Miller Electric Welder XMT 4 Rack User Manual

OM-815  
October 1994  
Eff. w/Serial Number KC310301  
Processes  
Multiprocess Welding  
Description  
Mounting Rack For Up To Four XMT  
300 Welding Power Sources With  
AUTO-LINK And Requiring 230/460  
Volt Input Power  
R
XMT 4-Rack  
Visit our website at  
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Call  
TABLE OF CONTENTS  
1-800-4-A-MILLER  
for your local  
Miller distributor.  
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. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 2 – SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
SECTION 4 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-1. Selecting A Location And Moving Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-2. Installing Welding Power Source Onto Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-3. Welding Power Source Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-4. Common Work Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-5. Paralleling Welding Power Sources For SMAW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-6. Connecting Input Power To Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1
1
1
Your distributor gives  
you ...  
3
Service  
3
4
You always get the fast,  
reliable response you  
need. Most replacement  
parts can be in your  
hands in 24 hours.  
5
5
6
Support  
6
6
7
8
Need fast answers to the  
tough welding questions?  
Contact your distributor.  
The expertise of the  
distributor and Miller is  
there to help you, every  
step of the way.  
9
10  
SECTION 5 – MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
5-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
5-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
11  
12  
12  
SECTION 6 – ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
WARRANTY  
Miller offers a Technical  
Manual which provides  
more detailed service and  
parts information for your  
unit. To obtain a Technical  
Manual, contact your local  
distributor. Your distributor  
can also supply you with  
Welding Process Manuals  
such as SMAW, GTAW,  
GMAW, and GMAW-P.  
For practical information on  
welding, process applica-  
tions, and Miller products,  
visit our website at  
www.MillerWelds.com  
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SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING  
som _nd_5/97  
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  
Y
The symbols shown below are used throughout this manual to  
call attention to and identify possible hazards. When you see  
the symbol, watch out, and follow the related instructions to  
avoid the hazard. The safety information given below is only  
a summary of the more complete safety information found in  
the Safety Standards listed in Section 1-4. Read and follow all  
Safety Standards.  
D
D
D
If earth grounding of the workpiece is required, ground it directly  
with a separate cable do not use work clamp or work cable.  
Do not touch electrode if you are in contact with the work, ground,  
or another electrode from a different machine.  
Use only well-maintained equipment. Repair or replace damaged  
parts at once. Maintain unit according to manual.  
D
D
D
Wear a safety harness if working above floor level.  
Keep all panels and covers securely in place.  
Y
Y
Only qualified persons should install, operate, maintain, and  
repair this unit.  
During operation, keep everybody, especially children, away.  
Clamp work cable with good metal-to-metal contact to workpiece  
or worktable as near the weld as practical.  
D
D
Insulate work clamp when not connected to workpiece to prevent  
contact with any metal object.  
ELECTRIC SHOCK can kill.  
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  
SIGNIFICANT DC VOLTAGE exists after removal of  
input power on inverters.  
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.  
D
Turn Off inverter, disconnect input power, and discharge input  
capacitors according to instructions in Maintenance Section  
before touching any parts.  
D
D
D
Do not touch live electrical parts.  
Wear dry, hole-free insulating gloves and body protection.  
FUMES AND GASES can be hazardous.  
Insulate yourself from work and ground using dry insulating mats  
or covers big enough to prevent any physical contact with the work  
or ground.  
Welding produces fumes and gases. Breathing  
these fumes and gases can be hazardous to your  
health.  
D
Do not use AC output in damp areas, if movement is confined, or if  
there is a danger of falling.  
D
D
Keep your head out of the fumes. Do not breathe the fumes.  
D
D
Use AC output ONLY if required for the welding process.  
If inside, ventilate the area and/or use exhaust at the arc to remove  
welding fumes and gases.  
If AC output is required, use remote output control if present on  
unit.  
D
D
If ventilation is poor, use an approved air-supplied respirator.  
D
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).  
Read the Material Safety Data Sheets (MSDSs) and the  
manufacturers instructions for metals, consumables, coatings,  
cleaners, and degreasers.  
D
D
Properly install and ground this equipment according to its  
Owners Manual and national, state, and local codes.  
D
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.  
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.  
D
D
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.  
D
D
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.  
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 if necessary, while wearing an  
air-suppliedrespirator. The coatings and any metals containing  
these elements can give off toxic fumes if welded.  
D
D
D
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.  
OM-815 Page 1  
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ARC RAYS can burn eyes and skin.  
BUILDUP OF GAS can injure or kill.  
D
D
Shut off shielding gas supply when not in use.  
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.  
Always ventilate confined spaces or use  
approved air-supplied respirator.  
D
Wear a welding helmet fitted with a proper shade of filter 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.  
