O230693b Mil

OM-230 693B 2007−07
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source

and Wire Feeder
Millermatic 252
Visit our website at

File: MIG (GMAW)
www.MillerWelds.com
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They Working as hard as you do
− every power source from
will help you protect yourself against potential hazards on the worksite. Miller is backed by the most
We’ve made installation and operation quick hassle-free warranty in the
business.
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard. particular model are also provided.
Miller Electric manufactures a full line

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 4/05
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . . 7
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-6. Information EMF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4-2. Welding Power Source Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4-4. Connecting To Weld Output Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-5. Installing Work Cable And Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-6. Connecting Spoolmatic) 15A Or 30A Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-7. Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-8. Setting Gun Polarity For Wire Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-9. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-10. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-11. Positioning Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-12. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4-13. Selecting A Location And Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4-14. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4-15. Weld Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5-2. Voltmeter And Wire Feed Speed Meter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-3. Jog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-4. Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5-5. Set Up Push Motor Torque (SUP) Or Reset (rES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 6 − MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-2. Unit Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-3. Changing Drive Roll and Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-4. Aligning Drive Rolls and Wire Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-5. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TABLE OF CONTENTS
SECTION 8 − MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8-1. Typical MIG Process Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8-2. Typical MIG Process Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8-3. Holding And Positioning Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8-4. Conditions That Affect Weld Bead Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8-5. Gun Movement During Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8-6. Poor Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8-7. Good Weld Bead Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8-8. Troubleshooting − Excessive Spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-9. Troubleshooting − Porosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-10. Troubleshooting − Excessive Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8-11. Troubleshooting − Lack Of Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-12. Troubleshooting − Incomplete Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-13. Troubleshooting − Burn-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8-14. Troubleshooting − Waviness Of Bead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8-15. Troubleshooting − Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8-16. Common MIG Shielding Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8-17. Troubleshooting Guide For Semiautomatic Welding Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
WARRANTY
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _3/05
Y 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

Y Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
. Means “Note”; not safety related. to avoid the hazards.
1-2. Arc Welding Hazards

Y The symbols shown below are used throughout this manual to D Turn off all equipment when not in use.
call attention to and identify possible hazards. When you see D Do not use worn, damaged, undersized, or poorly spliced cables.
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only D Do not drape cables over your body.
a summary of the more complete safety information found in D If earth grounding of the workpiece is required, ground it directly
the Safety Standards listed in Section 1-5. Read and follow all with a separate cable.
Safety Standards. D Do not touch electrode if you are in contact with the work, ground,
Y Only qualified persons should install, operate, maintain, and or another electrode from a different machine.
repair this unit. D Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
Y During operation, keep everybody, especially children, away.
present.
D Use only well-maintained equipment. Repair or replace damaged
ELECTRIC SHOCK can kill. parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is D Keep all panels and covers securely in place.
electrically live whenever the output is on. The input D Clamp work cable with good metal-to-metal contact to workpiece
power circuit and machine internal circuits are also or worktable as near the weld as practical.
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the D Insulate work clamp when not connected to workpiece to prevent
welding wire are electrically live. Incorrectly installed or improperly contact with any metal object.
grounded equipment is a hazard. D Do not connect more than one electrode or work cable to any
D Do not touch live electrical parts. single weld output terminal.
D Wear dry, hole-free insulating gloves and body protection.
SIGNIFICANT DC VOLTAGE exists in inverter-type
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
welding power sources after removal of input
or ground. power.
D Do not use AC output in damp areas, if movement is confined, or if D Turn Off inverter, disconnect input power, and discharge input
there is a danger of falling. capacitors according to instructions in Maintenance Section
D Use AC output ONLY if required for the welding process. before touching any parts.
D If AC output is required, use remote output control if present on FUMES AND GASES can be hazardous.
unit.
D Additional safety precautions are required when any of the follow-
Welding produces fumes and gases. Breathing
ing electrically hazardous conditions are present: in damp these fumes and gases can be hazardous to your
locations or while wearing wet clothing; on metal structures such health.
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid- D Keep your head out of the fumes. Do not breathe the fumes.
able or accidental contact with the workpiece or ground. For these D If inside, ventilate the area and/or use local forced ventilation at the
conditions, use the following equipment in order presented: 1) a arc to remove welding fumes and gases.
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
D If ventilation is poor, wear an approved air-supplied respirator.
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder D Read and understand the Material Safety Data Sheets (MSDSs)
is recommended. And, do not work alone! and the manufacturer’s instructions for metals, consumables,
D Disconnect input power or stop engine before installing or coatings, cleaners, and degreasers.
servicing this equipment. Lockout/tagout input power according to D Work in a confined space only if it is well ventilated, or while
OSHA 29 CFR 1910.147 (see Safety Standards). wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
D Properly install and ground this equipment according to its
lower the oxygen level causing injury or death. Be sure the breath-
Owner’s Manual and national, state, and local codes.
ing air is safe.
D Always verify the supply ground − check and be sure that input D Do not weld in locations near degreasing, cleaning, or spraying op-
power cord ground wire is properly connected to ground terminal in erations. The heat and rays of the arc can react with vapors to form
disconnect box or that cord plug is connected to a properly highly toxic and irritating gases.
grounded receptacle outlet.
D Do not weld on coated metals, such as galvanized, lead, or
D When making input connections, attach proper grounding conduc- cadmium plated steel, unless the coating is removed from the weld
tor first − double-check connections. area, the area is well ventilated, and while wearing an air-supplied
D Frequently inspect input power cord for damage or bare wiring − respirator. The coatings and any metals containing these elements
replace cord immediately if damaged − bare wiring can kill. can give off toxic fumes if welded.
OM-230 693 Page 1
ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill.
Arc rays from the welding process produce intense D Shut off shielding gas supply when not in use.
visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use
that can burn eyes and skin. Sparks fly off from the approved air-supplied respirator.
weld.
D 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.
D Wear approved safety glasses with side shields under your
helmet. D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
D Use protective screens or barriers to protect others from flash,
torch.
glare and sparks; warn others not to watch the arc.
D To handle hot parts, use proper tools and/or
D Wear protective clothing made from durable, flame-resistant mate-
wear heavy, insulated welding gloves and
rial (leather, heavy cotton, or wool) and foot protection.
clothing to prevent burns.
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 D Pacemaker wearers keep away.
can fly off from the welding arc. The flying sparks, hot D Wearers should consult their doctor before
workpiece, and hot equipment can cause fires and going near arc welding, gouging, or spot
burns. Accidental contact of electrode to metal objects can cause welding operations.
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D 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.
D Do not weld where flying sparks can strike flammable material.
Noise from some processes or equipment can
D Protect yourself and others from flying sparks and hot metal. damage hearing.
D Be alert that welding sparks and hot materials from welding can D Wear approved ear protection if noise level is
easily go through small cracks and openings to adjacent areas. high.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side. CYLINDERS can explode if damaged.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see Shielding gas cylinders contain gas under high
Safety Standards). pressure. If damaged, a cylinder can explode. Since
D Connect work cable to the work as close to the welding area as gas cylinders are normally part of the welding
practical to prevent welding current from traveling long, possibly process, be sure to treat them carefully.
unknown paths and causing electric shock, sparks, and fire D Protect compressed gas cylinders from excessive heat, mechani-
hazards. cal shocks, physical damage, slag, open flames, sparks, and arcs.
D Do not use welder to thaw frozen pipes. D Install cylinders in an upright position by securing to a stationary
D Remove stick electrode from holder or cut off welding wire at support or cylinder rack to prevent falling or tipping.
contact tip when not in use. D Keep cylinders away from any welding or other electrical circuits.
D Wear oil-free protective garments such as leather gloves, heavy D Never drape a welding torch over a gas cylinder.
shirt, cuffless trousers, high shoes, and a cap.
D Never allow a welding electrode to touch any cylinder.
D Remove any combustibles, such as a butane lighter or matches,
D Never weld on a pressurized cylinder − explosion will result.
from your person before doing any welding.
D Use only correct shielding gas cylinders, regulators, hoses, and fit-
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
tings designed for the specific application; maintain them and
for hot work and have a fire watcher and extinguisher nearby.
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
FLYING METAL can injure eyes. D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Welding, chipping, wire brushing, and grinding D Use the right equipment, correct procedures, and sufficient num-
cause sparks and flying metal. As welds cool, ber of persons to lift and move cylinders.
they can throw off slag.
D Read and follow instructions on compressed gas cylinders,
D Wear approved safety glasses with side associated equipment, and Compressed Gas Association (CGA)
shields even under your welding helmet. publication P-1 listed in Safety Standards.
OM-230 693 Page 2

