OM-2254 219485AE

2016−01
Processes

Multiprocess Welding

Description

Arc Welding Power Source

XMT 350 CC/CV

Auto-Line ™

CE

File: MULTIPROCESS

Visit our website at

[Link]
 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
 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-3. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-4. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-6. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-1. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-2. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-3. Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-4. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-5. 115 Volts AC Duplex Receptacle And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-6. Optional Gas Valve Operation And Shielding Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-7. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-8. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6-2. Mode Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 7 − GTAW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7-1. Typical Connection For GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7-2. Scratch Start TIG Welding Mode - GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-3. Lift-Arc TIG Welding Mode - GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7-4. TIG Welding Mode - GTAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 8 − GMAW/FCAW OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . . 28
8-2. MIG Welding Mode - GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8-3. Typical Connection For Remote Control Feeder GMAW-P Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8-4. Pulsed MIG Welding Mode - GMAW-P Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8-5. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . 32
8-6. V-Sense Feeder Welding Mode - GMAW/FCAW Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
 TABLE OF CONTENTS

SECTION 9 − SMAW/CAC-A OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

9-1. Typical Connection For SMAW And CAC-A Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9-2. CC Welding Mode - SMAW/CAC-A Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9-3. Stick Welding Mode - SMAW/CAC-A Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9-4. Optional Low Open Circuit Voltage (OCV) Welding Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9-5. Alternate Configuration Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SECTION 10 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10-3. Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 11 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
WARRANTY
COMPLETE PARTS LIST − Available at [Link]
DECLARATION OF CONFORMITY
for European Community (CE marked) products.

MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).

Product/Apparatus Identification:

Product Stock Number

XMT 350 CC/CV W/AUX POWER, CE 907161012

Council Directives:
• 2014/35/EU Low Voltage
• 2014/30/EU Electromagnetic Compatibility
• 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment

Standards:
• IEC 60974­1:2012 Arc welding equipment – Part 1: Welding power sources
• IEC 60974­10:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements

Signatory:

May 12, 2015

_____________________________________ ___________________________________________
David A. Werba Date of Declaration

MANAGER, PRODUCT DESIGN COMPLIANCE

271284A
 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

 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  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.  Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and  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.  Turn off all equipment when not in use.
 Do not use worn, damaged, undersized, or repaired cables.
 Do not drape cables over your body.
ELECTRIC SHOCK can kill.
 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  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  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  Use only well-maintained equipment. Repair or replace damaged
grounded equipment is a hazard.
parts at once. Maintain unit according to manual.
 Do not touch live electrical parts.  Wear a safety harness if working above floor level.
 Keep all panels and covers securely in place.
 Wear dry, hole-free insulating gloves and body protection.
 Insulate yourself from work and ground using dry insulating mats  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.  Insulate work clamp when not connected to workpiece to prevent
 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.  Do not connect more than one electrode or work cable to any
 Use AC output ONLY if required for the welding process. single weld output terminal. Disconnect cable for process not in
use.
 If AC output is required, use remote output control if present on
unit.  Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
 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-  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!
 Do not touch hot parts bare handed.
 Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to  Allow cooling period before working on
OSHA 29 CFR 1910.147 (see Safety Standards). equipment.
 Properly install, ground, and operate this equipment according to  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.

OM-2254 Page 1
  Remove stick electrode from holder or cut off welding wire at
FUMES AND GASES can be hazardous. contact tip when not in use.
 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.
 Keep your head out of the fumes. Do not breathe the fumes.  Remove any combustibles, such as a butane lighter or matches,
 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  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.  Use only correct fuses or circuit breakers. Do not oversize or by-
 If ventilation is poor, wear an approved air-supplied respirator. pass them.
 Read and understand the Safety Data Sheets (SDSs) and the  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.  Read and understand the Safety Data Sheets (SDSs) and the
 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.
 Do not weld in locations near degreasing, cleaning, or spraying op-  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.
 Do not weld on coated metals, such as galvanized, lead, or  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.  Shut off compressed gas supply when not in use.
 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.
 Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and  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).  Implanted Medical Device wearers should consult their doctor
 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
 Use protective screens or barriers to protect others from flash, operations.
glare and sparks; warn others not to watch the arc.
 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.
 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.
 Protect compressed gas cylinders from excessive heat, mechani-
 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.  Install cylinders in an upright position by securing to a stationary
 Do not weld where flying sparks can strike flammable material. support or cylinder rack to prevent falling or tipping.
 Protect yourself and others from flying sparks and hot metal.  Keep cylinders away from any welding or other electrical circuits.
 Be alert that welding sparks and hot materials from welding can  Never drape a welding torch over a gas cylinder.
easily go through small cracks and openings to adjacent areas.
 Never allow a welding electrode to touch any cylinder.
 Watch for fire, and keep a fire extinguisher nearby.
 Never weld on a pressurized cylinder − explosion will result.
 Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.  Use only correct compressed gas cylinders, regulators, hoses,
 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  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.
 Do not weld where the atmosphere can contain flammable dust,  Keep protective cap in place over valve except when cylinder is in
gas, or liquid vapors (such as gasoline). use or connected for use.
 Connect work cable to the work as close to the welding area as  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  Read and follow instructions on compressed gas cylinders,
hazards. associated equipment, and Compressed Gas Association (CGA)
 Do not use welder to thaw frozen pipes. publication P-1 listed in Safety Standards.
OM-2254 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard. MOVING PARTS can injure.