D
D
D
Wear approved safety glasses with side shields under your  
helmet.  
D
D
Do not touch hot parts bare handed.  
Use protective screens or barriers to protect others from flash and  
glare; warn others not to watch the arc.  
Allow cooling period before working on gun or  
torch.  
Wear protective clothing made from durable, flame-resistant mate-  
rial (leather and wool) and foot protection.  
MAGNETIC FIELDS can affect pacemakers.  
WELDING can cause fire or explosion.  
D
D
Pacemaker wearers keep away.  
Wearers should consult their doctor before  
going near arc welding, gouging, or spot  
welding operations.  
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  
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.  
NOISE can damage hearing.  
D
D
D
Protect yourself and others from flying sparks and hot metal.  
Do not weld where flying sparks can strike flammable material.  
Noise from some processes or equipment can  
damagehearing.  
Remove all flammables within 35 ft (10.7 m) of the welding arc. If  
this is not possible, tightly cover them with approved covers.  
D
Wear approved ear protection if noise level is  
high.  
D
Be alert that welding sparks and hot materials from welding can  
easily go through small cracks and openings to adjacent areas.  
D
D
Watch for fire, and keep a fire extinguisher nearby.  
CYLINDERS can explode if damaged.  
Be aware that welding on a ceiling, floor, bulkhead, or partition can  
cause fire on the hidden side.  
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.  
D
D
Do not weld on closed containers such as tanks, drums, or pipes,  
unless they are properly prepared according to AWS F4.1 (see  
Safety Standards).  
Connect work cable to the work as close to the welding area as  
practical to prevent welding current from traveling long, possibly  
unknown paths and causing electric shock and fire hazards.  
D
D
Protect compressed gas cylinders from excessive heat, mechani-  
cal shocks, slag, open flames, sparks, and arcs.  
Install cylinders in an upright position by securing to a stationary  
support or cylinder rack to prevent falling or tipping.  
D
D
Do not use welder to thaw frozen pipes.  
Remove stick electrode from holder or cut off welding wire at  
contact tip when not in use.  
D
D
D
D
D
Keep cylinders away from any welding or other electrical circuits.  
Never drape a welding torch over a gas cylinder.  
D
D
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.  
FLYING METAL can injure eyes.  
D
D
Turn face away from valve outlet when opening cylinder valve.  
D
Welding, chipping, wire brushing, and grinding  
cause sparks and flying metal. As welds cool,  
they can throw off slag.  
Keep protective cap in place over valve except when cylinder is in  
use or connected for use.  
D
Read and follow instructions on compressed gas cylinders,  
associated equipment, and CGA publication P-1 listed in Safety  
Standards.  
D
Wear approved safety glasses with side  
shields even under your welding helmet.  
OM-815 Page 2  
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1-3. Additional Symbols For Installation, Operation, And Maintenance  
FIRE OR EXPLOSION hazard.  
MOVING PARTS can cause injury.  
D
Do not install or place unit on, over, or near  
combustiblesurfaces.  
D
D
Keep away from moving parts such as fans.  
Keep all doors, panels, covers, and guards  
closed and securely in place.  
D
Do not install unit near flammables.  
D
Do not overload building wiring be sure power supply system is  
properly sized, rated, and protected to handle this unit.  
FALLING UNIT can cause injury.  
H.F. RADIATION can cause interference.  
D
D
D
Use lifting eye to lift unit only, NOT running  
gear, gas cylinders, or any other accessories.  
D
High-frequency (H.F.) can interfere with radio  
navigation, safety services, computers, and  
communicationsequipment.  
Use equipment of adequate capacity to lift and  
support unit.  
D
Have only qualified persons familiar with  
electronic equipment perform this installation.  
If using lift forks to move unit, be sure forks are  
long enough to extend beyond opposite side of  
unit.  
D
D
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.  
OVERUSE can cause OVERHEATING  
D
D
Allow cooling period; follow rated duty cycle.  
D
D
Have the installation regularly checked and maintained.  
Reduce current or reduce duty cycle before  
starting to weld again.  
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.  
D
Do not block or filter airflow to unit.  
STATIC (ESD) can damage PC boards.  
D
D
Put on grounded wrist strap BEFORE handling  
boards or parts.  
ARC WELDING can cause interference.  
Use proper static-proof bags and boxes to  
store, move, or ship PC boards.  
D
Electromagnetic energy can interfere with  
sensitive electronic equipment such as  
computers and computer-driven equipment  
such as robots.  
MOVING PARTS can cause injury.  
D
Be sure all equipment in the welding area is  
electromagneticallycompatible.  
D
D
Keep away from moving parts.  
Keep away from pinch points such as drive  
rolls.  
