OM-221 694B
2006−07
Processes
Multiprocess Welding
Description
Arc Welding Power Source
R
XMC 4000
400 Volts
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INDICE
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Manufacturer’s Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturer’s Rating Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
3
3
4
4
3-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3-5. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-6. Remote 7 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-7. Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-8. Filling Coolant Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-9. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3-10. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-2. Switching On the Unit and Recalling Factory Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-3. Welding Process Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-4. Wire Type Selection In Synergic MIG Or Synergic Pulsed MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . 17
4-5. Wire Diameter Selection In Synergic MIG Or Synergic Pulsed MIG Welding . . . . . . . . . . . . . . . . . . . . 17
4-6. Trigger Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-7. Inductance, Material Thickness, And Gas Selection In Manual MIG, Synergic MIG, And Synergic Pulsed
MIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-8. Jog And Purge Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4-9. Setting And Using Weld Parameters From Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-10. Setup Push Button And Advanced Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4-11. Preparing Unit For MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-12. Selecting Manual MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4-13. Manual MIG Welding Advanced Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-14. Preparing Unit For Synergic MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4-15. Synergic MIG Welding Advanced Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4-16. Preparing Unit For Synergic Pulsed MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4-17. Synergic Pulsed MIG Welding Advanced Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4-18. Preparing Unit For TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-19. TIG Welding Advanced Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4-20. TIG Lift-Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-21. Preparing Unit For Stick Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4-22. Stick Welding Advanced Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 5 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5-3. Circuit Breakers CB7 And CB10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5-5. Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SECTION 6 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
GARANZIA
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Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
NOTE
Manufacturer:
European Contact:
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203
European Contact Signature:
Declares that this product:
XMCR 4000
conforms to the following Directives and Standards:
Directives
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC
and their amendments 91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: Augusst1995
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and tests: IEC 664-1: 1992
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.
dec_stat_Milan_6/05
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SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _3/05
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Warning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
Y
Marks a special safety message.
. Means “Note”; not safety related.
1-2. Arc Welding Hazards
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The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
Safety Standards.
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Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
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Only qualified persons should install, operate, maintain, and
repair this unit.
Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
During operation, keep everybody, especially children, away.
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Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
ELECTRIC SHOCK can kill.
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Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
groundedequipment is a hazard.
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Do not touch live electrical parts.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on
unit.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
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Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
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FUMES AND GASES can be hazardous.
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Additionalsafety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomaticDC 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
is recommended. And, do not work alone!
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
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Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
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If ventilation is poor, wear an approved air-supplied respirator.
Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
Do not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
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Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
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Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
groundedreceptacle outlet.
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When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
OM-221 694 Page 1
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ARC RAYS can burn eyes and skin.
BUILDUP OF GAS can injure or kill.
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Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use
approved air-supplied respirator.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
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Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
HOT PARTS can cause severe burns.
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Wear approved safety glasses with side shields under your
helmet.
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Do not touch hot parts bare handed.
Allow cooling period before working on gun or
torch.
To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
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Wear protective clothing made from durable, flame-resistant mate-
rial (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
MAGNETIC FIELDS can affect pacemakers.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
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Pacemaker wearers keep away.
Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
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Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
NOISE can damage hearing.
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Do not weld where flying sparks can strike flammable material.
Protect yourself and others from flying sparks and hot metal.
Noise from some processes or equipment can
damagehearing.
Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
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Wear approved ear protection if noise level is
high.
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Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
CYLINDERS can explode if damaged.
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Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
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Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
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Do not use welder to thaw frozen pipes.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
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Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
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Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associated parts in good condition.
Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
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Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in
use or connected for use.
FLYING METAL can injure eyes.
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Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
Wear approved safety glasses with side
shields even under your welding helmet.
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Use the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
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OM-221 694 Page 2
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1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
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Do not install or place unit on, over, or near
combustiblesurfaces.
Do not install unit near flammables.
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Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
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Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
Reinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connecting input power.
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Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
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Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and
support unit.
If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
READ INSTRUCTIONS.
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Read Owner’s Manual before using or servic-
ing unit.
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Use only genuine Miller/Hobart replacement
parts.
H.F. RADIATION can cause interference.
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High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
Have only qualified persons familiar with
electronic equipment perform this installation.
OVERUSE can cause OVERHEATING
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Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before
starting to weld again.
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Do not block or filter airflow to unit.
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The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
If notified by the FCC about interference, stop using the
equipmentat once.
STATIC (ESD) can damage PC boards.
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Have the installation regularly checked and maintained.
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Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
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ARC WELDING can cause interference.
MOVING PARTS can cause injury.
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Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
Be sure all equipment in the welding area is
electromagneticallycompatible.
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Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
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To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
WELDING WIRE can cause injury.
D
Do not press gun trigger until instructed to do
so.
Be sure this welding machine is installed and grounded
according to this manual.
D
Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings
Y
Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
Y
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductiveharm. Wash hands after handling.
Y
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-221 694 Page 3
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1-5. Principal Safety Standards
Safety inWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
ternational.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1 from Global Engineering Documents (phone:
1-877-413-5184,website: www.global.ihs.com).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101(phone: 617−770−3000, website: www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web-
site: www.cganet.com).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
Welding current, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.
To reduce magnetic fields in the workplace, use the following
procedures:
OM-221 694 Page 4
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SECTION 2 − DEFINITIONS
2-1. Manufacturer’s Warning Label Definitions
Warning! Watch Out! There are possible
hazards as shown by the symbols.
2.1 Keep your head out of the fumes.
4
Arc rays can burn eyes and injure
skin.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
1
Electric shock can kill.
4.1 Wear hat and safety glasses. Use
ear protection and button shirt collar.
Use welding helmet with correct
shade of filter. Wear complete body
protection.
2.3 Use ventilating fan to remove fumes.
1.1 Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.
3
Welding sparks can cause explosion
or fire.
1.2 Protect yourself from electric shock
by insulating yourself from work and
ground.
3.1 Keep flammables away from welding.
Do not weld near flammables.
5
Become trained and read the
instructions before working on the
machine or welding.
3.2 Welding sparks can cause fires.
Have a fire extinguisher nearby, and
have a watchperson ready to use it.
1.3 Disconnect input plug or power
before working on machine.
6
Do not remove or paint over (cover)
the label.
2
Breathing welding fumes can be
hazardous to your health.
3.3 Do not weld on drums or any closed
containers.
1
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
1
2
3
Drive rolls can injure fingers
Welding wire and drive parts
are at welding voltage during
operation − keep hands and
metal objects away.
2
3
OM-221 694 Page 5
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A
1
2
4
5
3
V
V
> 60 s
V
S-185 836
9
8
6
7
A
Warning! Watch Out! There are possible
not touch fully charged capacitors.
explode or cause other parts to
explode.
hazards as shown by the symbols.
4
5
Always wait 60 seconds after power is
turned off before working on unit, OR
7
Flying pieces of parts can cause injury.
Always wear a face shield when
servicing unit.
1
2
Electric shock from wiring can kill.
Check input capacitor voltage, and be
sure it is near 0 before touching any
parts.
Disconnect input plug or power before
working on machine.
8
9
Always wear long sleeves and button
your collar when servicing unit.
3
Hazardous voltage remains on input
capacitors after power is turned off. Do
After taking proper precautions as
shown, connect power to unit.
6
When power is applied failed parts can
A
B
C
D
A
Warning!Watch Out! There are
possible hazards as shown by the
symbols.
B
kill.
Electric shock from wiring can
C
Disconnect input plug or power
before working on machine.
D
Read the Owner’s Manual
before working on this machine.