 Do not install or place unit on, over, or near  Keep away from moving parts such as fans.
combustible surfaces.  Keep all doors, panels, covers, and guards
 Do not install unit near flammables. closed and securely in place.
 Do not overload building wiring − be sure power supply system is  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.
 Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
FALLING EQUIPMENT can injure.
 Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
 Use equipment of adequate capacity to lift and
support unit.
 If using lift forks to move unit, be sure forks are long enough to
READ INSTRUCTIONS.
extend beyond opposite side of unit.
 Read and follow all labels and the Owner’s
 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
 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.  Use only genuine replacement parts from the manufacturer.
 Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
OVERUSE can cause OVERHEATING local codes.
 Allow cooling period; follow rated duty cycle.
 Reduce current or reduce duty cycle before
starting to weld again.
 Do not block or filter airflow to unit. H.F. RADIATION can cause interference.
 High-frequency (H.F.) can interfere with radio
FLYING SPARKS can injure. navigation, safety services, computers, and
communications equipment.
 Wear a face shield to protect eyes and face.
 Have only qualified persons familiar with
 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.  The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
 Sparks can cause fires — keep flammables away. tion.
 If notified by the FCC about interference, stop using the
STATIC (ESD) can damage PC boards. equipment at once.
 Have the installation regularly checked and maintained.
 Put on grounded wrist strap BEFORE handling  Keep high-frequency source doors and panels tightly shut, keep
boards or parts. spark gaps at correct setting, and use grounding and shielding to
 Use proper static-proof bags and boxes to minimize the possibility of interference.
store, move, or ship PC boards.

MOVING PARTS can injure.

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

OM-2254 Page 3
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.

OM-2254 Page 4
 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

 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
 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.  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.
 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.  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  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  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  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  Ne pas enrouler les câbles autour du corps.
du fil, le fil, le dérouleur, le bloc de commande du  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  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.
 Ne pas toucher des porte électrodes connectés à deux machines
 Ne pas toucher aux pièces électriques sous tension. en même temps à cause de la présence d’une tension à vide dou-
 Porter des gants isolants et des vêtements de protection secs et blée.
sans trous.  N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
 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.  Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
 Ne pas se servir de source électrique à courant électrique dans les  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.
 Fixer le câble de retour de façon à obtenir un bon contact métal-
 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.
 Si l’utilisation d’une source électrique à courant électrique s’avère  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.  Ne pas raccorder plus d’une électrode ou plus d’un câble de
 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  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,  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.
OM-2254 Page 5
 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.  Déplacer toutes les substances inflammables à une distance de
 Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
 Prévoir une période de refroidissement avant soigneusement avec des protections homologués.
de travailler à l’équipement.  Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
 Ne pas toucher aux pièces chaudes, utiliser les outils recomman-  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.  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.  Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
Le soudage génère des fumées et des gaz. Leur
 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.
 Ne pas effectuer le soudage sur des conteneurs fermés tels que
 Eloigner votre tête des fumées. Ne pas respirer les fumées. des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
 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  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.  Brancher le câble de masse sur la pièce le plus près possible de la
 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-
 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  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.  En cas de non utilisation, enlever la baguette d’électrode du porte-
 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  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.
 Ne pas souder dans des endroits situés à proximité d’opérations  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-  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.
 Ne pas souder des métaux munis d’un revêtement, tels que l’acier  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  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.  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.  Le soudage, l’écaillement, le passage de la pièce à
 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).  Porter des lunettes de sécurité avec écrans latéraux ou un écran
 Porter des lunettes de sécurité avec écrans latéraux même sous facial.
votre casque.
 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.
 Porter un équipement de protection pour le corps fait d’un matériau  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  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.
 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
 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.
OM-2254 Page 6
  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  Ne jamais placer une torche de soudage sur une bouteille à gaz.
affecter l’ouïe.  Une électrode de soudage ne doit jamais entrer en contact avec
 Porter des protections approuvées pour les une bouteille.
oreilles si le niveau sonore est trop élevé.  Ne jamais souder une bouteille pressurisée − risque d’explosion.
LES BOUTEILLES peuvent exploser  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  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.  Le couvercle du détendeur doit toujours être en place, sauf lorsque
la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
 Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des  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.
 Placer les bouteilles debout en les fixant dans un support station-  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

 Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-
Risque D’INCENDIE OU D’EXPLOSION. placer ou expédier des cartes de circuits imprimes.
 Ne pas placer l’appareil sur, au-dessus ou Les PIÈCES MOBILES peuvent
à proximité de surfaces inflammables. causer des blessures.
 Ne pas installer l’appareil à proximité de pro-
duits inflammables.  Ne pas s’approcher des organes mobiles.
 Ne pas surcharger l’installation électrique − s’assurer que  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.  Ne pas appuyer sur la gâchette avant d’en
 Utiliser l’anneau de levage uniquement pour avoir reçu l’instruction.
soulever l’appareil, NON PAS les chariots, les  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
 Utiliser un équipement de levage de capacité suffisante pour lever soudage.
l’appareil.
 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.
 Tenir l’équipement (câbles et cordons) à distance des véhicules  Ne pas utiliser l’appareil de soudage pour
mobiles lors de toute opération en hauteur. charger des batteries ou faire démarrer des
 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.
 Prévoir une période de refroidissement ; res-
pecter le cycle opératoire nominal.  S’abstenir de toucher des organes mobiles tels
 Réduire le courant ou le facteur de marche que des ventilateurs.
avant de poursuivre le soudage.  Maintenir fermés et verrouillés les portes,
 Ne pas obstruer les passages d’air du poste. panneaux, recouvrements et dispositifs de protection.
 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.
 Remettre les portes, panneaux, recouvrements ou dispositifs de
 Porter un écran facial pour protéger le visage et protection quand l’entretien est terminé et avant de rebrancher
les yeux. l’alimentation électrique.
 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.  Lire et appliquer les instructions sur les
 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-  N’utiliser que les pièces de rechange recommandées par le
constructeur.
cuits imprimés.
 Effectuer l’installation, l’entretien et toute intervention selon les
 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.
OM-2254 Page 7
 LE RAYONNEMENT HAUTE LE SOUDAGE À L’ARC risque de
FRÉQUENCE (H.F.) risque de provoquer des interférences.
provoquer des interférences.
 L’énergie électromagnétique risque de
 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.
 Veiller à ce que tout l’équipement de la zone de soudage soit com-
patible électromagnétiquement.
 Demander seulement à des personnes qualifiées familiarisées avec  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).
 L’utilisateur est tenu de faire corriger rapidement par un électricien
 Veiller à souder à une distance de 100 mètres de tout équipement
qualifié les interférences résultant de l’installation. électronique sensible.
 Si le FCC signale des interférences, arrêter immédiatement l’appareil.  Veiller à ce que ce poste de soudage soit posé et mis à la terre
 Effectuer régulièrement le contrôle et l’entretien de l’installation. conformément à ce mode d’emploi.
 En cas d’interférences après avoir pris les mesures précédentes,
 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.
OM-2254 Page 8
  A complete Parts List is available at [Link]