D
D
D
D
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.  
Be sure this welding machine is installed and grounded  
according to this manual.  
D
D
Do not press gun trigger until instructed to do  
so.  
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.  
Do not point gun toward any part of the body,  
other people, or any metal when threading  
welding wire.  
1-4. Principal Safety Standards  
Safety in Welding and Cutting, ANSI Standard Z49.1, from American  
Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126  
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,  
from Compressed Gas Association, 1235 Jefferson Davis Highway,  
Suite 501, Arlington, VA 22202.  
Safety and Health Standards, OSHA 29 CFR 1910, from Superinten-  
dent of Documents, U.S. Government Printing Office, Washington, D.C.  
20402.  
Code for Safety in Welding and Cutting, CSA Standard W117.2, from  
Canadian Standards Association, Standards Sales, 178 Rexdale  
Boulevard, Rexdale, Ontario, Canada M9W 1R3.  
Safe Practices For Occupation And Educational Eye And Face  
Protection, ANSI Standard Z87.1, from American National Standards  
Institute, 1430 Broadway, New York, NY 10018.  
Recommended Safe Practices for the Preparation for Weldingand Cut-  
ting of Containers That Have Held Hazardous Substances, American  
Welding Society Standard AWS F4.1, from American Welding Society,  
550 N.W. LeJeune Rd, Miami, FL 33126  
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-  
tion Association, Batterymarch Park, Quincy, MA 02269.  
Cutting And Welding Processes, NFPA Standard 51B, from National  
Fire Protection Association, Batterymarch Park, Quincy, MA 02269.  
OM-815 Page 3  
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1-5. 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  
committees 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:  
To reduce magnetic fields in the workplace, use the following  
procedures:  
Pacemaker wearers consult your doctor first. If cleared by your doctor,  
then following the above procedures is recommended.  
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SECTION 2 SAFETY INFORMATION  
mod1.1 2/93  
Read all safety messages throughout this manual.  
Obey all safety messages to avoid injury.  
Learn the meaning of WARNING and CAUTION.  
1
2
Safety Alert Symbol  
Signal Word  
1
2
2
WARNING means possible death  
or serious injury can happen.  
WARNING  
CAUTION  
3
4
CAUTION means possible minor  
injury or equipment damage can  
happen.  
ELECTRIC SHOCK can kill.  
MOVING PARTS can injure.  
Do not touch live electrical parts.  
Keep away from moving parts.  
Disconnect input power before  
Keep all panels and covers closed  
3
Statement Of Hazard And Re-  
sult  
installing or servicing.  
when operating.  
4
Safety Instructions To Avoid  
Hazard  
5
5
6
Hazard Symbol (If Available)  
Safety Banner  
READ SAFETY BLOCKS at start of  
Section 3-1 before proceeding.  
WARNING  
Read safety blocks for each sym-  
bol shown.  
6
7
7
NOTE  
Turn Off switch when using high frequency.  
Special instructions for best oper-  
NOTE  
ation not related to safety.  
Figure 2-1. Safety Information  
SECTION 3 SPECIFICATIONS  
Table 3-1. Rack  
Description  
Specifications  
Overall Dimensions  
Required Input Power  
Weight  
Height: 48-5/8 in (1.23 m); Width: 63 in (1.60 m); Depth: 40 in (1.02 m)  
230 Or 460 Volts AC; 50/60 Hz; Three-Phase  
Net: 850 lb (385.6 kg); Ship: 860 lb (390.1 kg)  
Required Welding Power Source  
Capacity  
300 Amp XMT With AUTO-LINK Requiring 230 Or 460 Volts Input Power  
4 Welding Power Sources Maximum  
OM-815 Page 5  
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SECTION 4 INSTALLATION  
4-1. Selecting A Location And Moving Rack  
WARNING  
ELECTRIC SHOCK can kill.  
FUMES can be hazardous; LACK OF  
FRESH AIR AND PROPER VEN-  
TILATION can be harmful.  
Do not touch live electrical parts.  
Disconnect input power conductors from de-  
Do not breathe welding fumes.  
energized supply line BEFORE moving rack.  
Place unit only where there is a good fresh air supply  
and proper ventilation.  
FIRE OR EXPLOSION can result from  
placing unit on, over, or near com-  
bustible surfaces.  
FALLING EQUIPMENT can cause  
serious personal injury and equipment  
damage.  
Do not locate unit on, over, or near combustible  
surfaces.  
Move unit with crane or fork lift vehicle of adequate  
Do not install unit near flammables.  
capacity.  
swarn11.1* 3/93  
1
Lifting Eye  
Use lifting eye to move unit.  
Lifting Forks  
1
2
If using lifting forks, be sure forks  
are fully inserted.  