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 D Keep away from moving parts such as fans.
combustible surfaces. D Keep all doors, panels, covers, and guards
D Do not install unit near flammables. closed and securely in place.
D Do not overload building wiring − be sure power supply system is D Have only qualified persons remove doors,
properly sized, rated, and protected to handle this unit. panels, covers, or guards for maintenance as
necessary.
D Reinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connecting input power.
FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running READ INSTRUCTIONS.
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and D Read Owner’s Manual before using or servic-
support unit. ing unit.
D If using lift forks to move unit, be sure forks are D Use only genuine Miller/Hobart replacement
long enough to extend beyond opposite side of parts.
unit.
H.F. RADIATION can cause interference.
OVERUSE can cause OVERHEATING D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
D Allow cooling period; follow rated duty cycle. communications equipment.
D Reduce current or reduce duty cycle before D Have only qualified persons familiar with
starting to weld again. electronic equipment perform this installation.
D Do not block or filter airflow to unit. D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the
STATIC (ESD) can damage PC boards. equipment at once.
D Have the installation regularly checked and maintained.
D Put on grounded wrist strap BEFORE handling D Keep high-frequency source doors and panels tightly shut, keep
boards or parts. spark gaps at correct setting, and use grounding and shielding to
D Use proper static-proof bags and boxes to minimize the possibility of interference.
store, move, or ship PC boards.
ARC WELDING can cause interference.

MOVING PARTS can cause injury. D Electromagnetic energy can interfere with
sensitive electronic equipment such as
D Keep away from moving parts. computers and computer-driven equipment
D Keep away from pinch points such as drive such as robots.
rolls. D Be sure all equipment in the welding area is
electromagnetically compatible.
D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
WELDING WIRE can cause injury. D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D Do not press gun trigger until instructed to do D Be sure this welding machine is installed and grounded
so. according to this manual.
D Do not point gun toward any part of the body, D If interference still occurs, the user must take extra measures
other people, or any metal when threading such as moving the welding machine, using shielded cables,
welding wire. using line filters, or shielding the work area.
1-4. California Proposition 65 Warnings

Y Welding or cutting equipment produces fumes or gases which For Gasoline Engines:
contain chemicals known to the State of California to cause Y Engine exhaust contains chemicals known to the State of
birth defects and, in some cases, cancer. (California Health & California to cause cancer, birth defects, or other reproductive
Safety Code Section 25249.5 et seq.) harm.
Y Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of Y Diesel engine exhaust and some of its constituents are known
California to cause cancer and birth defects or other to the State of California to cause cancer, birth defects, and
reproductive harm. Wash hands after handling. other reproductive harm.
OM-230 693 Page 3
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in-
www.global.ihs.com). ternational.org).
Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection,
ting of Containers and Piping, American Welding Society Standard ANSI Standard Z87.1, from American National Standards Institute, 11
AWS F4.1 from Global Engineering Documents (phone: West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
1-877-413-5184, website: www.global.ihs.com). website: www.ansi.org).
National Electrical Code, NFPA Standard 70, from National Fire Protec- Standard for Fire Prevention During Welding, Cutting, and Other Hot
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, from National Fire Protection Association,
02269−9101 (phone: 617−770−3000, website: www.nfpa.org). 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, OSHA, Occupational Safety and Health Standards for General Indus-
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
site: www.cganet.com). and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
Code for Safety in Welding and Cutting, CSA Standard W117.2, from are 10 Regional Offices−−phone for Region 5, Chicago, is
Canadian Standards Association, Standards Sales, 178 Rexdale 312−353−2220,website: www.osha.gov).
1-6. EMF Information

Considerations About Welding And The Effects Of Low Frequency 1. Keep cables close together by twisting or taping them.
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electro- 2. Arrange cables to one side and away from the operator.
magnetic fields. There has been and still is some concern about such
3. Do not coil or drape cables around your body.
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National 4. Keep welding power source and cables as far away from opera-
Research Council concluded that: “The body of evidence, in the
tor as practical.
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.” 5. Connect work clamp to workpiece as close to the weld as possi-
However, studies are still going forth and evidence continues to be
ble.
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when About Pacemakers:
welding or cutting. Pacemaker wearers consult your doctor before welding or going near
To reduce magnetic fields in the workplace, use the following welding operations. If cleared by your doctor, then following the above
procedures: procedures is recommended.
OM-230 693 Page 4

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som _3/05
Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes.
2-1. Symboles utilisés

Symbole graphique d’avertissement ! Attention ! Cette pro-
cédure comporte des risques possibles ! Les dangers éven-
tuels sont représentés par les symboles graphiques joints.
Y Indique un message de sécurité particulier Ce groupe de symboles signifie Avertissement ! Attention ! Risques
d’ÉLECTROCUTION, ORGANES MOBILES et PARTIES
CHAUDES. Consulter les symboles et les instructions afférentes
ci-dessous concernant les mesures à prendre pour supprimer
. Signifie NOTE ; n’est pas relatif à la sécurité. les dangers.
2-2. Dangers relatifs au soudage à l’arc