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

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

Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05

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

Safe2 2012−05

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

Safe3 2012−05

Disconnect input plug or power before working on machine.

Safe5 2012−05

Keep your head out of the fumes.

Safe6 2012−05

Use forced ventilation or local exhaust to remove the fumes.

Safe8 2012−05

Use ventilating fan to remove fumes.

Safe10 2012−05

Keep flammables away from welding. Do not weld near flammables.

Safe12 2012−05

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Safe14 2012−05

OM-2254 Page 9
  A complete Parts List is available at [Link]

Do not weld on drums or any closed containers.

Safe16 2012−05

Do not remove or paint over (cover) the label.

Safe20 2012−05

Disconnect input plug or power before working on machine.

Safe30 2012−05

Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.

Safe27 2012−05

Always wear long sleeves and button your collar when servicing unit.

Safe28 2012−05

After taking proper precautions as shown, connect power to unit.

Safe29 2012−05

Do not use one handle to lift or support unit.

Safe31 2012−05

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

Safe38 2012−05

Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

Become trained and read the instructions before working on the

machine or welding.

Safe40 2012−05

V Hazardous voltage remains on input capacitors after power is turned

V off. Do not touch fully charged capacitors. Always wait 60 seconds
after power is turned off before working on unit, OR check input ca-
pacitor voltage, and be sure it is near 0 before touching any parts.
>60s V Safe43 2012−05

= < 60° Always lift and support unit using both handles. Keep angle of lifting
device less than 60 degrees.
Use a proper cart to move unit.

Safe44 2012−05

OM-2254 Page 10
  A complete Parts List is available at [Link]

3-2. Miscellaneous Symbols And Definitions

A Amperage
Negative
IP Degree Of
Protection
Inductance
Panel Lift-Arc Trigger
Hold Operation
(GTAW)
Foot Control
Alternating
Current (AC) Maximum Effec-
I1eff tive Supply Cur-
rent
V Voltage Gas Metal Arc
Welding (GMAW)
Voltage Sensing
On Feeder

Voltage Input
U2 Conventional
Load Voltage
Output

Protective Earth
(Ground)
I2 Rated Welding
Current Off

Single Phase Direct Current

Line Connection (DC)

Increase Constant Current

Three Phase
Static Frequency
Converter- Circuit Breaker
Transformer- Arc Force
Rectifier
Gas Tungsten Arc
Welding
X Duty Cycle
U0 Rated No Load
Voltage (Average)
Positive

% Percent
Constant Voltage
Hz Hertz

Three Phase Pulsed

Shielded Metal
Lift-Arc Operation
(GTAW)
Arc Welding
(SMAW) I1max Rated Maximum
Supply Current

Remote
U1 Primary Voltage Scratch Start TIG

OM-2254 Page 11
  A complete Parts List is available 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 the rear. 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 5-7 and 5-8 for information on
connecting input power.

Input Rated Voltage Amperage Max. RMS Amps Input at Rated Load Output, KVA KW
Power Output Range Range in Open-Circuit 50/60 Hz 3-Phase at NEMA Load Volt-
in CV CC Mode Voltage ages and Class I Rating
Mode
230 V 380 V 400 V 460 V

3-Phase 350 A at 34 10−38 V 5−425 A 75 VDC 36.1 22.3 20.6 17.8 14.2 13.6
VDC, 60%
Duty Cycle

*See Section 4-5 for Duty Cycle Rating.

4-3. Dimensions And Weight

Hole Layout Dimensions A
E
A 11-3/4 in. (298 mm)
F 24 in.
G
(610 mm)
B 1-11/16 in. (42 mm)

C 15-3/4 in. (400 mm) 17 in.

(432 mm)
D 19-3/32 in. (485 mm)

E 8-11/16 in. (221 mm) D

C
F 1-17/32 in. (39 mm)

G 1/4-20 UNC -2B thread

12-1/2 in.
(318 mm)
Weight

B
93.5 lb (42.4 kg)
804 801-A

4-4. Environmental Specifications

A. IP Rating
IP Rating
IP23
This equipment is designed for outdoor use. It may be stored, but is not intended to be used
for welding outside during precipitation unless sheltered.
IP23 2014−06

B. Information On Electromagnetic Fields (EMF)

! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.

 The EMF assessment on this equipment was conducted at 0.5 meter.