2
ST-158 366  
Figure 4-1. Location And Movement Of Rack  
4-2. Installing Welding Power Source Onto Rack  
1
Bracket  
Remove user-supplied bolt or lock  
if applicable.  
6
As Shipped  
2
Securing Bolts  
Loosen.  
3
Front Bracket  
In Use  
Swing end near rack center away  
from rack.  
4
5
Rear Bracket  
Securing Bracket  
Place welding power source on  
rack so rear is against rear bracket  
and securing bracket is centered  
between welding power source  
feet.  
4
Swing front bracket back into  
position.  
1
Tighten securing bolts.  
5
Reinstall user-supplied bolt or lock  
if applicable.  
2
3
6
Weld Cable Hanger  
ST-158 332 / S-0548 / ST-151 268-A  
Figure 4-2. Welding Power Source Installation  
OM-815 Page 6  
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4-3. Welding Power Source Input Power Connections  
WARNING  
ELECTRIC SHOCK can kill.  
Do not touch live electrical parts.  
Turn Off welding power source, and disconnect input power to rack before inspecting or installing.  
Have only qualified persons install unit.  
swarn3.1* 2/93  
Installation must meet National Electrical Code and all other codes.  
When installing conductors from the welding power source, torque the Power  
circuit breaker terminals and grounding terminal to 40 in-lbs (4.5 N·m).  
NOTE  
1
2
5
8
7
Tools Needed:  
6
4
3
ST-158 333 / ST-151 269-B  
Have only qualified persons make this instal-  
lation.  
4
Strain Relief Connector  
8
Grounding Terminal  
Insert input power cord through strain relief  
into entry hole for opened access door.  
Install input conductors from welding power  
source to Power circuit breaker.  
1
2
Control Box  
Access Door  
5
Grounding Conductor Green Or  
Green With Yellow Stripe(s)  
Open access door with same number as  
welding power source location.  
Install grounding conductor to grounding  
terminal.  
6
7
Input Conductors  
3
Welding Power Source Input Power  
Cord  
Power Circuit Breaker Terminals  
Close and secure access door.  
Figure 4-3. Welding Power Source Input Power Connections  
Table 4-1. Weld Cable Size*  
Total Cable (Copper) Length In Weld Circuit Not Exceeding  
150 ft  
(45 m)  
200 ft  
(60 m)  
250 ft  
(70 m)  
300 ft  
(90 m)  
350 ft  
(105 m)  
400 ft  
(120 m)  
100 ft (30 m) Or Less  
Welding  
Amperes  
10 To 60% 60 Thru 100%  
10 Thru 100% Duty Cycle  
Duty Cycle  
Duty Cycle  
100  
150  
200  
250  
300  
350  
400  
500  
600  
700  
800  
900  
1000  
1250  
1500  
4
3
4
4
3
2
1
1/0  
1/0  
3
2
1
1/0  
2/0  
3/0  
3/0  
3
2
1
1/0  
2/0  
3/0  
4/0  
4/0  
2
1
1/0  
2/0  
3/0  
4/0  
2-2/0  
2-3/0  
2-3/0  
2-4/0  
3-3/0  
3-4/0  
3-4/0  
4-4/0  
4-4/0  
2-2/0  
2-3/0  
2-4/0  
2-4/0  
3-3/0  
3-4/0  
4-4/0  
4-4/0  
1
1/0  
2/0  
3/0  
4/0  
2-2/0  
2-3/0  
2-3/0  
2-4/0  
3-3/0  
3-4/0  
3-4/0  
4-4/0  
4-4/0  
1/0  
1/0  
2/0  
3/0  
4/0  
4/0  
2-2/0  
2-2/0  
2-3/0  
2-4/0  
2/0  
3/0  
4/0  
2-2/0  
2-2/0  
2-3/0  
2-4/0  
3-3/0  
3-4/0  
3-4/0  
4-3/0  
4-4/0  
2/0  
3/0  
4/0  
3/0  
4/0  
2-2/0  
2-3/0  
2-4/0  
2-4/0  
3-3/0  
3-3/0  
4-3/0  
4-4/0  
4/0  
2-2/0  
2-3/0  
2-3/0  
2-4/0  
2-4/0  
3-3/0  
3-4/0  
2-2/0  
2-2/0  
2-3/0  
2-3/0  
2-4/0  
3-3/0  
*Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.  
S-0007-D  
OM-815 Page 7  
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4-4. Common Work Connections  
WARNING  
ELECTRIC SHOCK can kill.  
ARCING can burn skin or damage  
electrical equipment.  
Do not touch live electrical parts.  
Do not change position of the welding cable  
Turn Off welding power sources by placing Power  
connectors while welding.  
circuit breakers in the Off position before making any  
weld output connections.  