Y Les symboles représentés ci-dessous sont utilisés dans ce manuel D Vérifier fréquemment le cordon d’alimentation afin de s’assurer qu’il
pour attirer l’attention et identifier les dangers possibles. En n’est pas altéré ou à nu, le remplacer immédiatement s’il l’est. Un fil à nu
présence de l’un de ces symboles, prendre garde et suivre les peut entraîner la mort.
instructions afférentes pour éviter tout risque. Les instructions en D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
matière de sécurité indiquées ci-dessous ne constituent qu’un D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante
sommaire des instructions de sécurité plus complètes fournies ou mal épissés.
dans les normes de sécurité énumérées dans la Section 2-5. Lire et D Ne pas enrouler les câbles autour du corps.
observer toutes les normes de sécurité.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
Y Seul un personnel qualifié est autorisé à installer, faire fonction- câble distinct.
ner, entretenir et réparer cet appareil. D Ne pas toucher l’électrode quand on est en contact avec la pièce, la terre
Y Pendant le fonctionnement, maintenir à distance toutes les per- ou une électrode provenant d’une autre machine.
sonnes, notamment les enfants de l’appareil. D Ne pas toucher des porte électrodes connectés à deux machines en
même temps à cause de la présence d’une tension à vide doublée.
UNE DÉCHARGE ÉLECTRIQUE peut D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
entraîner la mort. champ les pièces endommagées. Entretenir l’appareil conformément à
ce manuel.
Le contact d’organes électriques sous tension peut D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
provoquer des accidents mortels ou des brûlures
graves. Le circuit de l’électrode et de la pièce est D S’assurer que tous les panneaux et couvercles sont correctement en
sous tension lorsque le courant est délivré à la place.
sortie. Le circuit d’alimentation et les circuits internes de la machine D Fixer le câble de retour de façon à obtenir un bon contact métal-métal
sont également sous tension lorsque l’alimentation est sur Marche. avec la pièce à souder ou la table de travail, le plus près possible de la
Dans le mode de soudage avec du fil, le fil, le dérouleur, le bloc de soudure.
commande du rouleau et toutes les parties métalliques en contact D Isoler la pince de masse quand pas mis à la pièce pour éviter le contact
avec le fil sont sous tension électrique. Un équipement installé ou mis avec tout objet métallique.
à la terre de manière incorrecte ou impropre constitue un danger. D Ne pas raccorder plus d’une électrode ou plus d’un câble de masse à
une même borne de sortie de soudage.
D Ne pas toucher aux pièces électriques sous tension.
D Porter des gants isolants et des vêtements de protection secs et sans
Il reste une TENSION DC NON NÉGLIGEABLE dans
trous. les sources de soudage onduleur quand on a coupé
D S’isoler de la pièce à couper et du sol en utilisant des housses ou des l’alimentation.
tapis assez grands afin d’éviter tout contact physique avec la pièce à D Arrêter les convertisseurs, débrancher le courant électrique et
couper ou le sol. décharger les condensateurs d’alimentation selon les instructions indi-
D Ne pas se servir de source électrique à courant électrique dans les zo- quées dans la partie Entretien avant de toucher les pièces.
nes humides, dans les endroits confinés ou là où on risque de tomber. LES FUMÉES ET LES GAZ peuvent
D Se servir d’une source électrique à courant électrique UNIQUEMENT si être dangereux.
le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère né- Le soudage génère des fumées et des gaz. Leur
cessaire, se servir de la fonction de télécommande si l’appareil en est inhalation peut être dangereuse pour la santé.
équipé.
D D’autres consignes de sécurité sont nécessaires dans les conditions D Ne pas mettre sa tête au-dessus des vapeurs. Ne pas respirer ces va-
suivantes : risques électriques dans un environnement humide ou si l’on peurs.
porte des vêtements mouillés ; sur des structures métalliques telles que D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au niveau de
sols, grilles ou échafaudages ; en position coincée comme assise, à ge- l’arc pour l’évacuation des fumées et des gaz de soudage.
noux ou couchée ; ou s’il y a un risque élevé de contact inévitable ou D Si la ventilation est médiocre, porter un respirateur anti-vapeurs approu-
accidentel avec la pièce à souder ou le sol. Dans ces conditions, utiliser vé.
les équipements suivants, dans l’ordre indiqué : 1) un poste à souder DC D Lire et comprendre les spécifications de sécurité des matériaux (MSDS) et
à tension constante (à fil), 2) un poste à souder DC manuel (électrode) les instructions du fabricant concernant les métaux, les consommables, les
ou 3) un poste à souder AC à tension à vide réduite. Dans la plupart des revêtements, les nettoyants et les dégraisseurs.
situations, l’utilisation d’un poste à souder DC à fil à tension constante D Travailler dans un espace fermé seulement s’il est bien ventilé ou en
est recommandée. En outre, ne pas travailler seul ! portant un respirateur à alimentation d’air. Demander toujours à un sur-
D Couper l’alimentation ou arrêter le moteur avant de procéder veillant dûment formé de se tenir à proximité. Des fumées et des gaz de
à l’installation, à la réparation ou à l’entretien de l’appareil. Déverrouiller soudage peuvent déplacer l’air et abaisser le niveau d’oxygène provo-
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir normes de quant des blessures ou des accidents mortels. S’assurer que l’air de
sécurité). respiration ne présente aucun danger.
D Installer le poste correctement et le mettre à la terre convenablement D Ne pas souder dans des endroits situés à proximité d’opérations de dé-
selon les consignes du manuel de l’opérateur et les normes nationales, graissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de
provinciales et locales. l’arc peuvent réagir en présence de vapeurs et former des gaz haute-
ment toxiques et irritants.
D Toujours vérifier la terre du cordon d’alimentation. Vérifier et s’assurer D Ne pas souder des métaux munis d’un revêtement, tels que l’acier gal-
que le fil de terre du cordon d’alimentation est bien raccordé à la borne vanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait
de terre du sectionneur ou que la fiche du cordon est raccordée à une été enlevé dans la zone de soudure, que l’endroit soit bien ventilé et en