 At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10

OM-2254 Page 12
  A complete Parts List is available at [Link]

C. Information On Electromagnetic Compatibility (EMC)

! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con-
ducted as well as radiated disturbances.
This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Zmax at the point of common coupling is less than 46.39 mW (or the short−circuit power Ssc is greater than
3,449,293 VA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if
necessary, that the system impedance complies with the impedance restrictions.
ce-emc 1 2014-07

4-5. Duty Cycle And Overheating

Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, output stops, a
Help message is displayed and
cooling fan runs. Wait fifteen min-
utes for unit to cool. Reduce amper-
age or voltage, or duty cycle before
welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.

500
425
400
WELDING AMPERES

350
300
THREE PHASE
250 OPERATION

200

150

100
10 15 20 25 30 40 50 60 70 80 90 100
% DUTY CYCLE

60% Duty Cycle

6 Minutes Welding 4 Minutes Resting

Overheating
0 A or V

15
OR
Minutes Reduce Duty Cycle
Ref. 219 523-A

OM-2254 Page 13
  A complete Parts List is available at [Link]

4-6. Volt-Ampere Curves

A. CC Mode Volt-ampere curves show minimum

and maximum voltage and amper-
age output capabilities of welding
100 power source. Curves of other set-
90 tings fall between curves shown.

80
70
60
VOLTS

50 SMAW GTAW
MAX MAX
40
30 GTAW
SMAW
80A
MN
20 0% ARC
25% CONTROL

10 50%
75%
100%
0
0 100 200 300 400 500
AMPERAGE
B. CV Mode
100

90

80

70

60
VOLTS

50
MAX
40

30

20
MIN
10

0
0 100 200 300 400 5 00
AMPERAGE
217 836-A / 217 837-B

Notes

OM-2254 Page 14
  A complete Parts List is available at [Link]

SECTION 5 − INSTALLATION

5-1. Selecting A Location

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

OR 3

Location And Airflow 4 ! Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1 Lifting Forks
Extend forks beyond opposite side
18 in. of unit.
(460 mm) 2 Lifting Handles
Use handles to lift unit.
3 Hand Cart
Use cart or similar device to move
unit.
4 Line Disconnect Device
Locate unit near correct input
power supply.
18 in.
(460 mm)

loc_med 2015-04

Notes

OM-2254 Page 15
  A complete Parts List is available at [Link]

5-2. Selecting Cable Sizes*

NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60%
60 − 100%
Welding Duty 10 − 100% Duty Cycle
Duty Cycle
Amperes Cycle AWG (mm2)
AWG (mm2)
AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95)
600 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120) 3x4/0 (3x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-L 2015−02

5-3. Weld Output Terminals

! Turn off power before connecting
to weld output terminals.
! Do not use worn, damaged, un-
dersized, or repaired cables.
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal

 See Sections 7-1 thru 9-1 for stan-

dard connection diagrams.

Ref. 803 692-C / output term1 2015−02

OM-2254 Page 16
  A complete Parts List is available at [Link]

5-4. Remote 14 Receptacle Information

Socket* Socket Information

A 24 volts AC. Protected by supplementary protect-

A J 24 VOLTS AC or CB2.
K I
B
B Contact closure to A completes 24 volts AC
C L N H
contactor control circuit.
D M G
E F C Output to remote control; 0 to +10 volts DC, +10
volts DC in MIG mode.

REMOTE D Remote control circuit common.

OUTPUT
CONTROL E 0 to +10 volts DC input command signal from
remote control.

M CC/CV select

F Current feedback; +1 volt DC per 100 weld am-

A/V peres.
AMPERAGE
VOLTAGE H Voltage feedback; +1 volt DC per 10 weld volts.

G Circuit common for 24 volts AC circuits.

GND
K Chassis common.

*The remaining sockets are not used.

5-5. 115 Volts AC Duplex Receptacle And Supplementary Protectors

1 115 V 10 Amp. AC
Receptacle
2 Supplementary Protector CB1
3 Supplementary Protector CB2
CB1 protects duplex receptacle
from overload.
1
CB2 protects 24 volts AC portion of
Remote 14 receptacle from
overload.
Press button to reset supplement-
ary protector.

2 3

Ref. 803 879-C

OM-2254 Page 17
  A complete Parts List is available at [Link]

5-6. Optional Gas Valve Operation And Shielding Gas Connection

Obtain gas cylinder and chain to
running gear, wall, or other station-
ary support so cylinder cannot fall
and break off valve.
1 Cylinder
2 Regulator/Flowmeter
4 Install so face is vertical.
3 Gas Hose Connection
GAS IN Fitting has 5/8-18 right-hand
threads. Obtain and install gas
hose.
4 Gas In Fitting
2
5 Gas Out Fitting
The Gas In and Gas Out fittings
have 5/8-18 right-hand threads.
Obtain proper size, type, and length
hose and make connections as fol-
lows:
Connect hose from shielding gas
supply regulator/flowmeter to Gas
In fitting.
Connect hose coupler to torch.
Connect one end of gas hose to
hose coupler. Connect remaining
end of gas hose to Gas Out fitting.
Operation
3 The gas solenoid controls gas flow
during the TIG process as follows:
1
Remote TIG
Gas flow starts with remote contac-
tor on.
Gas flow stops at end of post−flow
if current was detected, or with re-
mote contactor off if no current was
detected.
Lift−Arc Trigger Hold TIG
Gas flow starts when output switch
is depressed.
Gas flow stops at end of post−flow.
Scratch Start TIG
5 Gas flow starts when current is de-
tected.
Gas flow stops at end of post−flow.
GAS OUT Post−flow time is factory set to 5
seconds per 100 amps of weld cur-
rent. The minimum post−flow time
is 5 seconds. The maximum post−
flow is 20 seconds (post flow set-
tings are not adjustable by the end
user).