1
Consult rating label for input
power requirements, and
check power available at the
job site − they must match.
2
Read Owner’s Manual and
inside labels for connection
points and procedures.
3
4
Not Applicable
Having a loop of extra length,
connect grounding conductor
first.
5
Not Applicable
Do not discard this product with
general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collec-
tion facility.
Contact your local recycling office
or your local distributor for further
information.
OM-221 694 Page 6
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1
2
3
100 h. std.
4
6
5
7
=
(B) 050024004
207 290
1
2
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
3
Wear approved safety glasses with
side shields while working on the unit.
5
Every 100 hours, check and clean filter
and check condition of hoses.
6
7
Read Owner’s Manual.
4
Plugged filter or hoses can cause
overheating to the power source and
torch.
Disconnect input plug or power before
working on machine.
Use coolant suggested by
manufacturer.
1
1
2
3
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling unit can cause injury.
Do not move or operate unit
where it could tip.
Cylinders can expolde if
damaged. Protect
compressed gas cylinders
from excessive heat,
mechanical shock, slag, open
flames, sparks, and arcs.
2
3
1
2
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
1
Moving parts can cause injury.
Keep away from moving parts
such as fans.
2
S-176 106
OM-221 694 Page 7
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2-2. Manufacturer’s Rating Labels
2-3. Symbols And Definitions
Alternating
Amperage
Voltage
Current (AC)
V
A
Protective Earth
(Ground)
Remote
On
Off
Direct Current
(DC)
Line connection
Constant Voltage
Three Phase
Gas Tungsten Arc
Welding
Lift-Arc Operation
(GTAW)
Constant Current
Inductance
Increase
Three Phase Static
Frequency Con-
verter-
Recycle or dispose
of used coolant in
an environmentally
safe way
Gas Metal Arc
Welding (GMAW)
Shielded Metal Arc
Welding (SMAW)
Transformer-
Rectifier
Rated Maximum
Supply Current
Maximum Effective
Supply Current
Primary Voltage
U1
U2
U0
I1max
I2
IP
I1eff
X
Conventional
Load Voltage
Rated Welding
Current
Duty Cycle
Percent
%
Rated No Load
Voltage (Average)
Degree Of
Protection
Circuit Breaker
Pulsed
Hertz
Hz
OM-221 694 Page 8
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SECTION 3 − INSTALLATION
3-1. Specifications
Amperes Input
Maximum
Open-Circuit
Voltage DC
at Rated Load
Rated Welding
Output
Voltage
Range
Amperage
Range
IP Rating
Output 50/60 Hz
400 V
KVA
KW
300 A @
32 Volts DC,
60% Duty Cycle
17.0
(0,15*)
12.4
(0,09*)
11.5
(0,04*)
10 − 35
5 − 400
90
23C
*While idling
3-2. 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 (see
Wait fifteen minutes for unit to cool.
Reduce amperage or duty cycle be-
fore welding.
Y
Exceeding duty cycle can
damage unit and void war-
ranty.
60% Duty Cycle
6 Minutes Welding
4 Minutes Resting
Overheating
0
A
15
OR
Reduce Duty Cycle
Minutes
Ref. SA-178 651
OM-221 694 Page 9
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3-3. Volt-Ampere Curves
Volt-amperecurves show minimum
and maximum voltage and amper-
age output capabilities of unit.
Curves of other settings fall be-
tween curves shown.
A. CC Mode
B. CV Mode
ARC CONTROL
va_curve1 4/95 − SA-178 652 / SA-178 653
OM-221 694 Page 10
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3-4. Selecting A Location
Dimensions And Weight
Movement
Do not move or operate unit where it could tip.
Y
96.2 kg
1000 mm
813 mm
1
Lifting Handles
Do not use handle to lift unit.
Rating Label
2
Use label to determine input power
needs.
483 mm
3
Line Disconnect Device
Locate unit near correct input
power supply.
Y
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
Location
3
500 mm
500 mm
2
500 mm
500 mm
loc_2 3/96 - ST-801 192
OM-221 694 Page 11
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3-5. Weld Output Terminals And Selecting Cable Sizes
Y
ARC WELDING can cause Electromagnetic Interference.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment. Be sure this welding machine is installed
and grounded according to this manual. If interference still occurs, the user must take extra measures such as moving
the welding machine, using shielded cables, using line filters, or shielding the work area.
Total Cable (Copper) Length In Weld Circuit Not Exceeding
30 m Or Less
45 m
60 m
70 m
90 m
105 m
120 m
10 − 60% 60 − 100%
Welding
Amperes
Weld Output Terminals
Duty
Duty
10 − 100% Duty Cycle
Cycle
Cycle
100
150
200
250
300
350
400
500
600
20
30
30
35
50
60
60
70
95
20
30
35
50
60
70
70
95
120
20
35
30
50
35
60
50
70
60
60
95
95
MIG connector
50
60
70
95
120
120
60
70
95
120
2//70
2//95
2//95
2//120
3//95
3//120
2//70
2//95
2//120
2//120
3//95
3//120
70
95
120
2//70
2//70
2//95
2//120
2//70
2//95
2//95
2//120
3//95
95
120
120
2//70
2//95
95
Ground connector
120
2//70
// means 2 cables with the same section in parallel.
3-6. Remote 7 Receptacle Information
Socket
Socket Information
1
2
3
4
5
6
7
+10 volts dc supply voltage to remote
GND Remote control circuit common
IREF 0 to 10 current control signal
VREF 0 to 10 voltage control signal
UP 0V/10V digital signal
DOWN 0V/10V digital signal
Remote 7
TYPE 0V/10V digital signal
Note: This remote receptacle cannot be used with a standard Miller remote control. A customer supplied remote control is required to use the
remote receptacle.
OM-221 694 Page 12
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3-7. Circuit Breakers
Circuit breakers with numbers 7
and 10 are placed inside the welder
on the wire feeder side as shown.
1
2
1
Circuit Breaker 7
Protects the auxiliary 115 volt AC
used for the water cooling unit in-
side the power source, from over-
load.
2
Circuit Breaker 10
Protects the auxiliary 24 volt AC
used for the wire feeder unit inside
the power source, from overload.
3-8. Filling Coolant Tank
. Operatingcooler when coolant
is low can damage cooler and
torch components. Always
have proper amount of coolant
in tank and use coolant recom-
mendedby the manufacturer.
1
2
Coolant Tank Cap
Coolant Level Indicator
. Remove shielding gas cylinder
from rear of unit to fill coolant
tank.
1
2
Unscrew cap from tank.
Use table to select proper coolant,
and fill tank until coolant appears in
upper half of indicator.
Check coolant level after attaching
torch coolant hoses and running
cooler. Be sure coolant appears in
upper half of indicator. Add coolant
if necessary.
Rear View
GTAW Or Where
HF* Is Used
GMAW Or Where
HF* Is Not Used
Where Coolant Contacts
Aluminum Parts
Application
MILLER Low Conductivity
Coolant No. 043 810**;
MILLER Low Conductivity
Coolant No. 043 810**; Or
MILLER Aluminum Protecting
Coolant No. 043 809**;
MILLER Aluminum
Protecting Coolant
No. 043 809**
Distilled Or Deionized Water
OK Above 32° F (0° C)
Distilled Or Deionized Water
OK Above 32° F (0° C)
Coolant
*HF: High Frequency Current
**MILLER coolants protect to -37° F (-38°C) and resist algae growth.
Y
Use of any coolant other than those listed in the table voids the warranty on any parts
that come in contact with the coolant (pump, radiator, etc.).