prise correctement mise à la terre. portant un respirateur à alimentation d’air. Les revêtements et tous les
D En effectuant les raccordements d’entrée, fixer d’abord le conducteur métaux renfermant ces éléments peuvent dégager des fumées toxi-
de mise à la terre approprié et contre-vérifier les connexions. ques en cas de soudage.
OM-230 693 Page 5
LES RAYONS D’ARC peuvent entraî- LES ACCUMULATIONS DE GAZ
ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures
Le rayonnement de l’arc du procédé de soudage ou même la mort.
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provo- D Fermer l’alimentation du gaz protecteur en cas
quer des brûlures dans les yeux et sur la peau. de non-utilisation.
Des étincelles sont projetées pendant le soudage. D Veiller toujours à bien aérer les espaces confi-
nés ou se servir d’un respirateur d’adduction
D Porter un casque de soudage approuvé muni de verres filtrants ap- d’air homologué.
proprié pour protéger visage et yeux pendant le soudage (voir ANSI
Z49.1 et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous vo- DES PIÈCES CHAUDES peuvent
tre casque.
provoquer des brûlures graves.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements et D Ne pas toucher des parties chaudes à mains
les étincelles ; prévenir toute personne sur les lieux de ne pas nues.
regarder l’arc. D Prévoir une période de refroidissement avant
D Porter des vêtements confectionnés avec des matières résistantes d’utiliser le pistolet ou la torche.
et ignifuges (cuir, coton lourd ou laine) et des bottes de protection. D Ne pas toucher aux pièces chaudes, utiliser les outils recom-
mandés et porter des gants de soudage et des vêtements épais
LE SOUDAGE peut provoquer un pour éviter les brûlures.
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut LES CHAMPS MAGNÉTIQUES peuvent
provoquer leur éclatement. Des étincelles peuvent affecter les stimulateurs cardiaques.
être projetées de l’arc de soudure. La projection D Porteurs de stimulateur cardiaque, rester
d’étincelles, des pièces chaudes et des équipements chauds peuvent
provoquer des incendies et des brûlures. Le contact accidentel de à distance.
l’électrode avec des objets métalliques peut provoquer des étincelles, D Les porteurs d’un stimulateur cardiaque doi-
une explosion, une surchauffe ou un incendie. Avant de commencer vent d’abord consulter leur médecin avant de
le soudage, vérifier et s’assurer que l’endroit ne présente pas de s’approcher des opérations de soudage à l’arc,
danger. de gougeage ou de soudage par points.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité, les recouvrir soi- LE BRUIT peut endommager l’ouïe.
gneusement avec des protections homologuées.
D Ne pas souder dans un endroit où des étincelles peuvent tomber sur Le bruit des processus et des équipements peut
des substances inflammables. affecter l’ouïe.
D Se protéger, ainsi que toute autre personne travaillant sur les lieux, D Porter des protections approuvées pour les
contre les étincelles et le métal chaud.
oreilles si le niveau sonore est trop élevé.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Afin d’éliminer tout risque de feu, être vigilant et garder toujours un
LES BOUTEILLES peuvent exploser
extincteur à la portée de main. si elles sont endommagées.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation Des bouteilles de gaz protecteur contiennent du gaz
peut déclencher un incendie de l’autre côté. sous haute pression. Si une bouteille est endomma-
D Ne pas effectuer le soudage sur des conteneurs fermés tels que des gée, elle peut exploser. Du fait que les bouteilles de
réservoirs, tambours, ou conduites, à moins qu’ils n’aient été prépa- gaz font normalement partie du procédé de soudage,
rés correctement conformément à AWS F4.1 (voir les normes de les manipuler avec précaution.
sécurité).
D Brancher le câble de masse sur la pièce le plus près possible de la D Protéger les bouteilles de gaz comprimé d’une chaleur excessi-
zone de soudage pour éviter le transport du courant sur une longue ve, des chocs mécaniques, des dommages physiques, du lai-
distance par des chemins inconnus éventuels en provoquant des tier, des flammes ouvertes, des étincelles et des arcs.
risques d’électrocution, d’étincelles et d’incendie. D Placer les bouteilles debout en les fixant dans un support sta-
D Ne pas utiliser le poste de soudage pour dégeler des conduites tionnaire ou dans un porte-bouteilles pour les empêcher de tom-
gelées. ber ou de se renverser.
D En cas de non-utilisation, enlever la baguette d’électrode du porte- D Tenir les bouteilles éloignées des circuits de soudage ou autres
électrode ou couper le fil à la pointe de contact. circuits électriques.
D Porter des vêtements de protection exempts d’huile tels que des D Ne jamais placer une torche de soudage sur une bouteille à gaz.
gants en cuir, une veste résistante, des pantalons sans revers, des D Une électrode de soudage ne doit jamais entrer en contact avec
bottes et un casque. une bouteille.
D Avant de souder, retirer toute substance combustible de ses poches D Ne jamais souder une bouteille pressurisée − risque d’explosion.
telles qu’un allumeur au butane ou des allumettes. D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
D Suivre les consignes de OSHA 1910.252 (a) (2) (iv) et de NFPA 51B tuyaux et raccords convenables pour cette application spécifi-
pour travaux de soudage et prévoir un détecteur d’incendie et un ex- que ; les maintenir ainsi que les éléments associés en bon état.
tincteur à proximité. D Détourner votre visage du détendeur-régulateur lorsque vous
ouvrez la soupape de la bouteille.
DES PARTICULES VOLANTES D Le couvercle du détendeur doit toujours être en place, sauf lors-
peuvent blesser les yeux. que la bouteille est utilisée ou qu’elle est reliée pour usage ulté-
rieur.
D Le soudage, l’écaillement, le passage de la
pièce à la brosse en fil de fer, et le meulage D Utiliser les équipements corrects, les bonnes procédures et suf-
génèrent des étincelles et des particules fisamment de personnes pour soulever et déplacer les bouteil-
les.
métalliques volantes. Pendant la période de
refroidissement des soudures, elles risquent D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
de projeter du laitier. l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécuri-
D Porter des lunettes de sécurité avec écrans latéraux ou un écran té.
facial.
OM-230 693 Page 6