Ref. 803 705-B / Ref. 803 879-C

OM-2254 Page 18
  A complete Parts List is available at [Link]

5-7. Electrical Service Guide Elec Serv 2014−01

NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input
voltage.

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

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.
50/60 Hz Three Phase
Input Voltage (V) 230 380 400 460
Input Amperes (A) At Rated Output 36.1 22.3 20.6 17.8
Max Recommended Standard Fuse Rating In
Amperes 1
Time-Delay Fuses 2 40 25 25 20
Normal Operating Fuses 3 50 30 30 25
Min Input Conductor Size In AWG 4 10 12 12 14
Max Recommended Input Conductor Length In 96 158 175 150
Feet (Meters) (29) (48) (53) (46)
Min Grounding Conductor Size In AWG 4 10 12 12 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.

Notes

OM-2254 Page 19
  A complete Parts List is available at [Link]
5-8. Connecting 3-Phase Input Power

= GND/PE Earth Ground

L1
3 L2 5

6 L3

Tools Needed:

Input2 2012−05 − Ref. 803 766-C / Ref. 802 136-A / Ref. 803 879-B

OM-2254 Page 20
  A complete Parts List is available at [Link]

5-8. Connecting 3-Phase Input Power (Continued)

! Installation must meet all National and voltage available at site. This unit can be con- 5 Input Conductors (L1, L2 And L3)
Local Codes − have only qualified per- nected to any input power between 208 and 6 Disconnect Device Line Terminals
sons make this installation. 575 VAC without removing cover to relink the
power source. Connect green or green/yellow grounding
! Disconnect and lockout/tagout input conductor to disconnect device grounding ter-
power before connecting input con- See rating label on unit and check input volt- minal first.
ductors from unit. Follow established age available at site.
procedures regarding the installation Connect input conductors L1, L2, and L3 to
and removal of lockout/tagout For Three-Phase Operation disconnect device line terminals.
devices. 7 Over-Current Protection
1 Input Power Cord.
! Always connect green or green/yellow 2 Disconnect Device (switch shown in the
Select type and size of over-current protec-
conductor to supply grounding termi- tion using Section 5-7 (fused disconnect
OFF position)
nal first, and never to a line terminal. switch shown).
3 Green Or Green/Yellow Grounding
NOTICE − The Auto-Line circuitry in this unit Conductor Close and secure door on disconnect device.
automatically adapts the power source to the Follow established lockout/tagout procedures
primary voltage being applied. Check input 4 Disconnect Device Grounding Terminal to put unit in service.

Input2 2012−05

Notes

Work like a Pro!

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

OM-2254 Page 21
  A complete Parts List is available at [Link]

SECTION 6 − OPERATION

6-1. Front Panel Controls

2 3 4

1 7 5

10

9
6
8
803 692-C /242 020-A

 Weld process operation sections de- values after arc initiation and remains dis-
played for approximately three seconds
set towards maximum, “wetness” (puddle
fluidity) increases.
scribe functionality of the identified items
after the arc is broken.
(See Sections 7-2 thru 9-3). For self-shielding wires (FCAW) adjust arc
4 Adjust Control control to FCAW setting.
 The fan motor is thermostatically con- 5 Arc Control
trolled and only runs when cooling is When Pulsed MIG or one of the TIG modes is
needed. Control adjusts Dig when Stick or CC mode is selected, this control is not functional.
selected on mode switch. When set towards 6 Power Switch
1 Remote 14 Receptacle minimum, short-circuit amperage at low arc
For remote control, make connections to Re- 7 Mode Switch
voltage is the same as normal welding
mote 14 receptacle. In TIG and STICK modes amperage. The Mode switch setting determines both the
the remote control is a percent of V/A Adjust process and output On/Off control (see Sec-
When set towards maximum, short-circuit
control setting (value selected on V/A Adjust tion 6-2).
amperage is increased at low arc voltage to
is maximum available on remote). In the MIG For Air Carbon Arc (CAC-A) cutting and goug-
assist with arc starts as well as reduce stick-
mode, remote control provides full range of ing, place switch in Stick position. For best re-
ing while welding.
unit output regardless of V/A Adjust control
sults, place Arc Control in the maximum posi-
setting. Select setting best suited for application.
tion.
2 Left Display Control adjusts inductance when MIG or 8 Weld Output Terminal (−)
3 Right Display V-Sense Feeder position is selected on the
mode switch. Inductance (0-100%) deter- 9 Optional Gas Valve Knockout
 The meters display the actual weld output mines the “wetness” of the weld puddle. When 10 Weld Output Terminal (+)

OM-2254 Page 22
  A complete Parts List is available at [Link]

6-2. Mode Switch Settings

Switch Position Process Output Control Panel Adjust Remote Adjust

Scratch Start TIG GTAW Electrode Hot Amps % Panel Amps

Lift-Arc TIG GTAW Electrode Hot Amps % Panel Amps

TIG GTAW Remote 14 Amps % Panel Amps

MIG GMAW Remote 14 Volts Volts

Pulsed MIG GMAW-P* Remote 14 N/A Arc Length (0−100)

SMAW
CC Remote 14 Amps % Panel Amps
CAC-A

SMAW
Stick Electrode Hot Amps % Panel Amps**
CAC-A

V-Sense Feeder GMAW Electrode Hot Volts Volts

*Requires an external pulsing device.