OM-221 694 Page 13
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3-9. Electrical Service Guide
Actual input voltage should not exceed 10% of indicated required input voltage. If
actual input voltage is outside of this range, output may not be available.
NOTE
50/60 Hz Three Phase
Input Voltage
400
Input Amperes At Rated Output
17
1
Max Recommended Standard Fuse Rating In Amperes
2
3
Time-Delay
20
25
Normal Operating
4
2
Min Input Conductor Size In mm ,
2.5
41
Max Recommended Input Conductor Length In Meters
4
2
Min Grounding Conductor Size In mm ,
2.5
Reference: 1999 National Electrical Code (NEC)
1 Consult factory for circuit breaker applications.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
3-10. Connecting Input Power
Y
Always connect green/yel-
low wire to supply ground-
ing terminal, never to a line
terminal.
Check input voltage available at
site.
1
Input And Grounding
Conductors
2
Line Disconnect Device
2
Select type and size of overcurrent
L1
L2
L3
Green/Yellow
1
Y
Always connect grounding
conductor first.
= GND/PE
Tools Needed:
OM-221 694 Page 14
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SECTION 4 − OPERATION
4-1. Front Panel Controls
11
9
10
12
7
8
13
14
18
17
16
15
19
20
5
6
2
1
4
3
1
ON/OFF Switch (I/O)
Use switch to turn unit On/Off.
MIG Gun Connector
9
D1 (Display 1)
15 P3 (Process Push Button)
Allows selecting welding process.
16 P4 (Material Push Button)
Displays values and parameters for se-
lected welding process.
10 D2 (Display 2)
Displays values and parameters for se-
lected welding process.
11 E1 (Encoder Control 1)
Use control to change values and parame-
ters that appear on D1.
12 E2 (Encoder Control 2)
Use control to change values and parame-
ters that appear on D2.
13 P1 (Memory Push Button)
Allows selecting program storage locations
1-4 as indicated by LED’s.
14 P2 (Setup Push Button)
Allows selecting setup or advanced pro-
grammingmenus.
2
Positive gun connection for MIG or elec-
trode holder for Stick Electrode Positive
welding process, or work clamp connec-
tion for TIG welding process.
Allows selecting material type for synergic
MIG and synergic pulsed MIG processes.
17 P5 (Wire Diameter Push Button)
Allows selecting desired welding wire di-
ameter for synergic MIG and synergic
pulsed MIG processes.
3
Work Connector
Work clamp connection for MIG or Stick
Electrode Positive welding process, or
torch connection for TIG welding process.
4
5
18 P6 (Trigger Selection Push Button)
Allows selecting desired trigger mode.
19 P7 (Inductance/Thickness/Gas Push
Button
Allows selecting additional welding param-
eters.
20 P8 (Jog/Purge Push Button)
Performs jog and purge operations.
Remote Control Receptacle
Red Quick Connect Fitting
Coolant return from torch.
Blue Quick Connect Fitting
Coolant output to torch.
6
7
8
Handle
Control Panel
OM-221 694 Page 15
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4-2. Switching On the Unit and Recalling Factory Parameters
. Write down any parameters
that need to be restored before
performingthis procedure.
1
Power Switch
Use power switch to turn unit On.
When ITW appears on D1 and D2,
press P3 and P8 simultaneously.
1
When MEMO CLEAR appears on
D1 and D2, release P3 and P8.
Wait until DONE appears on D1,
and turn unit Off.
The next time unit is turned On, all
parameters will return factory de-
fault settings.
4-3. Welding Process Selection
L1
L2
L3
L4
P3
1
2
3
4
5
L1 LED
pulsed).
L3 selection is Synergic Pulsed MIG weld-
ing.
L2 LED
D1 value is trim, default is 0.0 T (range is
−5.0 T to 5.0 T).
D1 value is trim, default is 0.0 T (range is
−5.0 T to 5.0 T).
L3 LED
L4 LED
D2 value is wire feed speed (from minimum
to maximum value according to welding
curve selection).
D2 value is wire feed speed (from minimum
to maximum value according to welding
curve selection).
P3 Push Button
Press P3 until desired process LED illumi-
nates.
. When L2 is flashing, material transfer
in the arc is by large droplets (globular
transfer) and produces considerable
spatter. This is the result of selecting a
specific material, wire, gas, voltage,
and current combination. To avoid this
situation, Synergic Pulsed MIG weld-
ing with the same parameter combina-
tion is recommended. When L2 is On
continuously (not flashing), material
transfer in the arc is either short circuit
(Short Arc) or by small droplets (Spray
Transfer). Both MIG processes pro-
vide a stable arc and minimum spatter.
L4 selection is TIG welding or STICK weld-
ing.
Values and parameters that appear on D1
and D2 are either factory default settings or
last settings entered for the selected pro-
cess.
If selected process is TIG:
D1 displays TIG, and D2 value is welding
current, default is 220 A (range is 10 A to
400 A).
L1 selection is Manual MIG welding.
D1 value is welding voltage, default is
18.5V (range is 10.0V to 50.0V).
If selected process is STICK:
D2 value is wire feed speed, default is 5.0
m/min (range is 1 m/min to 20 m/min). See
D1 initially displays STICK and changes to
open circuit voltage at approximately 85 V,
and D2 value is welding current, default is
220 A (range is 10 A to 400 A).
L2 selection is Synergic MIG welding (non-
OM-221 694 Page 16
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4-4. Wire Type Selection In Synergic MIG Or Synergic Pulsed MIG Welding
L5
L6
L7
L8
P4
1
2
3
4
5
L5 LED
there is no program for the process,
material, wire diameter, and shielding
gas combination.
SG2/3 allows selecting SG2 or SG3.
L6 LED
CrNi allows selecting 308L, 309L, or 316L.
L7 LED
L5 selection is for carbon steel.
L6 selection is for stainless steel.
L7 selection is for aluminum.
Al allows selecting AlMg (AlMg5) or AlSi
(AlSi5).
L8 LED
P4 Push Button
Special allows selecting cored wire or spe-
cial wire (abbreviations for the different
wire types will appear on D1 and D2).
Press P4 until desired material LED illumi-
nates. D1 and D2 will show material name
only momentarily, and then return to the
main display.
L8 selection is for other wire types not pro-
vided by standard selection.
. Be aware that the wire type selection is
retained in the welding process
memory until a new selection is made.
Pressing P2 push button after a selection
is made to allow choosing other wire types
within the main selection.
. D1 and D2 will show NO PROG or a
selection will not be allowed when
4-5. Wire Diameter Selection In Synergic MIG Or Synergic Pulsed MIG Welding
L9
L10
L11
L12
P5
1
2
3
4
5
L9 LED
min values.
L10 selection is for 1.0 mm diameter wire.
L11 selection is for 1.2 mm diameter wire.
L10 LED
. D1 and D2 will show NO PROG or a
L11 LED
L12 selection is for other wire diameters not
provided by standard selection.
selection will not be allowed when
there is no program for the process,
material, wire diameter, and shielding
gas combination.
L12 LED
Pressing P2 push button after the special
selection is made to allow choosing other
wire diameters not available by standard
selection.
P5 Push Button
Press P5 until desired wire diameter LED
illuminates.D1 and D2 will show trim in m/
L9 selection is for 0.8 mm diameter wire.
OM-221 694 Page 17
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4-6. Trigger Mode Selection
L13
L14
L15
L16
P6
ing (L16 OFF, D1 shows STK and D2
shows set current).