Be sure the connectors are secure in receptacles  
before welding.  
Do not connect welding output of different polarities  
to the same structure.  
INADEQUATE  
WORK  
CABLE  
See ANSI Z49.1 and OSHA Title 29, Chapter XVII,  
Part 1910, Subpart Q (addresses at beginning of  
manual).  
CONNECTIONS can cause serious  
damage to input power service and  
create a hazardous condition.  
Do not handle or come in contact with two live  
Connect an electrical cable of adequate size  
between the isolated terminal and the workpiece  
whenever any welding power sources are  
connected to the isolated terminal.  
electrodes at the same time.  
The following procedure is for  
Electrode  
Positive  
welding  
connections.  
3
1
Positive (+) Weld Output  
Cables  
2
Determine cable lengths and sizes  
according to welding power source  
Owners Manual.  
2
3
Isolated Terminal  
Negative () Weld Output  
Cables  
5
Determinecable sizes according to  
welding power source Owners  
Manual. Cable must reach from  
negative () output receptacle to  
isolated terminal.  
4
4
Common Negative () Weld  
Output Cable  
2
4
Cable must be able to carry com-  
bined weld output of all welding  
power sources using common work  
connections. Use Table 4-1 to se-  
lect proper cable size.  
5
Terminal Lugs  
Use lugs of proper amperage ca-  
pacity and hole size for connecting  
to isolated terminal.  
For Electrode Negative, reverse  
cable connections. Positive (+)  
weld output cables connect to iso-  
lated terminal, negative () weld  
output cables go to electrode. Com-  
mon weld output cable is positive.  
3
GTAW  
GMAW  
SMAW  
GTAW  
GMAW  
SMAW  
1
ST-155 335 / Ref. ST-154 540-A  
Figure 4-4. Common Work Connections  
OM-815 Page 8  
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4-5. Paralleling Welding Power Sources For SMAW  
WARNING  
ELECTRIC SHOCK can kill.  
ARCING can burn skin or damage  
electrical equipment.  
Do not touch live electrical parts.  
Do not change position of the welding cable  
Turn Off welding power sources by placing Power  
circuit breakers in the Off position before making any  
weld output connections.  
connectors while welding.  
Be sure the connectors are secure in receptacles  
before welding.  
Do not connect welding output of different polarities  
to the same structure.  
INADEQUATE  
WORK  
CABLE  
See ANSI Z49.1 and OSHA Title 29, Chapter XVII,  
CONNECTIONS can cause serious  
damage to input power service and  
create a hazardous condition.  
Part 1910, Subpart Q (addresses at beginning of  
manual).  
Do not handle or come in contact with two live  
electrodes at the same time.  
Connect an electrical cable of adequate size  
between the isolated terminal and the workpiece  
whenever any welding power sources are  
connected to the isolated terminal.  
UNDERSIZED WELDING CABLES can  
cause fire.  
Use single cables of adequate capacity to carry the  
total combined amperage of the paralleled welding  
power sources.  
Set the Amperage/Voltage control  
on all paralleled welding power  
sources to the same value. The iso-  
lated terminal may be used as a  
common connection point if no  
other connections are made to it.  
The procedure shown is for  
Electrode  
Positive  
welding  
connections.  
1
Weld Output Cables  
Determinecable sizes according to  
welding power source Owners  
Manual. Cables must reach cable  
connection point. Cables con-  
nected together must be the same  
polarity.  
2
ConnectionPoint  
Cover with proper insulating  
material after making connections.  
1
3
Terminal Lugs  
Use lugs of proper amperage  
capacity and hole size for connec-  
tion.  
1
4
Common Weld Output Cable  
4
4
Cable must be able to carry com-  
bined weld output of all welding  
power sources connected in paral-  
lel. Use Table 4-1 to select proper  
cable size.  
2
SMAW  
+
For Electrode Negative, reverse  
cable connections. Positive (+)  
weld output cables connect to work,  
negative () weld output cables go  
to electrode.  
1
Securely cover connection  
with proper insulating  
material.  
3
4
ST-158 334 / Ref. ST-154 540-A  
Figure 4-5. Paralleling Welding Power Sources For SMAW  
OM-815 Page 9  
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4-6. Connecting Input Power To Rack  
WARNING  
ELECTRIC SHOCK can kill.  
Do not touch live electrical parts.  
Turn Off welding power sources before inspecting or installing rack.  
Have only qualified persons install rack.  
swarn3.1* 2/93  
Installation must meet National Electrical Code and all other codes.  
Have only qualified persons make  
this installation.  
1
2
Rear Control Box Center  
Access Panel  
Remove access panel.  