2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent

SION. provoquer des blessures.
D Ne pas placer l’appareil sur, au-dessus ou D S’abstenir de toucher des organes mobiles tels
à proximité de surfaces inflammables. que des ventilateurs.
D Ne pas installer l’appareil à proximité de D Maintenir fermés et verrouillés les portes,
produits inflammables. panneaux, recouvrements et dispositifs de
D Ne pas surcharger l’installation électrique − s’assurer que protection.
l’alimentation est correctement dimensionnée et protégée avant D Seules des personnes qualifiées sont autorisées à enlever les
de mettre l’appareil en service. portes, panneaux, recouvrements ou dispositifs de protection
pour l’entretien.
D Remettre les portes, panneaux, recouvrements ou dispositifs de
protection quand l’entretien est terminé et avant de rebrancher
LA CHUTE DE L’APPAREIL peut l’alimentation électrique.
blesser.
D Utiliser l’anneau de levage uniquement pour LIRE LES INSTRUCTIONS.
soulever l’appareil, NON PAS les chariots, les D Lire le manuel d’utilisation avant d’utiliser ou
bouteilles de gaz ou tout autre accessoire. d’intervenir sur l’appareil.
D Utiliser un équipement de levage de capacité D Utiliser uniquement des pièces de rechange
suffisante pour lever l’appareil. Miller/Hobart.
D En utilisant des fourches de levage pour déplacer l’unité, s’assu-
rer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil. LE RAYONNEMENT HAUTE
FRÉQUENCE (HF) risque de provoquer
des interférences.
L’EMPLOI EXCESSIF peut SUR- D Le rayonnement haute fréquence (HF) peut
CHAUFFER L’ÉQUIPEMENT. provoquer des interférences avec les équipe-
D Prévoir une période de refroidissement ; ments de radio-navigation et de communica-
respecter le cycle opératoire nominal. tion, les services de sécurité et les ordinateurs.
D Réduire le courant ou le facteur de marche D Demander seulement à des personnes qualifiées familiarisées
avant de poursuivre le soudage. avec des équipements électroniques de faire fonctionner l’instal-
lation.
D Ne pas obstruer les passages d’air du poste.
D L’utilisateur est tenu de faire corriger rapidement par un électri-
cien qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement
LES CHARGES ÉLECTROSTATIQUES l’appareil.
peuvent endommager les circuits D Effectuer régulièrement le contrôle et l’entretien de l’installation.
imprimés. D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une
D Établir la connexion avec la barrette de terre distance correcte et utiliser une terre et un blindage pour réduire
avant de manipuler des cartes ou des pièces. les interférences éventuelles.
D Utiliser des pochettes et des boîtes antistati-
ques pour stocker, déplacer ou expédier des
cartes PC. LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D L’énergie électromagnétique peut gêner le
DES ORGANES MOBILES peuvent fonctionnement d’appareils électroniques
provoquer des blessures. comme des ordinateurs et des robots.
D Ne pas s’approcher des organes mobiles. D Veiller à ce que tout l’équipement de la zone de
soudage soit compatible électromagnétiquement.
D Ne pas s’approcher des points de coincement
D Pour réduire la possibilité d’interférence, maintenir les câbles de
tels que des rouleaux de commande. soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipe-
LES FILS DE SOUDAGE peuvent ment électronique sensible.
provoquer des blessures. D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction. D En cas d’interférences après avoir pris les mesures précéden-
tes, il incombe à l’utilisateur de prendre des mesures supplé-
D Ne pas diriger le pistolet vers soi, d’autres mentaires telles que le déplacement du poste, l’utilisation de
personnes ou toute pièce mécanique en enga- câbles blindés, l’utilisation de filtres de ligne ou la pose de protec-
geant le fil de soudage. teurs dans la zone de travail.
2-4. Proposition californienne 65 Avertissements

Y Les équipements de soudage et de coupage produisent des Pour les moteurs à essence :
fumées et des gaz qui contiennent des produits chimiques dont Y Les gaz d’échappement des moteurs contiennent des produits
l’État de Californie reconnaît qu’ils provoquent des malformations chimiques dont l’État de Californie reconnaît qu’ils provoquent
congénitales et, dans certains cas, des cancers. (Code de santé et des cancers et des malformations congénitales ou autres pro-
de sécurité de Californie, chapitre 25249.5 et suivants) blèmes de procréation.
Y Les batteries, les bornes et autres accessoires contiennent du Pour les moteurs diesel :
plomb et des composés à base de plomb, produits chimiques Y Les gaz d’échappement des moteurs diesel et certains de leurs
dont l’État de Californie reconnaît qu’ils provoquent des can- composants sont reconnus par l’État de Californie comme
cers et des malformations congénitales ou autres problèmes de provoquant des cancers et des malformations congénitales ou au-
procréation. Se laver les mains après manipulation. tres problèmes de procréation.
OM-230 693 Page 7
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone :
de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet :
ternet : www.global.ihs.com). www.csa-international.org).
Recommended Safe Practices for the Preparation for Welding and Cut- Practice For Occupational And Educational Eye And Face Protection,
ting of Containers and Piping, American Welding Society Standard AWS ANSI Standard Z87.1, de American National Standards Institute, 11 West
F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site 42nd Street, New York, NY 10036-8002 (téléphone : 212-642-4900, site
Internet : www.global.ihs.com). Internet : www.ansi.org).
National Electrical Code, NFPA Standard 70, de National Fire Protection Standard for Fire Prevention During Welding, Cutting, and Other Hot
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA Work, NFPA Standard 51B, de National Fire Protection Association, P.O.
02269-9101 (téléphone : 617-770-3000, site Internet : www.nfpa.org). Box 9101, 1 Battery March Park, Quincy, MA 02269-9101 (téléphone :
617-770-3000, site Internet : www.nfpa.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
de Compressed Gas Association, 1735 Jefferson Davis Highway, Suite OSHA, Occupational Safety and Health Standards for General Industry,
1004, Arlington, VA 22202-4102 (téléphone : 703-412-0900, site Internet Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
: www.cganet.com). Part 1926, Subpart J, de U.S. Government Printing Office, Superinten-
dent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a 10
Code for Safety in Welding and Cutting, CSA Standard W117.2, de bureaux régionaux−−le téléphone de la région 5, Chicago, est
Canadian Standards Association, Standards Sales, 178 Rexdale 312-353-2220, site Internet : www.osha.gov).
2-6. Information EMF

Considérations sur le soudage et les effets de basse fréquence et des 1. Maintenir les câbles ensemble en les tordant ou en les enveloppant.
champs magnétiques et électriques.
Le courant de soudage, pendant son passage dans les câbles de souda- 2. Disposer les câbles d’un côté et à distance de l’opérateur.
ge, causera des champs électromagnétiques. Il y a eu et il y a encore un
3. Ne pas courber pas et ne pas entourer pas les câbles autour de
certain souci à propos de tels champs. Cependant, après avoir examiné
plus de 500 études qui ont été faites pendant une période de recherche votre corps.
de 17 ans, un comité spécial ruban bleu du National Research Council a
4. Garder le poste de soudage et les câbles le plus loin possible de
conclu : « L’accumulation de preuves, suivant le jugement du comité, n’a
vous.
pas démontré que l’exposition aux champs magnétiques et champs élec-
triques à haute fréquence représente un risque à la santé humaine ». 5. Connecter la pince sur la pièce aussi près que possible de la sou-
Toutefois, des études sont toujours en cours et les preuves continuent à
dure.
être examinées. En attendant que les conclusions finales de la recherche
soient établies, il vous serait souhaitable de réduire votre exposition aux En ce qui concerne les stimulateurs cardiaques
champs électromagnétiques pendant le soudage ou le coupage. Les porteurs de stimulateur cardiaque doivent consulter leur médecin
Pour réduire les champs magnétiques sur le poste de travail, appliquer avant de souder ou d’approcher des opérations de soudage. Si le méde-
les procédures suivantes : cin approuve, il est recommandé de suivre les procédures précédentes.
OM-230 693 Page 8

. A complete Parts List is available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. Symbols And Definitions
Wire Feed Output

X Duty Cycle
Do Not Switch
While Welding
V Volts Increase On Off
Gas Metal Arc

Wire Feed Spool
Welding (GMAW) Gas Input Gas Output
Gun
Gun
Voltage Input Press To Reset U0 Rated No-Load