When trigger is released the second time,
welding stops.
. Always check and set a trigger mode.
If trigger mode is undefined for a weld-
ing process, select the desired mode.
Press P6 to select the desired trigger
mode:
. L15 trigger mode is useful for certain
materialslike aluminum, and for a cra-
ter fill sequence.
1
2
3
4
5
L13 LED
L14 LED
L15LED
L16 LED
L13 ON selects 2 times trigger function.
When trigger is pressed, welding starts.
When trigger is released, welding stops.
L14 ON selects 4 times trigger function.
When trigger is pressed, welding starts.
L16 ON means weld output power is pres-
ent at weld connectors. This LED must be
on for the STICK process to enable weld-
ing. LED will turn on when weld output pow-
er is present at weld connectors for MIG
and TIG processes.
P6 Push Button
Trigger mode can be set for TIG, Manual
MIG, Synergic MIG, and Synergic Pulsed
MIG welding to change when weld output
power is present at the weld connnectors.
Trigger mode also allows enabling and dis-
abling STICK welding.
When trigger is released, welding contin-
ues.
In Manual MIG process, 2 times and 4
times trigger mode can be selected.
When trigger is pressed and released a
second time, welding stops.
In Synergic MIG process, 2 times, 4 times,
and 3 levels can be selected.
In TIG, Manual MIG, Synergic MIG, and
Synergic Pulsed MIG welding, pressing P6
will change trigger mode, but D1 and D2 will
not change values.
L15 ON selects 3 levels trigger function.
When trigger is pressed, welding starts
with level 1 parameters.
In Synergic Pulsed MIG process, 2 times,
4 times, and 3 levels can be selected.
When trigger is released, welding contin-
ues with main parameters.
In STICK welding, pressing P6 will enable
welding (L16 ON, D1 shows open circuit
voltage or weld voltage and D2 shows set
current or welding current) or disable weld-
In TIG process, 2 times, 4 times, and 3 lev-
els can be selected.
When trigger is pressed a second time,
welding continues at level 2 parameters.
In STICK process, only L16 can be ON.
OM-221 694 Page 18
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4-7. Inductance, Material Thickness, And Gas Selection In Manual MIG, Synergic MIG,
And Synergic Pulsed MIG
L17
L18
L19
P7
Use E2 to change material thickness val-
. Incorrect settings in any process can
. If a mode is selected and not used with-
in several seconds, the LED will turn
off .
Press P7 until desired mode LED illumi-
nates.
L17 ON selects Inductance. Default setting
is 100% (range is 1% to 200%). D1 and D2
return to main display after several sec-
onds.
L18 ON selects material thickness. D2
shows thickness in mm for the welding pro-
cess.
ue. This value is stored in process memory.
Material thickness is a reference value
only, not a mandatory setting. D1 and D2
return to main display when P7 is pressed
again.
result in a program with undesirable
weld characteristics. Settings should
only be changed by operators familiar
with various welding processes and
parameters.
L19 ON selects type of gas. D1 and D2
shows gas abbreviation.
1
2
3
4
L17 LED
Use E2 to change gas type. This setting is
stored in process memory.
L18 LED
L19 LED
LED will turn off after several seconds and
D1 and D2 will return to main display.
P7 Push Button
4-8. Jog And Purge Selection
L20
L21
P8
1
2
3
L20 LED
L21 LED
P8 Push Button
When L20 illuminates, press and hold P8 to
perform jog function.
welding arc. Front panel Jog is recom-
mended.
When L21 illuminates, press and hold P8 to
perform purge function.
Jog feeds welding wire without weld output
power applied to the wire.
. If a function is selected and not used
within several seconds, the LED will
turn off .
. Purge is used to remove impurities and
fill the gas hose with shielding gas.
Pre−Gas is a similar function, but only
operates at the beginning of a welding
process. Purge can be performed in
the TIG process by pressing the torch
trigger without striking an arc.
In Jog mode, D1 shows JOG and D2
shows wire feed speed.
To use the jog and purge function, proceed
as follows:
Use E2 to change wire feed speed setting.
. Jog will be performed if gun trigger is
Pressing P8 once selects jog. Pressing P8
a second time selects purge.
pressed and held without striking a
OM-221 694 Page 19
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4-9. Setting And Using Weld Parameters From Memory
. Check memory parameter for
proper settings before the
selections.
Four memory selections are avail-
able for each welding process (20
total).
These memory selections provide
quick changes to welding pro-
cesses with preset parameter val-
ues. All memory selections have
factory set defaults and may re-
quire changes for the desired weld
characteristics.
P1
Press P1 until desired memory
selection LED illuminates.
4-10. Setup Push Button And Advanced Programming
P2
Press P2 to enter SET UP menu.
E2 changes the parameter value.
Setting Menu Type
SET UP will appear on D1 and D2 only mo-
mentarily and then change to the selected
process parameter values.
. MENU EASY only shows basic pa-
rameters for welding processes.
MENU FULL shows all parameters for
welding processes.
. Incorrect settings in any process can
result in a program with undesirable
weld characteristics. Setup should
only be used by operators familiar with
various welding processes and pa-
rameters.
Setup allows viewing and changing default
parametervalues for all welding processes
for the desired weld characteristics.
To set menu type, proceed as follows:
Press P2 to enter SET UP menu.
D1 shows the welding parameter.
D2 shows the parameter value.
E1 changes the welding parameter.
Use E1 to select MENU EASY on D1 and
D2 (default setting).
Pressing P2 again allows changing wire
Use E2 to change D2 to FULL.
OM-221 694 Page 20
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4-11. Preparing Unit For MIG Welding
5
6
2
3
1
To select MIG welding process, proceed as
follows:
If using a water-cooled gun, connect input
coolant hose to blue quick connect fitting
and return coolant hose to red quick con-
nect fitting.
Connect gas hose to gas connector on rear
of unit.
Follow safety precautions according to
Section 1.
Turn unit On.
Allow time for unit to complete its start up
cycle.
Check coolant level after attaching torch
coolant hoses and running cooler. Be sure
coolant appears in upper half of indicator.
Using a cable with a proper adapter, con-
nect gun to the MIG gun connector.
Set MIG welding process using P3 push
button.
Connect work clamp cable to the WORK
connector.
If a remote control is desired, connect it to
the Remote Control receptacle.
Purge air from gun gas hose using P8 push
4-12. Selecting Manual MIG Welding
E1
D1
D2
E2
P3
P6
P7
Set Manual MIG welding process using P3 push button.
Setting Inductance
In Manual MIG mode, the operator may need to adjust main welding
parameters for specific arc characteristics. Wire feed speed and arc
voltage will appear on D1 and D2.
Press P7 until L17 LED illuminates.
D1 value is default voltage setting of 18.5 V (range is 10.0 V to 50.0
V).
L17 ON selects Inductance. Default setting is 100% (range is 1% to
200%). D1 and D2 return to main display after several seconds.
Use E1 to change voltage.
. Higher inductance setting produces a softer weld puddle and
less spatter, but arc starts may be more difficult. Lower induc-
tance setting produces a stiffer weld puddle and more spatter,
but arc starts may be easier.
D2 value is default wire feed speed setting of 5.0 m/min (range is 1.0
m/min to 20.0 m/min).
Use E2 to change wire feed speed.
OM-221 694 Page 21
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4-13. Manual MIG Welding Advanced Settings
To change all values list, unit must be
MENU FULL. To set unit to MENU FULL,
proceed as follows:
Setting Pre−Gas (only in MENU FULL)
D2 value is default setting of Auto (range is
1% to 200%).