3
Line Disconnect Device Of  
Proper Rating  
1
2
4
5
Input Conductors  
Grounding Conductor  
Select size and length using  
Table 4-2. Conductors must be  
able to carry the combined amper-  
age draw of all welding power  
sources mounted on the rack. Con-  
ductor insulation must comply with  
national, state, and local electrical  
codes. Use lugs of proper amper-  
age capacity and correct hole size.  
6
User-SuppliedStrain Relief  
Connector  
Insert conductors through strain  
relief.  
7
8
9
Input Terminal Block  
Line Terminals  
Ground Terminal  
Connect grounding conductor to  
ground terminal first. Then connect  
input conductors to line terminals.  
Reinstall access panel.  
Install grounding conductor and in-  
put conductors in conduit or equiv-  
alent to deenergized line discon-  
nect device.  
8
7
4
3
Connect grounding conductor first,  
then line input conductors.  
Be sure grounding conductor goes  
to an earth ground.  
10  
10 Overcurrent Protection  
Select type and size using  
Table 4-2. Install into deenergized  
line disconnect device (fused  
disconnect switch shown).  
5
6
5
9
ST-151 270-C  
Figure 4-6. Input Power Connections  
OM-815 Page 10  
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Table 4-2. Electrical Service Requirements*  
230  
250  
460  
Input Voltage  
1
125  
Recommended Standard Fuse Or Circuit Breaker Rating In Amperes  
2
1/0  
4
397 (121)  
6
Input Conductor Size In AWG/Kcmil  
3
229 (70)  
4
Max Input Conductor Length In Feet (Meters)  
4
Grounding Conductor Size In AWG/Kcmil  
*
These values are calculated from the 1993 edition of the National Electrical Code (NEC).  
1 Recommendedfuse or circuit breaker size is that closest to 150% of rated input amperage of the welding power source. Article 630-12(a) of NEC  
allows fuse or circuit breaker sizing up to 200% of rated input amperage.  
2 Input conductor size is for insulated copper wire with 75°C rating with not more than three single current-carrying conductors in a cable or raceway  
(Table 310-16 of NEC).  
3 Maximum length is to prevent more than a 3% voltage drop between service entrance and input terminals of the welding power source (Articles  
210-19(a) and 215-2(b) of NEC).  
4 The grounding conductor shall be colored or identified as specified in the NEC. Grounding conductor size for copper wire is not required to be larger  
than input conductor (Article 250-95 of NEC).  
Ref. S-0092-G  
SECTION 5 MAINTENANCE & TROUBLESHOOTING  
WARNING  
ELECTRIC SHOCK can kill.  
Do not touch live electrical parts.  
Turn Off welding power sources, and disconnect input power to rack before inspecting, maintaining, or servicing.  
Maintenance to be performed only by qualified persons.  
5-1. Routine Maintenance  
Turn Off all power before maintaining.  
3 Months  
Tape Or  
Replace  
Cracked  
Cables  
6 Months  
Replace  
Unreadable  
Labels  
See  
Section  
7
Blow Out  
Or  
Vacuum  
Inside  
OR  
During Heavy Service,  
Clean Monthly  
– –  
Clean  
And  
Tighten Weld  
Connections  
ST-151 267-B  
Figure 5-1. Maintenance Schedule  
OM-815 Page 11  
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5-2. Overload Protection  
1
Power Circuit Breakers  
CB1-CB4  
Each Power circuit breaker CB1  
through CB4 protects the welding  
power source connected to it from  
overload.  
If a Power circuit breaker opens,  
the matching welding power source  
would shut down. Manually reset  
the Power circuit breaker.  
1
ST-158 333 / Ref. ST-155 839 / Ref. ST-151 269-B  
Figure 5-2. Circuit Breaker Locations  
5-3. Troubleshooting  
WARNING  
ELECTRIC SHOCK can kill.  
Do not touch live electrical parts.  
Turn Off welding power sources, and disconnect input power to rack before inspecting, maintaining, or servicing.  
Troubleshooting to be performed only by qualified persons.  
Table 5-1. Rack Trouble  
Trouble  
Remedy  
Section  
No weld output from any welding power  
sources; units completely inoperative.  
Place line disconnect switch in On position.  
4-6  
Check line fuse(s) and replace if needed. Reset circuit breakers.  
Check for proper input power connections to rack.  
4-6  
4-6  
No weld output from one welding power  
source.  
Place applicable Power circuit breaker in On position.  
5-2  
Check for proper input power connections to welding power source.  
Check applicable welding power source according to its manual.  
4-3  
– –  
OM-815 Page 12  
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SECTION 6 ELECTRICAL DIAGRAM  
SA-155 857  
Figure 6-1. Circuit Diagram For Rack Control Box  
OM-815 Page 13  
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SECTION 7 PARTS LIST  
Item  
No.  