**See Section 9-5 Alternate Configuration Functions

Notes

OM-2254 Page 23
  A complete Parts List is available at [Link]

SECTION 7 − GTAW OPERATION

7-1. Typical Connection For GTAW Process

3
2
6

8
9

264 339-A

! Turn off power before making con- 3 Remote 14 Receptacle 6 Gas Out Connection (Optional)
nections. Connect desired remote control to Remote 7 Negative (−) Weld Output Terminal
14 receptacle if required.
1 Foot Control 8 TIG Torch
4 Gas In Connection (Optional)
2 Positive (+) Weld Output Terminal 5 Gas Cylinder 9 Workpiece

OM-2254 Page 24
  A complete Parts List is available at [Link]

7-2. Scratch Start TIG Welding Mode - GTAW Process

2 3 4

8 4.5 85

242 020-A
1

! Weld terminals are energized at all Setup Operation

times in Scratch Start TIG welding For typical system connections refer to The Adjust Control is used to set desired
mode. Section 7-1. preset amperage.
1 Mode Switch Rotate Mode Switch to SCRATCH START  If a remote control is used for amper-
TIG position as shown. age adjustment, the adjustment will
2 Left Display
The open circuit voltage is shown in the Left function as a percentage of the preset
3 Right Display Display. Preset amperage is shown in the amperage.
4 Adjust Control Right Display.
 For best results, gently scratch the
tungsten electrode to the work to initi-
ate an arc. To minimize arc flare at the
end of the weld, pull back the electrode
quickly to extinguish the arc.

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7-3. Lift-Arc TIG Welding Mode - GTAW Process

2 3 4 5 6

1 3. 5 85

242 020-A
1

1−2
“Touch” Seconds
8
7

Do NOT Strike Like A Match!

! Weld terminals are energized at all Rotate Mode Switch to LIFT-ARC TIG posi- welding, momentarily depress output
times in Lift Arc TIG welding mode. tion as shown. switch and output will shut off.
1 Mode Switch The preset amperage is shown in the Right
2 Left Display
Display with the Amps Indicator lit.  If a remote control is used for amper-
Operation age adjustment, the adjustment will
3 Volts Indicator function as a percentage of the preset
The Adjust Control is used to set desired amperage.
4 Right Display
preset amperage.
5 Amps Indicator
6 Adjust Control
A remote control is required to turn on the  For best results, firmly touch the tung-
weld output. sten electrode to the workpiece at the
7 Workpiece To start welding, momentarily depress out- weld start point. Hold electrode to
8 Tungsten Electrode put switch. Touch tungsten electrode to workpiece for 1-2 seconds, and lift
workpiece at weld start point. Slowly lift electrode. An arc will form when the
Setup
electrode. An arc will form when electrode electrode is lifted. To minimize arc flare
For typical system connections refer to is lifted. If welding arc is not established at the end of the weld, pull back the
Section 7-1. within 3 seconds, output will turn off. To stop electrode quickly to extinguish the arc.

OM-2254 Page 26
  A complete Parts List is available at [Link]

7-4. TIG Welding Mode - GTAW Process

2 3 4

85

242 020-A
1

! Weld terminals are energized Setup Operation

through the remote control in TIG For typical system connections refer to The Adjust Control is used to set desired
welding mode. Section 7-1. preset amperage.
1 Mode Switch Rotate Mode Switch to TIG position as A remote control is required to turn on the
shown. weld output.
2 Left Display
3 Right Display
The preset amperage is shown in the Right
Display.
 If the remote control has an amperage
4 Adjust Control adjustment, the adjustment will func-
tion as a percentage of the preset am-
perage.
 For best results, gently scratch the
tungsten electrode to the work to initi-
ate an arc. To minimize arc flare at the
end of the weld, pull back the electrode
quickly to extinguish the arc.

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SECTION 8 − GMAW/FCAW OPERATION

8-1. Typical Connection For Remote Control Feeder GMAW/FCAW Process

264 343-A

! Turn off power before making 5 Workpiece Use of shielding gas is dependant on Wire
connections. Type.
6 Gun
1 Remote 14-Receptacle
7 Wire Feeder
 The connection diagram illustrates
2 Positive (+) Weld Output Terminal DCEP (reverse polarity) suitable for all
8 Gas Hose wires except self-shielded FCAW. The
3 Negative (−) Weld Output Terminal majority of self-shielded FCAW wires
4 Ground Cable to Workpiece 9 Gas Cylinder require DCEN (straight polarity).

OM-2254 Page 28
  A complete Parts List is available at [Link]

8-2. MIG Welding Mode - GMAW/FCAW Process

2 3 4

2 5.0

242 020-A
1

! Weld terminals are energized Rotate Mode Switch to MIG position as has a voltage control. This voltage con-
through the remote control in MIG shown. trol will override the Adjust Control of
welding mode. preset voltage on the welding power
The preset voltage is shown in the Left Dis- source.
1 Mode Switch play.
2 Left Display Arc Control (Inductance)
Operation
3 Right Display Rotate Arc Control to select desired induc-
4 Adjust Control The Adjust Control is used to set desired tance setting from 0 to 100. Use lower in-
preset voltage. ductance settings to stiffen the arc and re-
Setup
duce puddle fluidity. Use higher inductance
For typical system connections refer to  The preset voltage can be adjusted re- settings to soften the arc and increase
Section 8-1. motely at the wire feeder if the feeder puddle fluidity.

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8-3. Typical Connection For Remote Control Feeder GMAW-P Process

2
10

264 347-A

! Turn off power before making 6 Workpiece  The connection diagram illustrates
connections. 7 Gun DCEP (reverse polarity) suitable for all
1 Optima - External Pulsing Device 8 Wire Feeder wires except self-shielded FCAW. The
2 Remote 14-Receptacle 9 Gas Hose majority of self-shielded FCAW wires
3 Positive (+) Weld Output Terminal 10 Gas Cylinder require DCEN (straight polarity). Flux
cored wires are not pulsed. No pulse
4 Negative (−) Weld Output Terminal Use of shielding gas is dependant on Wire program available for FCAW.
5 Ground Cable to Workpiece Type.