Use E1 to change D1 to PREG.
. Auto is a setting below 1% that pro-
D2 value is default setting of 0.0 s (range is
0.0 s to 10.0 s).
Press P2 to enter SET UP menu.
vides an automatic backback time.
Select MENU FULL on D1 and D2 (see
Use E2 to change D2 value.
Use E2 to change D2 value.
Setting Cooler Status
Setting Post−Gas (only in MENU FULL)
Use E1 to change D1 to POSG.
Wire Feed Speed Unit (only in MENU
FULL)
. Be sure that cooler is turned on for wa-
ter-cooled torch to prevent damage to
torch components.
Use E1 to change D1 to UNIT.
D2 value is default setting of 0.1 s (range is
0.0 s to 10.0 s).
D2 value is default setting of mpm (meter
per minute).
Use E1 to change D1 to W−UN.
Use E2 to change D2 value.
Setting BurnBack
D2 value is default setting of ON.
Use E2 to change D2 to desired setting, ei-
ther IPM (inches per minute) or CUR (weld-
ing current in amperes).
Use E2 to change D2 value to OFF, if appli-
cable.
Use E1 to change D1 to BURN.
4-14. Preparing Unit For Synergic MIG Welding
E1
D1
D2
E2
P3
P4 P5
P6
P7
Set Synergic MIG welding process using
P3 push button.
Trim is an arbitrary value related to MIG arc
length. Higher values produce a longer and
hotter arc. Lower values produce a shorter
and cooler arc. Recommended value for
trim is default setting or near 0.0T.
Use E2 to change material thickness val-
ue. This value is stored in process memory.
Material thickness is a reference value
only, not a mandatory setting. D1 and D2
return to main display when P7 is pressed
again.
In Synergic MIG mode, the operator may
need to adjust welding data (wire type, wire
diameter, and gas type) and only one weld
parameter. Generally, wire feed speed is
adjusted and the synergic process auto-
matically sets appropriate weld voltage.
Synergic welding also sets many secon-
dary welding parameters automatically for
improved weld quality.
. Trim setting may vary by a greater
amount depending on welding posi-
tion, parameter settings, and quality of
wire.
Setting Inductance
Press P7 until L17 LED illuminates.
L17 ON selects Inductance. Default setting
is 100% (range is 1% to 200%). D1 and D2
return to main display after several sec-
onds.
Setting Gas
Press P7 until L19 LED illuminates.
L19 ON selects type of gas. D1 will show
GAS and D2 shows gas abbreviation as
follows:
Trim parameter appears on D1 and D2:
D1 value is default trim setting of 0.0 T
(range is −5.0 T to 5.0 T).
8218 = 82% Ar, 18% CO
2
Ar = 100% Argon
D2 value is default wire feed speed setting
of 5.0 m/min (minimum (MIN), maximum
(MAX), or default (DEF) values are arbi-
trary based on set welding data). Set wire
feed speed in meters/min (M).
Select wire type using P4 push button.
Select wire diameter using P5 push button.
Select trigger mode using P6 push button.
Set desired wire feed speed using E2.
Setting Trim
CO = 100% CO
2
2
. Higher inductance setting produces a
softer weld puddle and less spatter, but
arc starts may be more difficult. Lower
inductance setting produces a stiffer
weld puddle and more spatter, but arc
starts may be easier.
Setting Thickness
Press P7 until L18 LED illuminates.
L18 ON selects material thickness. D2
shows thickness in mm for the welding pro-
cess.
9802 = 98% Ar, 2%CO
2
Use E2 to change gas type. This setting is
stored in process memory.
LED will turn off after several seconds and
D1 and D2 will return to main display.
. D1 and D2 will show NO PROG or a
selection will not be allowed when
there is no program for the process,
material, wire diameter, and shielding
gas combination.
D1 value is default trim setting of 0.0 T
(range is −5.0 T to 5.0 T).
OM-221 694 Page 22
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4-15. Synergic MIG Welding Advanced Settings
To change all values list, unit must be
MENU FULL. To set unit to MENU FULL,
proceed as follows:
Use E2 to change D2 value.
Use E2 to change D2 value.
Use E1 to change D1 to 3LS2.
Setting Post−Gas (only in MENU FULL)
Use E1 to change D1 to POSG.
D2 value is default setting of 80% (range is
20% to 200%).
Press P2 to enter SET UP menu.
D2 value is default setting of 0.1 s (range is
0.0 s to 10.0 s).
Select MENU FULL on D1 and D2 (see
Use E2 to change D2 value.
Use E2 to change D2 value.
Setting BurnBack
Use E1 to change D1 to 3LRT (only in
MENU FULL).
Wire Feed Speed Unit (only in MENU
FULL)
Use E1 to change D1 to BURN.
D2 value is default setting of 0.5 s (range is
0.1 s to 0.5 s).
Use E1 to change D1 to UNIT.
D2 value is default setting of Auto (range is
1% to 200%).
D2 value is default setting of mpm (meter
per minute).
Setting Cooler Status
. Auto is a setting below 1% that pro-
. Be sure that cooler is turned on for wa-
Use E2 to change D2 to desired setting, ei-
ther IPM (inches per minute) or CUR (weld-
ing current in amperes).
vides an automatic backback time.
ter-cooled torch to prevent damage to
torch components.
Use E2 to change D2 value.
3 Level Trigger Mode
Setting Pre−Gas (only in MENU FULL)
Use E1 to change D1 to W−UN.
Use E1 to change D1 to PREG.
D2 value is default setting of ON.
Use E1 to change D1 to 3LS1.
D2 value is default setting of 0.0 s (range is
0.0 s to 10.0 s).
D2 value is default setting of 130% (range
is 20% to 200%).
Use E2 to change D2 value to OFF, if appli-
cable.
OM-221 694 Page 23
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4-16. Preparing Unit For Synergic Pulsed MIG Welding
E1
D1
D2
E2
P3
P4 P5
P6
P7
Set Synergic Pulsed MIG welding process
using P3 push button.
Synergic Pulsed MIG welding is a high
quality welding process that produces very
little spatter. This process works well on
thin metals such as stainless steel and alu-
minum.
In Synergic Pulsed MIG mode, the opera-
tor may need to adjust welding data (wire
type, wire diameter, and gas type) and only
one weld parameter. Generally, wire feed
speed is adjusted and the synergic pro-
cess automatically sets appropriate weld
voltage. Synergic welding also sets many
secondary welding parameters automati-
cally for improved weld quality.
Setting Trim
L18 ON selects material thickness. D2
shows thickness in mm for the welding pro-
cess.
Use E2 to change material thickness val-
ue. This value is stored in process memory.
Material thickness is a reference value
only, not a mandatory setting. D1 and D2
return to main display when P7 is pressed
again.
Setting Gas
Press P7 until L19 LED illuminates.
L19 ON selects type of gas. D1 will show
GAS and D2 shows gas abbreviation as
follows:
D1 value is default trim setting of 0.0 T
(range is −5.0 T to 5.0 T).
Trim is an arbitrary value related to MIG arc
length. Higher values produce a longer and
hotter arc. Lower values produce a shorter
and cooler arc. Recommended value for
trim is default setting or near 0.0T.
. Trim setting may vary by a greater
amount depending on welding posi-
tion, parameter settings, and quality of
wire.
Setting Inductance
8218 = 82% Ar, 18% CO
Press P7 until L17 LED illuminates.