Part  
No.  
Description  
Quantity  
Figure 7-1. Main Assembly  
. . . 1 . . . 155 878 . . COVER, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . 032 473 . . GASKET, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 3 . . +155 844 . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 4 . . . 151 928 . . RETAINER, hold down brkt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 5 . . . 148 851 . . BRACKET, nut-sert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 6 . . . 049 399 . . NUT, speed push-on-type .312 stud .625 OD x .45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 7 . . . 153 926 . . BRACKET, hold down right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 8 . . . 151 946 . . WASHER, flat nyl .317 ID x .500 OD x .032thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
. . . 9 . . . 153 927 . . BRACKET, hold down left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 10 . . . 134 327 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 11 . . . 155 156 . . CHAIN, sash stl No. 30 double loop (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3ft  
. . . 12 . . . 147 380 . . PIN, cotter hair .148dia x 2.687 lg x .625 shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
. . . 13 . . . 147 331 . . PEG, cable holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 14 . . . . Fig 7-2 . . CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. Hardware is common and  
1
not available unless listed.  
2
3
Fig 7-2  
14  
13  
4
5
6
7
12  
11  
8
9
10  
8
ST-158 153-A  
Figure 7-1. Main Assembly  
+When ordering a component originally displaying a precautionary label, the label should also be ordered.  
To maintain the factory original performance of your equipment, use only Manufacturers Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
OM-815 Page 14  
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1
. Hardware is common and  
not available unless listed.  
2
19  
20  
21  
22  
18  
17  
23  
3
11  
12  
16  
4
15  
5
9
6
10  
7
11  
8
14  
12  
13  
ST-158 152  
Figure 7-2. Control Box  
OM-815 Page 15  
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Item  
No.  
Dia.  
Mkgs.  
Part  
No.  
Description  
Quantity  
Figure 7-2. Control Box (Fig 7-1 Item 14)  
. . . 1 . . . . . . . . . . . . . 155 846 . . COVER, top control box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 2 . . . CB1-4 . . 147 810 . . CIRCUIT BREAKER, mag 3P 60A 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 3 . . . . . . . . . . . . . . . . . . . + . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . 2  
. . . 4 . . . . . . . . . . . . . 155 843 . . BLANK, door opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 5 . . . . . . . . . . . . . 145 743 . . LUG, univ w/scr 600V 2-14 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 6 . . . . . . . . . . . . . . 148 311 . . DOOR, access w/hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 7 . . . . . . . . . . . . . 078 034 . . FASTENER, screw sltd hd .736 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 8 . . . . . . . . . . . . . 010 855 . . RETAINER, screw No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 9 . . . . . . . . . . . . . 010 357 . . NUT, speed No. 2 clip-on-type knrl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 10 . . . . . . . . . . . . . 604 102 . . CONNECTOR, clamp cable 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 11 . . . . . . . . . . . . . 124 245 . . LABEL, warning electric shock can kill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . 12 . . . . . . . . . . . . . 155 949 . . LABEL, caution unmatched voltage can cause . . . . . . . . . . . . . . . . . . . . . . 3  
. . . 13 . . . . . . . . . . . . . 057 360 . . BLANK, snap-in nyl 1.375mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 14 . . . . . . . . . . . . +155 847 . . CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 15 . . . . . . . . . . . . +147 228 . . COVER, box large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
. . . 16 . . . . . . . . . . . . . 148 025 . . LUG, univ w/scr 600V 2/0-6 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 17 . . . . DB1 . . . 147 861 . . DISTRIBUTION BLOCK, pwr 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 18 . . . . . . . . . . . . . 147 225 . . BRACKET, mtg distribution block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 19 . . . . . . . . . . . . . 084 435 . . SCREW, cap brs hexhd .500-13 x 2.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 20 . . . . . . . . . . . . . 039 045 . . TERMINAL BOARD, black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 21 . . . . . . . . . . . . . 602 247 . . WASHER, flat stl SAE .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 22 . . . . . . . . . . . . . 602 216 . . WASHER, lock stl split .500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . 23 . . . . . . . . . . . . . 601 840 . . NUT, brs hex .500-13 jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . . . . . . . . . 020 279 . . CLAMP, stl cush .750dia x .281mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . . . . . . . . . 087 318 . . CLAMP, stl cush 1.000dia x .203mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
. . . . . . . . . . . . . . . . . . . . 010 311 . . CLAMP, nyl .750 clamp dia x .500 wide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
. . . . . . . . . . . . . . . . . . . 010 145 . . CLAMP, nyl .500 clamp dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
+When ordering a component originally displaying a precautionary label, the label should also be ordered.  