Voltage (Average)
SECTION 4 − INSTALLATION
4-1. Specifications
Amps Input at Rated Output (60% Duty Cycle), 60 Hz, Single-Phase
Rated Output Max. OpenCircuit
Voltage 200 (208) V 230 V 460 V 575 V KVA KW
250 A at 28 VDC, 200 A at 28 VDC, 38 48 42 21 17 9.8 7.5
40% Duty Cycle 60% Duty Cycle 2.3* 2* 1* 0.8* 0.46* 0.13*
Wire Type and Diameter Wire Feed Speed Dimensions Net Weight Without Gun
Solid Steel Stainless Steel Flux Cored 50−700 IPM H: 30 in (762 mm) 205 lb
(1.3−17.8 m/min) W: 19 in (483 mm) (93 kg)
.023 − .045 in .023 − .045 in .030 − .045 in D: 40 in (1016 mm)
(0.6 − 1.2 mm) (0.6 − 1.2 mm) (0.8 − 1.2 mm)
* While idling
Operating Temperature Range − −20C to +40C Storage Temperature Range − -30C to + 50C
OM-230 693 Page 9

4-2. Welding Power Source Duty Cycle And Overheating

Duty Cycle is percentage of 10
minutes that unit can weld at rated
500 load without overheating.
450 If unit overheats, Thermistor (T)
400
opens, output stops, and cooling
350
fan runs. Wait fifteen minutes for
WELD AMPERES 300 unit to cool. Reduce amperage or
250 voltage, or duty cycle before
welding.
200
Y Exceeding duty cycle can
150 damage unit and void
warranty.
100
50
10 20 30 40 50 60 70 80 90 100
% DUTY CYCLE
60% Duty Cycle At 200 Amperes 40% Duty Cycle At 250 Amperes
6 Minutes Welding 4 Minutes Resting 4 Minutes Welding 6 Minutes Resting
Overheating
0
A or V
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 150 215-A
4-3. Volt-Ampere Curves

1 1 Normal Volt-Ampere Curves
35
The volt-ampere curves show the
normal minimum and maximum
30 voltage and amperage output
capabilities of the welding power
source. Curves of other settings fall
25 between the curves shown.
VOLTS
20
15
10
0
0 100 200 300 400
AMPERES ssb1.1 10/91 − 196 844 / S-0700
OM-230 693 Page 10

4-4. Connecting To Weld Output Terminals
4
1
Do not place
anything between
weld cable terminal
and copper bar.
3
Tools Needed:
3/4 in (19 mm)
803 778-A
Correct Installation Incorrect Installation
Y Turn off power before connecting to 1 Weld Output Terminal minal. Slide weld cable terminal onto weld
weld output terminals. output terminal and secure with nut so that
2 Supplied Weld Output Terminal Nut
weld cable terminal is tight against copper
Y Failure to properly connect weld 3 Weld Cable Terminal bar. Do not place anything between weld
cables may cause excessive heat 4 Copper Bar cable terminal and copper bar. Make
and start a fire, or damage your ma- sure that the surfaces of the weld cable
chine. Remove supplied nut from weld output ter- terminal and copper bar are clean.
4-5. Installing Work Cable And Clamp

1 Work Cable
2 Boot
Route cable through front panel
opening. Slide boot onto work
cable.
3 Negative (−) Output Terminal
Connect cable to terminal and
cover connection with boot.
Close door.
Tools Needed:
3/4 in
804 909-A
OM-230 693 Page 11

4-6. Connecting Spoolmatic) 15A Or 30A Gun

1 Gun Trigger Plug
Insert plug into receptacle, and
tighten threaded collar.
2 Weld Cable
3 Shielding Gas Hose
Route weld cable through opening
in front panel.
Route gas hose along side panel.
4 Positive Weld Output Terminal
Connect weld cable to weld output
terminal.
5 Regulator/Flowmeter
Route shielding gas hose up to
regulator/flowmeter. Connect gas
hose to fitting on regulator/flowme-
ter.
2
. Two welding guns may be
3 connected to the welding
power source at the same time,
but only one welding gun may
be in use at any one time. If the
triggers of both welding guns
1 are pulled at the same time, the
weld output and wirefeed motor
are disabled.
Tools Needed:
3/4, 5/8 in
804 910-A
OM-230 693 Page 12

4-7. Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python

. XR Edge guns prior to serial no.
LE079101 require an adapter
cord (part no. 195 498).
1 Gun End
2 Gun Liner
3 Wire Outlet Guide
Trim excess liner from end of gun
so no more than 3/32 in (2.4 mm) of
liner extends past wire outlet guide.
4 Gun Securing Knob
3/32 in Loosen securing knob. Insert gun
(2.4 mm) end through opening until it bottoms
against drive assembly (make sure
gun end does not touch drive rolls).
Tighten knob.
Be sure to change drive rolls to the
4 proper size and type.
5 Gun Trigger Plug
Insert plug into receptacle, and
2 3 tighten threaded collar.
. If Aluma-Pro push/pull gun has

a listed SUP value, set the
power source to match the
SUP value (see Section 5-5).
. Be sure to trim liner to proper extension.
Ref. 804 910-A / 804 936-A
OM-230 693 Page 13

4-8. Setting Gun Polarity For Wire Type

1 Polarity Changeover Label
Changing Polarity Information
Always read and follow manufacture’s
recommended polarity.
Wire Drive Work Clamp Lead

Assembly Lead
D
D
+ Positive Terminal - Negative Terminal
Shown as shipped − Electrode Positive (DCEP): For

solid steel, stainless steel, aluminum, or flux core with
gas wires (GMAW).
Electrode Negative (DCEN): Reverse lead connections
at terminals from that shown above for gasless flux core
wires (FCAW). Drive assembly becomes negative. 3/4, 11/16 in
Ref. 190 821-A
4-9. Installing Gas Supply

Obtain gas cylinder and chain to
. DO NOT use Argon/Mixed gas regulator/flowmeter running gear, wall, or other
with CO2 shielding gas. See Parts List for optional stationary support so cylinder
CO2 gas regulator/flowmeter. cannot fall and break off valve.
1 Cap
1 2 Cylinder Valve
4
Remove cap, stand to side of
valve, and open valve slightly. Gas
2 flow blows dust and dirt from valve.
Close valve.
3 Cylinder
4 Regulator/Flowmeter
3
Install so face is vertical.
7
5 5 Regulator/Flowmeter Gas
Hose Connection
6 Welding Power Source Gas
Argon Gas Or Hose Connection
Mixed Gas Connect customer supplied gas
hose between regulator/flowmeter
gas hose connection, and fitting on
rear of welding power source.
7 Flow Adjust
Typical flow rate is 20 cfh (cubic
6 feet per hour). Check wire
manufacturer’s recommended
flow rate.
Rear Panel
Tools Needed:
1-1/8, 5/8 in
802 028-A / Ref. 804 912-A
OM-230 693 Page 14

4-10. Installing Wire Spool And Adjusting Hub Tension

Use compression spring When a slight force is needed
with 8 in (200 mm) spools. to turn spool, tension is set.
Installing 1 Or 2 lb Wire Spool To install either a 1 lb or 2 lb wire

spool, follow the procedure as
Spindle
Install these shown in the illustration.
Spindle components
onto spindle.
Order extra spring