2
Ar = 100% Argon
L17 ON selects Inductance. Default setting
is 100% (range is 1% to 200%). D1 and D2
return to main display after several sec-
onds.
Trim parameter appears on D1 and D2:
D1 value is default trim setting of 0.0 T
(range is −5.0 T to 5.0 T).
CO = 100% CO
2
2
9802 = 98% Ar, 2%CO
2
D2 value is default wire feed speed setting
of 5.0 m/min (minimum (MIN), maximum
(MAX), or default (DEF) values are arbi-
trary based on set welding data). Set wire
feed speed in meters/min (M).
Select wire type using P4 push button.
Select wire diameter using P5 push button.
Select trigger mode using P6 push button.
Set desired wire feed speed using E2.
Use E2 to change gas type. This setting is
stored in process memory.
LED will turn off after several seconds and
D1 and D2 will return to main display.
. Higher inductance setting produces a
softer weld puddle and less spatter, but
arc starts may be more difficult. Lower
inductance setting produces a stiffer
weld puddle and more spatter, but arc
starts may be easier.
. D1 and D2 will show NO PROG or a
selection will not be allowed when
there is no program for the process,
material, wire diameter, and shielding
gas combination.
Setting Thickness
Press P7 until L18 LED illuminates.
OM-221 694 Page 24
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4-17. Synergic Pulsed MIG Welding Advanced Settings
To change all values list, unit must be
MENU FULL. To set unit to MENU FULL,
proceed as follows:
Use E1 to change D1 to 3LS2.
Use E2 to change D2 value to ON. This set-
ting will enable or disable Double Pulse in
Synergic Pulsed MIG welding.
Use E1 to change D1 to DPFR.
D2 value is default setting of OFF.
Use E2 to change D2 value.
The range of this setting is 0.1 H to 5.0 H.
This setting allows changing double pulse
frequency in hertz (cycles per second). A
recommendedfrequency is approximately
1 hertz. OFF means double pulse is off.
Use E1 to change D1 to DPDC.
D2 value is default setting of 50%.
Use E2 to change D2 value.
The range of this setting is 25% to 75%.
This setting allows changing the time that
the pulse is at high output. A lower setting
will produce less heating at the welding
puddle.
Use E1 to change D1 to DPOF.
D2 value is default setting of 1.0M.
Use E2 to change D2 value.
The range of this setting is 0.2 M to 2.0 M.
This setting allows changing the difference
in high wire feed speed and low wire feed
speed from the main wire feed speed set-
ting. For example, if main wire feed speed
is set at 5 M and DPOF setting in D2 is 1.0
M, the wire feed speed will change be-
tween 4 m/min and 6 m/min. A recom-
mended setting is 1.0 M or less.
D2 value is default setting of 80% (range is
20% to 200%).
Press P2 to enter SET UP menu.
Use E2 to change D2 value.
Select MENU FULL on D1 and D2 (see
Use E1 to change D1 to 3LRT (only in
MENU FULL).
Wire Feed Speed Unit (only in MENU
FULL)
D2 value is default setting of 0.5 s (range is
0.1 s to 0.5 s).
Use E1 to change D1 to UNIT.
Setting Cooler Status
D2 value is default setting of mpm (meter
per minute).
. Be sure that cooler is turned on for wa-
ter-cooled torch to prevent damage to
torch components.
Use E2 to change D2 to desired setting, ei-
ther IPM (inches per minute) or CUR (weld-
ing current in amperes).
Use E1 to change D1 to W−UN.
Setting Pre−Gas (only in MENU FULL)
D2 value is default setting of ON.
Use E1 to change D1 to PREG.
Use E2 to change D2 value to OFF, if appli-
cable.
D2 value is default setting of 0.0 s (range is
0.0 s to 10.0 s).
Setting Synergic Double Pulsed MIG
Welding
Use E2 to change D2 value.
Setting Post−Gas (only in MENU FULL)
Use E1 to change D1 to POSG.
Some metals weld better using the Synerg-
ic Pulsed Welding process due to the
unique pulsing of the welding arc. Heat
generated in the workpiece is generally
lower and the arc characteristics produce
a better weld bead appearance especially
on aluminum. The Synergic Double Pulsed
MIG process allows control all parameters
to produce high quality welds on aluminum.
D2 value is default setting of 0.1 s (range is
0.0 s to 10.0 s).
Use E2 to change D2 value.
Setting BurnBack
Use E1 to change D1 to BURN.
D2 value is default setting of Auto (range is
1% to 200%).
. Incorrect settings in Synergic Double
Pulsed Welding process can result in
a program with undesirable weld char-
acteristics. Setup should only be used
by operators familiar with various
welding processes and parameters. In
some cases, standard Synergic
Pulsed MIG welding can produce bet-
ter welds.
Use E1 to change D1 to DPAR.
D2 value is default setting of 0.0 T.
Use E2 to change D2 value.
The range of this setting is −5.0 T to 5.0 T.
This setting allows changing the high end
of trim in double pulse and the main setting
for trim will be the low end. A higher DPAR
setting will produce a longer and hotter arc
and lower setting will produce a shorter and
cooler arc.
. Auto is a setting below 1% that pro-
vides an automatic backback time.
Use E2 to change D2 value.
3 Level Trigger Mode
Use E1 to change D1 to 3LS1.
D2 value is default setting of 130% (range
is 20% to 200%).
Use E1 to change D1 to DP.
Use E2 to change D2 value.
D2 value is default setting of OFF.
OM-221 694 Page 25
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4-18. Preparing Unit For TIG Welding
P6
4
P3
5
6
2
1
3
To select TIG welding process, proceed as
follows:
coolant hose to blue quick connect fitting
and return coolant hose to red quick con-
nect fitting.
Turn unit On.
Allow time for unit to complete its start up
cycle.
Follow safety precautions according to
Section 1.
Check coolant level after attaching torch
coolant hoses and running cooler. Be sure
coolant appears in upper half of indicator.
Set TIG welding process using P3 push
button.
Connect torch to the WORK connector.
Purge air from torch gas hose using P8
Using a cable with a proper adapter, con-
nect work clamp cable to the MIG gun con-
nector.
If a remote control is desired, connect it to
the Remote Control receptacle.
Connect gas hose to gas connector on rear
of unit.
Select trigger mode using P6 push button
If using a water-cooled torch, connect input
4-19. TIG Welding Advanced Settings
Setting Initial And Final Amperage
process at a lower initial amperage setting.
D2 value is default setting of 0.1 second
(range is 0.0 seconds to 10.0 seconds).
To set initial and final amperage, proceed
as follows:
Use E1 to change D1 to FI−A.
Use E2 to change D2 value.
D2 value is default setting of 20 A (range is
0 A to 350 A).
Setting Cooler Status
Press P2 to enter SET UP menu.
. Be sure that cooler is turned on for wa-
ter-cooled torch to prevent damage to
torch components.
Select MENU FULL on D1 and D2 (see
Use E2 to change D2 value.
This parameter allows finishing the welding
process at a lower final amperage setting.
Use E1 to change D1 to IN−A.
Select MENU FULL on D1 and D2 (see
D2 value is default setting of 20 A (range is
0 A to 350 A).
Setting Postflow
Use E1 to change D1 to W−UN.
Select MENU FULL on D1 and D2 (see
D2 value is default setting of ON.
Use E2 to change D2 value.
Use E2 to change D2 value to OFF, if appli-
cable.
This parameter allows starting the welding
Use E1 to change D1 to POSG.