OM-2254 Page 30
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8-4. Pulsed MIG Welding Mode - GMAW-P Process

2 3 4

P P.P PPP

242 020-A
1

! Weld terminals are energized 4 Adjust Control Left and Right Display will show PPP PPP.
through the remote control in Setup Operation
Pulsed MIG welding mode.
For typical system connections refer to This unit requires an external pulsing
1 Mode Switch Section 8-3. device, like an Optima to pulse MIG weld.
2 Left Display Rotate Mode Switch to PULSED MIG posi- See Optima owner’s manual for more in-
3 Right Display tion as shown. formation.

OM-2254 Page 31
  A complete Parts List is available at [Link]

8-5. Typical Connection For Voltage-Sensing Feeder GMAW/FCAW Process

10

8
3

264 348-A

! Turn off power before making con- 6 Gun Use of shielding gas is dependant on Wire
nections. Type.
7 Gun Trigger Receptacle
1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal 8 Wire Feeder  The connection diagram illustrates
3 Ground Cable to Workpiece DCEP (reverse polarity) suitable for all
9 Gas Hose wires except self-shielded FCAW. The
4 Workpiece majority of self-shielded FCAW wires
5 Voltage Sensing Clamp 10 Gas Cylinder require DCEN (straight polarity).

OM-2254 Page 32
  A complete Parts List is available at [Link]

8-6. V-Sense Feeder Welding Mode - GMAW/FCAW Process

2 3 4

2 5.0

242 020-A
1

! Weld terminals are energized at all to Section 8-5.  The Left Display toggling momentarily
times in V-Sense Feeder welding pauses while the preset voltage is ad-
mode. Rotate Mode Switch to V-SENSE FEEDER
position as shown. justed.
1 Mode Switch Arc Control (Inductance)
2 Left Display The Left Display toggles between open cir-
cuit voltage and preset voltage. Rotate Arc Control to select desired induc-
3 Right Display tance setting from 0 to 100. Use lower in-
4 Adjust Control Operation ductance settings to stiffen the arc and re-
duce puddle fluidity. Use higher inductance
Setup
The Adjust Control is used to set desired settings to soften the arc and increase
For typical system setup connections refer preset voltage. puddle fluidity.

OM-2254 Page 33
  A complete Parts List is available at [Link]

SECTION 9 − SMAW/CAC-A OPERATION

9-1. Typical Connection For SMAW And CAC-A Process

3 4

6
2
1

264 349-A

! Turn off power before making con- cutting torch to to positive weld output ter- Connect desired remote control to remote
nections. minal. 14 receptacle as required.
1 Electrode Holder 2 Electrode Holder 5 Compressed Air LIne
(Carbon Arc) 3 Positive (+) Weld Output Terminal 6 Negative (−) Weld Output Terminal
For CAC-A process connect carbon arc 4 Remote 14 Receptacle 7 Workpiece

OM-2254 Page 34
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9-2. CC Welding Mode - SMAW/CAC-A Process

2 3

85

242 020-A
1

! Weld terminals are energized Operation Arc Control (Dig)

through the remote control in CC The Adjust Control is used to set desired Rotate Arc Control to select desired dig set-
welding mode. preset amperage. ting from 0 to 100.
A remote control is required to turn on the
Dig control allows the arc characteristics,
1 Mode Switch weld output.
soft versus stiff, to be changed for specific
 If the remote control has an amperage applications and electrodes. Lower the dig
2 Right Display adjustment, the adjustment will func- setting for smooth running electrodes like
tion as a percentage of the preset am- E7018 and increase the dig setting for stiff-
3 Adjust Control perage. When Configuration 3 is se- er, more penetrating electrodes like E6010.

Setup
lected, remote control preset will be
displayed in the amperage window.  Use this mode for Air Carbon Arc
See section 9-5 for more information (CAC−A) cutting and gouging. For best
regarding Alternate Configuration results, adjust Arc Control to maxi-
For typical system connections refer to mum.
Functionality.
Section 9-1.
Adaptive Hot Start automatically increases
welding amperage at the start of a weld.
Rotate Mode Switch to CC position as This helps eliminate electrode sticking dur-
shown. ing arc initiation.
 For best results at the end of the weld,
The preset amperage is shown in the Right pull back the electrode quickly to extin-
Display with the Amps Indicator lit. guish the arc.

OM-2254 Page 35
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9-3. Stick Welding Mode - SMAW/CAC-A Process

2 3 4

8 4.5 85

242 020-A
1

! Weld terminals are energized at all The open circuit voltage is shown in the Left Arc Control (Dig)
times in Stick welding mode. Display and the preset amperage is shown Rotate Arc Control to select desired dig set-
in the Right Display. ting from 0 to 100.
1 Mode Switch
Operation Dig control allows the arc characteristics,
2 Left Display
The Adjust Control is used to set desired soft versus stiff, to be changed for specific
3 Right Display preset amperage. applications and electrodes. Lower the dig
4 Adjust Control If a remote control is plugged into the setting for smooth running electrodes like
14−Pin receptacle, the remote will be a per- E7018 and increase the dig setting for stiff-
Setup
centage of the preset amperage. When er, more penetrating electrodes like E6010.
For typical system connections refer to
Section 9-1.
Configuration 2 or Configuration 3 are ac-
tive, remote controls will be ignored and
 Use this mode for Air Carbon Arc
(CAC−A) cutting and gouging. For best
Rotate Mode Switch to STICK position as amperage will operate in panel only control. results, adjust Arc Control to maxi-
shown. See section 9-5 for more information re- mum.
garding Alternate Configurations.
Adaptive Hot Start automatically increases
welding amperage at the start of a weld.
This helps eliminate electrode sticking dur-
ing arc initiation.
 For best results at the end of the weld,
pull back the electrode quickly to extin-
guish the arc.

