
(NOTE: Digital Recorders are Warranted Separately DEALING, INCLUDING ANY IMPLIED WARRANTY OF
by the Manufacturer.) MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* LiveArc Welding Performance Management System
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
* Load Banks MILLER.
* Motor-Driven Guns (except Spoolmate Spoolguns) Some states in the U.S.A. do not allow limitations of how long an
* PAPR Blower Unit (No Labor) implied warranty lasts, or the exclusion of incidental, indirect,
* Positioners and Controllers special or consequential damages, so the above limitation or
* Racks exclusion may not apply to you. This warranty provides specific
* Running Gear/Trailers legal rights, and other rights may be available, but may vary from
* Spot Welders state to state.
* Subarc Wire Drive Assemblies In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
* Water Coolant Systems
the extent that they may not be waived, the limitations and
* TIG Torches (No Labor) exclusions set out above may not apply. This Limited Warranty
* Wireless Remote Foot/Hand Controls and Receivers provides specific legal rights, and other rights may be available, but
* Work Stations/Weld Tables (No Labor) may vary from province to province. miller_warr 2016-01

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 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
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
For International Locations Visit
[Link]
Welding Process Handbooks
To locate a Distributor or Service Agency visit
[Link] or call 1-800-4-A-Miller

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.

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2016 Miller Electric Mfg. Co. 2016−01

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