OM-221 694 Page 26
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4-20. TIG Lift-Arc Welding
Lift-Arc Start
When Lift-Arct button light is On,
start arc as follows:
1
2
TIG Electrode
Workpiece
Touch tungsten electrode to work-
piece at weld start point, enable out-
put and shielding gas with torch trig-
ger, foot control, or hand control.
Hold electrode to workpiece for
1-2 seconds, and slowly lift elec-
trode. Arc is formed when electrode
is lifted.
1
2
1 − 2
“Touch”
Seconds
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece with-
out overheating, sticking, or getting
contaminated.
Application:
Do NOT Strike Like A Match!
Lift-Arc is used for the DCEN or AC
GTAW process when HF Start
method is not permitted, or to re-
place the scratch method.
Ref. S-156 279
4-21. Preparing Unit For Stick Welding
To select STICK welding process, proceed
as follows:
Connect work clamp cable to the WORK
connector.
Set STICK welding process using P3 push
button.
Follow safety precautions according to
Section 1.
If a remote control is desired, connect it to
the Remote Control receptacle.
. Be aware that STICK welding can be
enabled(L16 On) or disabled (L16 Off)
using P6 push button, and this status
is retained in the STICK welding pro-
cess memory.
Turn unit On.
Using a cable with a proper adapter, con-
nect electrode holder to the MIG gun con-
nector.
Allow time for unit to complete its start up
cycle.
4-22. Stick Welding Advanced Settings
HOT START
is 0% to 100%).
Select MENU FULL on D1 and D2 (see
Use E2 to change D2 value.
To change HOT START setting, proceed
as follows:
Use E1 to change D1 to ARC.
This parameter increases output amper-
age at the start of a weld to eliminate elec-
trode sticking.
Press P2 to enter SET UP menu.
D2 value is default setting of 80% (range is
0% to 100%).
Select MENU FULL on D1 and D2 (see
ARC FORCE
Use E2 to change D2 value.
To change ARC FORCE setting, proceed
as follows:
Use E1 to change D1 to HOT.
When setting is increased, short-circuit
amperageat low arc voltage increases.
D2 value is default setting of 100% (range
Press P2 to enter SET UP menu.
OM-221 694 Page 27
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SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
Y
Disconnect power
before maintaining.
. Maintain more often
during severe conditions.
3 Months
Clean And
Tighten
Weld
Replace
Damaged Or
Unreadable
Labels
Replace Damaged
Gas Hose
Terminals
Repair Or Replace
Cracked Cables
And Cords
6 Months
Clean
Drive
Rolls
Blow Out Or
Vacuum Inside
5-2. Blowing Out Inside Of Unit
Y
Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front, side, and back
louvers as shown.
OM-221 694 Page 28
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5-3. Circuit Breakers CB7 And CB10
1
Circuit Breaker CB7
Protects 115 volts ac power supply
to water cooler from overload. If
CB7 opens, water cooler stops op-
erating.
2
Circuit Breaker CB10
Protects 24 volts ac power supply
to wire feeder from overload. If
CB10 opens, wire feeding stops.
1
2
If either circuit breaker opens, allow
a cooling period and reset breaker.
Close door.
OM-221 694 Page 29
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5-4. Troubleshooting
Trouble
Remedy
Verify welding parameter settings.
No weld output: unit completely inopera-
tive.
No weld output; meter display On.
Verify Help messages and correction procedures as necessary.
Check, repair, or replace remote control.
Clean and tighten all weld connections.
Erratic or improper weld output.
Wire feeder does not work.
Check and clear any restrictions at drive assembly and liner.
Secure gun plug in receptacle or repair leads, or replace trigger switch.
Check and secure coolant hose connectors.
Coolant system not working (HELP 15
is displayed).
Motor overheated. Allow motor to cool and restart operation.
Have Factory Authorized Service Agent check cooling unit.
Add coolant.
Reduced or no coolant flow from cool-
ing unit (HELP 15 can be displayed).
Check for blockage at hoses.
Disconnect pump, and check for sheared coupling. Replace coupling if necessary.
Switch unit off and back on again to verify LED’s and display status.
Control panel not functioning properly.
Software problems.
Contact a Factory Authorized Service Agent.
OM-221 694 Page 30
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Help 4
Help 8
. All directions are in reference to the front
of the unit. All circuitry referred to is
located inside the unit.
Indicates a malfunction in the thermal
protectioncircuitry on right side of unit. Con-
tact a Factory Authorized Service Agent.
Indicates a malfunction in the secondary
power circuit of the unit. Contact a Factory
Authorized Service Agent.
Help 0
Help 5
Help 9
Indicates shorted thermistor RT2 on left side
Indicates overheating on right side of unit.
of unit. Contact a Factory Authorized Ser- Unit will shutdown and fan will run until inter-
vice Agent.
nal temperature drops within operational
range.
Indicates a shorted thermistor RT1 on right
side of unit. Contact a Factory Authorized
Service Agent.
Help 1
Help 6
Indicates a malfunction in the primary power Indicates input voltage is too low and unit has
circuit. Contact a Factory Authorized Ser- automaticallyshut down. Operation will con-
Help 15
vice Agent.
tinue when voltage is within an acceptable
lower range limit (15% below acceptable in-
put voltage). Contact an electrician to check
input line voltage.
Indicates a malfunctioning cooling unit. Unit
will shut down immediately. Turn off primary
power. Check and repair cooling unit compo-
nents as necessary. Unit will operate when
power to unit is turned off and back on.
Help 2
Indicates a malfunction in the thermal
protection circuitry on left side of unit. Con-
tact a Factory Authorized Service Agent.
Help 7
Indicates input voltage is too high and unit
has automatically shut down. Operation will
continue when voltage is within an accept-
Help 50
Help 3
able upper range limit (15% above accept- Indicates an overload at the power module.
Indicates overheating on left side of unit. Unit able input voltage). Contact an electrician to Reduce weld parameter settings and/or duty
will shutdown and fan will run until internal check input line voltage. HELP 7 may also in- cycle. If error continues, contact a Factory
temperaturedrops within operational range. dicate a bus voltage imbalance. Authorized Service Agent.