OM-2254 Page 36
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9-4. Optional Low Open Circuit Voltage (OCV) Welding Modes

Low OCV Operation

The unit can be optionally configured for low open circuit voltage (OCV) operation in Stick and Scratch Start TIG modes. When the unit is config-
ured for low OCV operation only a low sensing voltage (approximately 15 VDC) is present between the electrode and the workpiece prior to the
electrode touching the workpiece. Consult a Factory Authorized Service Agent for information regarding how to configure unit for low OCV welding
operation.

9-5. Alternate Configuration Functions

There are 3 ways that the remote control can be configured to operate on this machine. The configuration of the meters can be changed by placing
the process selection switch into Stick mode and turning the output on and off 3−5 times within a few seconds, this can be done by triggering
a feeder or by activating the output on−off switch on a remote control. The amperage window will briefly display what mode is selected before
returning to preset display

Configuration 1 is the default that the unit leaves the facto-

C1 ry set for. Stick mode recognizes a remote plugged into

the preset output set at the panel, CC mode displays pre-
set panel control instead of the percentage of the remote.

Configuration 2 changes Stick modes remote operation.

C2
When configuration 2 is selected Stick mode operates in
Panel Only control, meaning any remote control that is
plugged into the remote 14 control will be ignored and
have no effect on the output. When Stick mode is active,
a decimal point will be displayed in the amperage window.

Configuration 3 changes how the display works in the CC

mode. When configuration 3 is selected the amperage

C3 window will display the percentage of preset amperage

being set from the remote amperage control, the panel will
set the maximum amperage. When CC mode is active, a
decimal point will be displayed in the amperage window.

OM-2254 Page 37
  A complete Parts List is available at [Link]

SECTION 10 − MAINTENANCE & TROUBLESHOOTING

10-1. Routine Maintenance

! Disconnect power  Maintain more often during

before maintaining. severe conditions.

 = Check  = Change  = Clean = Replace

Every
3 Replace
Damaged Replace Cracked
Months
Or Torch Body
Unreadable  
 Labels

Repair Or Replace
Cracked Cables
 

Repair Or Replace
Cracked Cables And
Cords
 

Every
6 Clean
Drive Blow Out Or
Months Vacuum Inside
Rolls
 

10-2. Blowing Out Inside Of Unit

! Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.

Ref. 803 879-C

OM-2254 Page 38
  A complete Parts List is available at [Link]

10-3. Help Displays

 All directions are in reference to the front

of the unit. All circuitry referred to is lo-
cated inside the unit.

Help 1 Display

HELP 1 Indicates a malfunction in the primary power

circuit. If this display is shown, contact a Fac-
tory Authorized Service Agent.

Help 2 Display

HELP 2 Indicates a malfunction in the thermal protec-

tion circuitry. If this display is shown, contact
a Factory Authorized Service Agent.

Help 3 Display

HELP 3 Indicates the left side of the unit has over-

heated. The unit has shut down to allow the
fan to cool it (see Section 4-5). Operation will
continue when the unit has cooled.

Help 5 Display

HELP 5 Indicates the right side of the unit has over-

heated. The unit has shut down to allow the
fan to cool it (see Section 4-5). Operation will
continue when the unit has cooled.

Help 6 Display

HELP 6 Indicates operation at maximum input cur-

rent. The unit has a maximum allowable input
current limit. As the line voltage decreases,
the required input current increases. If the line
voltage is too low, the output power is limited
by the input current. When this limit is
reached, the unit automatically reduces out-
put power to continue operation. If this display
is shown, have a qualified electrician check
the input voltage.

Help 8 Display

HELP 8 Indicates a malfunction in the secondary

power circuit of the unit. If this display is
shown, contact a Factory Authorized Service
Agent.

Help 25 Display

HELP 25 Indicates machine has reached duty cycle

limits (see Section 4-5). Unit must be left on
to power the fan for cooling. Operation will
continue when unit has cooled.

OM-2254 Page 39
  A complete Parts List is available at [Link]

10-4. Troubleshooting

Trouble Remedy

No weld output; unit completely inop- Place line disconnect switch in On position (see Section 5-8).
erative.

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-8).

Check for proper input power connections (see Section 5-8).

No weld output; meter display On. Input voltage outside acceptable range of variation (see Sections 5-7, 5-8).

Check, repair, or replace remote control.

Unit overheated. Allow unit to cool with fan On (see Section 4-5).

Erratic or improper weld output. Use proper size and type of weld cable (see Section 5-2).

Clean and tighten all weld connections.

Check for correct polarity.

No 115 volts AC output at duplex Reset supplementary protector CB1 (see Section 5-5).
receptacle.

No 24 volts AC output at Remote 14 Reset supplementary protector CB2 (see Section 5-5).
receptacle.

Notes

OM-2254 Page 40
  A complete Parts List is available at [Link]

Notes

OM-2254 Page 41
 SECTION 11 − ELECTRICAL DIAGRAM

Figure 11-1. Circuit Diagram

OM-2254 Page 42
 271 739-A

OM-2254 Page 43
Notes
 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)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
for your local 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
 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