Part No. 186 437
Remove these
components
from spindle.
Tools Needed:
15/16 in
072573-B / 802 922
4-11. Positioning Jumper Links

Tools Needed: Check input voltage available at
site.
3/8 in 1 Jumper Links Access Door
Open door.
2 Jumper Link Label
230VOLTS 460VOLTS 575VOLTS Check label − only one is on unit.
200VOLTS 230VOLTS
3 Input Voltage Jumper Links
Move jumper links to match input
3 voltage.
153980−D 144916−E
Close and secure access door.
153 980-D / 144 916-E / 804 911-A
OM-230 693 Page 15

4-12. Electrical Service Guide

Input Voltage 200 230 460 575
Input Amperes At Rated Output 48 42 21 17
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
Circuit Breaker 1, Time-Delay 2 60 50 25 20
Normal Operating 3 70 60 30 25
Min Input Conductor Size In AWG4 8 8 12 14
96 127 206 209
Max Recommended Input Conductor Length In Feet (Meters)
(29) (39) (63) (64)
Min Grounding Conductor Size In AWG4 8 10 12 14
Reference: 2005 National Electrical Code (NEC) (including article 630)

1 Choose a circuit breaker with time-current curves comparable to a Time Delay Fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose − no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
Y Warning: Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These
recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source.
OM-230 693 Page 16

4-13. Selecting A Location And Connecting Input Power
8 =GND/PE Earth Ground

18 in (457 mm) of
space for airflow 10
L1 5
6 L2 Y Do not move or operate
unit where it could tip.
4 2
1
3
L2 L1
230 VAC, 1
804 912-A
Y Installation must meet all National 2 Plug (NEMA Type 6-50P) 9 Disconnect Device Line Terminals
and Local Codes − have only qualified 3 Receptacle Connect green or green/yellow grounding
persons make this installation. [NEMA Type 6-50R (Customer conductor to disconnect device grounding
Y Disconnect and lockout/tagout input Supplied)] terminal first.
power before connecting input con-
4 Input Power Cord. Connect input conductors L1 and L2 to
ductors from unit.
disconnect device line terminals.
Y Always connect green or green/yel- Connect directly to line disconnect device if
low conductor to supply grounding hard wiring is required. 10 Over-Current Protection
terminal first, and never to a line ter- Select type and size of over-current
5 Black And White Input Conductor (L1
minal. protection using Section 4-12 (fused
And L2)
Y Special installation may be required disconnect switch shown).
where gasoline or volatile liquids are 6 Green Or Green/Yellow Grounding Connect plug to receptacle if hard wiring
present − see NEC Article 511 or CEC Conductor method is not used.
Section 20. 7 Disconnect Device (switch shown in Close and secure door on disconnect device.
1 Rating Label the OFF position) Remove lockout/tagout device, and place
Supply correct input power. 8 Disconnect Device Grounding Terminal switch in the On position.
OM-230 693 Page 17

4-14. Threading Welding Wire

1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4
4 Pressure Adjustment Knob
5 Drive Roll
6 Outlet Wire Guide
7 Gun Conduit Cable
Lay gun cable out straight.
1 2 Tools Needed:
3
5 6
. Hold wire tightly to keep it

from unraveling.
6 in
(150 mm)
Open pressure assembly. Pull and hold wire; cut off end. Push wire thru guides into gun;
continue to hold wire.
. Use pressure indicator

Tighten scale to set a desired
drive roll pressure.
1 Pressure
2 Indicator
3 Scale
4
Close and tighten pressure Remove gun nozzle and contact tip. Turn On.
assembly, and let go of wire.
Tighten
1
2
3
WOOD 4
Press gun trigger until wire Feed wire to check drive roll pressure. Cut off wire. Close
comes out of gun. Reinstall Tighten knob enough to prevent slipping. and latch door.
contact tip and nozzle
Ref. 804 913-A
OM-230 693 Page 18

Notes
OM-230 693 Page 19

4-15. Weld Parameters
OM-230 693 Page 20

226 650-B
OM-230 693 Page 21

SECTION 5 − OPERATION
5-1. Controls
1 Voltage Control
Turn control clockwise to increase
voltage.
2 Wire Speed Control
Turn control clockwise to increase wire
feed speed.
3 Voltmeter
4 Wire Feed Speed Meter
3 4
1 2
. This unit has three automatic timers included in its operation to help save contact
tips, gas, and wire:
Tip Saver − Weld output shuts off if tip is shorted to work surface.
Safety shut-off − Weld output will shut off if no arc is detected within 3 seconds after
gun trigger is depressed.
Jog mode − When loading a new roll of wire or if the gun trigger is accidentally
pressed, gas will shut off after 1 minute and wire will shut off after 2 minutes saving
wire and gas.
226 647-B
OM-230 693 Page 22

JOG Mode which is recommended for most wire sizes trigger and pull the trigger again
and types. momentarily (one second).
If the trigger on either gun is held for more
than 3 seconds without striking an arc, the To change Run−in settings, start with the
unit will automatically shut off weld power Spool Gun Run−in is factory set at 50% power switch OFF. Press and hold the MIG
(and shielding gas output on MIG gun which is recommended for .030 & .035 or Spool Gun Trigger while turning the
only), but will feed wire continuously at the wire. A Run−in setting of 25% is power switch ON. The unit will power up
preset wire feed speed (which may be recommended for .047 wire.
with both the displays reading 888 , then
faster or slower than Run−in Speed) until
the voltage display will read run and the
trigger is released. To check Run−in settings, start with the wire feed display will read the preset Run−
Run−in Wire Feed Speed Settings power switch OFF. Press and hold the MIG in percentage from memory for the gun se-
or Spool Gun Trigger while turning the lected. To change the Run−in value, re-
Run−in settings for the MIG and Spool power switch ON. The unit will power up lease the trigger and turn the wire feed con-
Guns are independently set and stored in with both the displays reading 888 , then trol knob (or the wire feed adjustment knob
unit memory. The settings are in percent of
the voltage display will read run and the located on the bottom handle of the spool
the welding wire feed speed preset. Both
wire feed display will read the preset gun) to the desired setting for the selected
settings are adjustable from 25 to 150
Run−in percentage from memory for the gun. To return to weld mode after the Run−
percent.
gun selected. To return to the weld mode in speed change, pull the trigger momen-
MIG Gun Run−in is factory set at 100% without making a change, simply release tarily (one second).
OM-230 693 Page 23

5-2. Voltmeter And Wire Feed Speed Meter Operation
1 2
1 Voltmeter Welding Status Gun Selection