SC-187 212-A
OM-221 694 Page 32
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 1 . . . . . . . . . . . . . . . . . . . 000151187 . . . Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . . . . . . V16122015 . . . Side panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . . . . . 156034004 . . . Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 4 . . . . . . . . . . . . . . . . . . . 156005086 . . . Cylinder support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . . . . . 000207235 . . . Label, warning tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . . . V56142088 . . . Label, rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . . . . . 000207290 . . . Label, warning cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . . . . . . . . . 656043030 . . . Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . . . . . . . . . . 056054067 . . . Rubber wheel D=250mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . . . . . . 156012113 . . . Wheel pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . . . . . V16121013 . . . Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . . . . . 000207233 . . . Label, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 13 . . . . . . . . . . . . . . . . . . . 056054074 . . . Pivoting wheel D=100mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 14 . . . . . . . . . . . . . . . . . . . 000119503 . . . Label, logo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 15 . . . . . . . . . . . . . . . . . . . 000208154 . . . Front panel, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . . . . . 000207291 . . . Label, warning input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . . . . V16122014 . . . Expanded plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-221 694 Page 35
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Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
. . . 18 . . . CR5,6,R1 . . . 0001751940 . . . Resistor/Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . D1,2 . . . . . . . . 000201531 . . . Kit Diode, secondary circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . PC6 . . . . . . . . 000185697 . . . Circuit Board, EMI filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . HD1 . . . . . . . . 000189567 . . . Transducers, current 300A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . RT2 . . . . . . . . 000173632 . . . Thermistor, NTC 30k ohms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 23 . . . . . . . . . . . . . . . . . . V56120010 . . . Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . . . . . . . . . . . . . V56018092 . . . Nut, cable holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . . . . . 056061042 . . . Solenoid valve 24 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . . . . V16118004 . . . Rear panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . . . . . . . . . V56091091 . . . Cable holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . . . . . . . . . V56014026 . . . Handle, security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . . . . V57014066 . . . Main cable, 4m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . T1 . . . . . . . . . 000179616 . . . Transformer, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . L1 . . . . . . . . . 000173563 . . . Inductor, input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . Z1 . . . . . . . . . 000173570 . . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . . . . . T4 . . . . . . . . V58021080 . . . aux transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . WCP . . . . . . V57010072 . . . Motor, 115 VAC 120 W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . . . . V57011071 . . . Pump, 3/8” gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . WCF . . . . . . V56126035 . . . Fan motor 115 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 37 . . . . . . . . . . . . . . . . . . V56031027 . . . Radiator support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . . . . . . . . . . . . . . . V56082001 . . . Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . . . . . . . . . . . . . . 056061049 . . . Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . C1 . . . . . . . . 000188446 . . . Capacitor, 5 uf 900 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . . . . . V56031027 . . . Water cooling box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . . . . . . . . . . . . . . 000176106 . . . Label, warning fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . . . . . V27042020 . . . Tank, 8 L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . PC2 . . . . . . . . 000212210 . . . Circuit board, interconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . C3,4 . . . . . . . . 000192935 . . . Capacitor, 2700 uf 450 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 46 . . . . . . SR1 . . . . . . . . 000179629 . . . Kit Diode, primary circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 47 . . . . . PM1,2 . . . . . . . 000208173 . . . Kit, IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . . . . . . . . . . . . . . . 000197555 . . . tool tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . . . . . V56161034 . . . Reel holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . CB2 . . . . . . . . 000083432 . . . Circuit breaker, 10 A 250 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . CB1 . . . . . . . . 000161078 . . . Circuit breaker, 7 A 250 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . PC7 . . . . . . . V57084045 . . . Circuit board, motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . RL1 . . . . . . . . 000006393 . . . Relay, 24 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . PC1 . . . . . . . . 000215042 . . . Circuit board, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . . . . V560050008 . . . Circuit board support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . T2 . . . . . . . . . 000195829 . . . Transformer, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . . . . . . . . . . . . . . V57060005 . . . Baffle plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . . . . . . 000178937 . . . Label, warning gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . . . . . . . . . . . . . V56014017 . . . Board protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . . . . . V56005009 . . . Motor support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . . . . . . 028066243 . . . Wire drive system w/encoder motor . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . . . . . V57052030 . . . Euroadapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . . . . . V56005028 . . . Flange euroadapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . S1 . . . . . . . . 000128756 . . . Switch, 40 A 600 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . . . . . V16118003 . . . Front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 66 . . . . . . . . . . . . . . . . . . V57094063 . . . Receptacle kit, 7 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . . . . . . 000129525 . . . Power connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 68 . . . . . . . . . . . . . . . . . . V16006002 . . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 69 . . . . . . . M . . . . . . . . V56126046 . . . Fan motor 24 VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 70 . . . . . . . . . . . . . . . . . . V56005012 . . . Fan bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 71 . . . . . . . . . . . . . . . . . . . 000193919 . . . Knob, pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 72 . . . . . . PC3 . . . . . . . V57084081 . . . Circuit board, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 73 . . . . . . . . . . . . . . . . . . . 556049368 . . . Red fast coupling connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 74 . . . . . . . . . . . . . . . . . . . 556048369 . . . Blue fast coupling connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . V28066079 . . . Kit, water coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
♦Optional
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-221 694 Page 37
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Notes
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Effective January 1, 2006
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
below, ITW Welding Products Italy S.r.l., warrants to its
original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
material and workmanship at the time it is shipped by Miller.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
*
*
*
*
*
*
APT Model Plasma Cutting Torches
Remote Controls
Accessory Kits
Replacement Parts (No labor)
Spoolmate Spoolguns
Canvas covers
Miller’s True Blue® Limited Warranty shall not apply to:
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to
such defects in material or workmanship. Miller must be
notified in writing within thirty (30) days of such defect or
failure, at which time Miller will provide instructions on the
warranty claim procedures to be followed.
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
2. Items furnished by Miller, but manufactured by others,
such as engines or trade accessories. These items are
covered by the manufacturer’s warranty, if any.
Miller shall honor warranty claims on warranted equipment
listed below in the event of such a failure within the warranty
time periods. All warranty time periods start on the date that
the equipment was delivered to the original retail purchaser,
or one year after the equipment is sent to a European
distributor or eighteen months after the equipment is sent to
an International distributor.
3. Equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards, or equipment which has not had
reasonable and necessary maintenance, or equipment
which has been used for operation outside of the
specifications for the equipment.
1. 5 Years Parts − 3 Years Labor
*
*
Original main power rectifiers
Inverters (input and output rectifiers only)
MILLER PRODUCTS ARE INTENDED FOR PURCHASE
AND USE BY COMMERCIAL/INDUSTRIAL USERS AND
PERSONS TRAINED AND EXPERIENCED IN THE USE
AND MAINTENANCE OF WELDING EQUIPMENT.
2. 3 Years — Parts and Labor
*
*
*
*
*
*
*
*
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (unless otherwise stated)
Water Coolant Systems (integrated)
Intellitig
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or
(2) replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the
goods at customer’s risk and expense. Miller’s option of
repair or replacement will be F.O.B., Factory at ITW Welding
Products Group Europe, or F.O.B. at a Miller authorized
service facility as determined by Miller. Therefore no
compensation or reimbursement for transportation costs of
any kind will be allowed.
Maxstar 150
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
3. 2 year − Parts and Labor (Panther only)
Hydramate 1&2 Water Cooling Unit
4. 1 year − Parts and Labor unless specified
*
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL Miller BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
DC 253 & 403 Rectifier (April 06>)
Migmatic 171 (April 06>)
Motor Driven Guns (w/exception of Spoolguns)
Process Controllers
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
IHPS Power Sources and Coolers
Water Coolant Systems (non−integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Spot Welders
Load Banks
Arc Stud power sources and Arc Stud guns
Running Gear/Trailers
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED
AND DISCLAIMED BY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available, but may vary from state to state.
Plasma Cutting Torches (except APT
Models)
&
SAF
*
Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated
herein, and to the extent that they may not be waived, the
limitations and exclusions set out above may not apply. This
Limited Warranty provides specific legal rights, and other
rights may be available, but may vary from province to
province.
5
6 Months — Batteries
6. 90 Days — Parts
*
*
MIG Guns/TIG Torches
Induction heating coils and blankets
milan_warr 1/06
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Owner’s Record
Please complete and retain with your personal records.
Model Name
Purchase Date
Distributor
Address
Serial/Style Number
(Date which equipment was delivered to original customer.)
Country
Zip/Postal Code
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
Service and Repair
Replacement Parts
Owner’s Manuals
ITW Welding Products Italy S.r.l.
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39 (0) 2982901
Fax: 39 (0) 298290-203
email: miller@itw−welding.it
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA
© 2006 Miller Electric Mfg. Co. 1/06
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