To maintain the factory original performance of your equipment, use only Manufacturers Suggested  
Replacement Parts. Model and serial number required when ordering parts from your local distributor.  
OM-815 Page 16  
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Notes  
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Notes  
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Effective January 1, 2000  
(Equipment with a serial number preface of LAor newer)  
This limited warranty supersedes all previous Miller warranties and is exclusive with no other  
guarantees or warranties expressed or implied.  
Warranty Questions?  
LIMITED WARRANTY Subject to the terms and conditions  
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants  
to its original retail purchaser that new Miller equipment sold  
after the effective date of this limited warranty is free of defects  
in material and workmanship at the time it is shipped by Miller.  
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER  
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE  
WARRANTIES OF MERCHANTABILITY AND FITNESS.  
*
APT, ZIPCUT & PLAZCUT Model Plasma Cutting  
Torches  
Call  
1-800-4-A-MILLER  
for your local  
Miller distributor.  
*
*
*
*
*
Remote Controls  
Accessory Kits  
Replacement Parts (No labor)  
Spoolmate 185 & Spoolmate 250  
Canvas Covers  
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.  
Your distributor also gives  
you ...  
Millers True Blue Limited Warranty shall not apply to:  
1. Consumable components; such as contact tips,  
cutting nozzles, contactors, brushes, slip rings,  
relays or parts that fail due to normal wear.  
Service  
You always get the fast,  
reliable response you  
need. Most replacement  
parts can be in your  
hands in 24 hours.  
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 North American  
distributor or eighteen months after the equipment is sent to an  
International distributor.  
2. Items furnished by Miller, but manufactured by others,  
such as engines or trade accessories. These items are  
covered by the manufacturers warranty, if any.  
Support  
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.  
Need fast answers to the  
tough welding questions?  
Contact your distributor.  
The expertise of the  
distributor and Miller is  
there to help you, every  
step of the way.  
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  
*
*
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Transformer/Rectifier Power Sources  
Plasma Arc Cutting Power Sources  
Semi-Automatic and Automatic Wire Feeders  
Inverter Power Supplies  
In the event of a warranty claim covered by this warranty, the  
exclusive remedies shall be, at Millers 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 customers risk and expense. Millers option of repair or  
replacement will be F.O.B., Factory at Appleton, Wisconsin, or  
F.O.B. at a Miller authorized service facility as determined by  
Miller. Therefore no compensation or reimbursement for  
transportation costs of any kind will be allowed.  
Intellitig  
Engine Driven Welding Generators  
(NOTE: Engines are warranted separately by  
the engine manufacturer.)  
3. 1 Year Parts and Labor  
*
*
DS-2 Wire Feeder  
Motor Driven Guns (w/exception of Spoolmate  
185 & Spoolmate 250)  
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.  
*
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Process Controllers  
Positioners and Controllers  
Automatic Motion Devices  
RFCS Foot Controls  
Induction Heating Power Sources  
Water Coolant Systems  
HF Units  
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  
Grids  
Maxstar 140  
PROVISION,  
MIGHT  
ARISE  
BY  
IMPLICATION,  
Spot Welders  
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.  
Load Banks  
Miller Cyclomatic Equipment  
Running Gear/Trailers  
Plasma Cutting Torches (except APT & SAF  
Models)  
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.  
*
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.  
4. 6 Months Batteries  
5. 90 Days Parts  
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*
MIG Guns/TIG Torches  
Induction Heating Coils and Blankets  
miller_warr 7/00  
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Owners 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.)  
City  
State  
Zip  
For Service  
to locate a DISTRIBUTOR or SERVICE AGENCY near you.  
Always provide Model Name and Serial/Style Number.  
Contact your Distributor for:  
Welding Supplies and Consumables  
Options and Accessories  
Personal Safety Equipment  
Service and Repair  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
1635 West Spencer Street  
Appleton, WI 54914 USA  
Replacement Parts  
Training (Schools, Videos, Books)  
International HeadquartersUSA  
USA Phone: 920-735-4505 Auto-Attended  
USA & Canada FAX: 920-735-4134  
International FAX: 920-735-4125  
Technical Manuals (Servicing Information  
and Parts)  
Circuit Diagrams  
European Headquarters –  
United Kingdom  
Phone: 44 (0) 1204-593493  
FAX: 44 (0) 1204-598066  
Welding Process Handbooks  
www.MillerWelds.com  
Contact the Delivering Carrier for:  
File a claim for loss or damage during  
shipment.  
For assistance in filing or settling claims,  
contact your distributor and/or equipment  
manufacturers Transportation Department.  
PRINTED IN USA  
2000 Miller Electric Mfg. Co. 6/00  
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