2 Wire Feed Speed Meter When either a MIG gun or spool gun trigger
The wire feed speed meter will display
is pressed and a welding arc is established,
preset wire feed speed (IPM) for the
Power Up Status the voltmeter displays actual weld voltage.
appropriate gun selection either MIG,
When the gun trigger is released and
Spool or Push/Pull gun. To preset desired
Both meters display 888 at unit power up. welding arc extinguished, the voltmeter
wire feed speed, connect desired gun,
After 0.5 seconds, preset values appear on displays the last actual voltage for 5
press gun trigger for one second, and
both meters. The settings for the last active seconds and then returns to preset voltage.
release trigger. The meter preset will be
gun used will be the default at initial power If welding resumes before unit displays
retained by the meter board until a different
up of the unit. If the power is reset to quickly, preset voltage, actual welding voltage will
gun is connected and preset is performed
characters other than 888 may appear. To appear on the voltmeter.
or the unit is turned off and back on. The
reset, turn power off for at least 3 seconds, The wire feed speed meter always displays settings for the last active gun used will be
then turn power back on. preset wire feed speed (IPM). the default at initial power up of the unit.
5-3. Jog Mode

If the trigger on either gun is held for more than 3 seconds without striking an arc, the unit will automatically shut off
weld power (and shielding gas output on MIG or push/pull gun), but will feed wire continuously at the preset wire feed
speed (which may be faster or slower than Run−in Speed) until trigger is released. Jog wire feed speed is the same as
weld wire feed speed, so any time jog speed is changed, be sure to change back to weld wire feed speed before weld-
ing. Jog wire feed speed for the spool gun and push/pull gun is limited to 300 ipm (7.6 m/min).
OM-230 693 Page 24

5-4. Timers
3 4
1 2
1 Voltage Control Run-in speed (run) − The speed of the wire gized after the wire feeding has stopped.
2 Wire Speed Control prior to the welding arc being struck. The The range is from 0.01 to 0.25 seconds.
range is from 25 to 150% of wire feed Spot Timer (SPO) − The amount of time
3 Voltmeter
speed(WFS). that the arc will be active before it shuts off
4 Wire Feed Speed Meter
Preflow (PrE) − The amount of time that automatically. The range is from 0 to 120
To enter the TIMERS menu press and hold the shielding gas will flow after the trigger seconds. Spot timer is reset upon release
the gun trigger while turning on the power is depressed and before the welding arc of welding gun trigger.
switch until the left meter displays (run), will be allowed to be active. The range is “Stitch” Timer (dLY) − Used in conjunc-
then release trigger. from 0.0 to 5.0 seconds. tion with the Spot timer and while the trigger
Once in the TIMERS menu, rotate the left Postflow (POS) − The amount of time that is continuously depressed. Controls the
knob clockwise (CW) to find the particular the shielding gas will flow after the arc has amount of time that the arc will be inactive
item, and rotate the right knob to change been shut off. The range is from 0.0 to 10.0 after the Spot timer times out. The range is
the setting. seconds. from 0 to 120 seconds.
The following items can be adjusted by ro- Burnback (Bur) − The amount of time that To save settings and exit the TIMERS
tating the left knob clockwise (CW): the welding wire remains electrically ener- menu, depress the gun trigger.
OM-230 693 Page 25

. Welding wire birdnesting at the welding power source drive rolls may occur if this value is set too high.
5-5. Set Up Push Motor Torque (SUP) Or Reset (rES)
3 4
1 2
1 Voltage Control The following items can be adjusted by over-torque limit and speed up the remote
2 Wire Speed Control rotating the left knob counterclockwise wire feed speed motor.
3 Voltmeter (CCW):
Set up Push Motor Torque (SUP) − This
. If Aluma-Pro push/pull gun has a listed
4 Wire Feed Speed Meter SUP value, set the power source to
feature is only active when a push/pull gun
Depress the gun trigger while turning on match the SUP value.
is connected to the welding power source.
the power switch until the left meter The (SUP) setting will adjust the To save settings and exit the (SUP) menu,
displays (run). over-torque limit of the push motor inside depress the gun trigger.
Rotate the left knob counterclockwise the welding power source. The range is Reset (rES) − Rotate the right knob to
(CCW) to find the particular item, and rotate 0-250 and the default value is 130. select ON. Press and release gun trigger to
the right knob to change the setting. Increasing this setting will increase the reset system to factory default values.
OM-230 693 Page 26

SECTION 6 − MAINTENANCE &TROUBLESHOOTING
6-1. Routine Maintenance
Y Disconnect power . Maintain more often

before maintaining. during severe conditions.
n = Check Z = Change ~ = Clean l = Replace Reference

* To be done by Factory Authorized Service Agent
Every
3
Months
l Unreadable Labels ~ Weld Terminals nl Weld Cables

Every
6
OR
Months
~ Inside Unit n Apply Light Coat Of Oil

Or Grease To Drive Motor
Shaft
6-2. Unit Overload
Thermistor T in SCR1 protects the unit from damage due to overheating. If HL.P 002 is displayed on the meters, wait
for unit to cool allowing fan motor to run before trying to weld. If unit is cool and no weld output continues, contact
Factory Authorized Service Agent.
6-3. Changing Drive Roll and Wire Inlet Guide

1 Securing Screw
2 2 Inlet Wire Guide
Loosen screw. Slide tip as close to
drive rolls as possible without
touching. Tighten screw.
4
3 Drive Roll
The drive roll consists of two
different sized grooves. The
stamped markings on the end
surface of the drive roll refers to the
groove on the opposite side of the
1 drive roll. The groove closest to the
motor shaft is the proper groove to
thread (see Section 4-14).
4 Drive Roll Securing Nut
Turn nut one click to secure drive
roll.
3
Tools Needed:
7/16 in
Ref. 804 914-A
OM-230 693 Page 27

6-4. Aligning Drive Rolls and Wire Guide

Y Turn Off power.
View is from top of drive rolls
looking down with pressure
assembly open.
Correct Incorrect 1 Drive Roll Securing Nut
3 4 2 Drive Roll
2 3 Wire Guide
1 4 Welding Wire
5 Drive Gear
5 Insert screwdriver, and turn screw
in or out until drive roll groove lines
up with wire guide.
Close pressure roll assembly.
Tools Needed:
Ref. 800 412-A
OM-230 693 Page 28

6-5. Troubleshooting
Trouble Remedy
No weld output; wire does not feed. Be sure line disconnect switch is On (see Section 4-13).
Replace building line fuse or reset circuit breaker if open (see Section 4-13).
Secure gun trigger connections (see welding gun Owner’s Manual).
HL.P 001 appears on meters. Turn power switch off and back on, if HL.P 001 appears on meters again,
have Factory Authorized Service Agent check unit.
HL.P 002 appears on meters. Thermistor T is detecting an overheating condition. Wait for unit to cool
allowing the fan to run. After unit is cool, if HL.P 002 message remains, have Factory Authorized Service
Agent check for an open Thermistor T (see Section 6-2).
HL.P 004 appears on meters. Reset message by releasing the trigger or removing stuck wire causing
short circuit (see Section 5-2) . If message remains, have Factory Authorized Service Agent check for
shorted trigger leads.
Have Factory Authorized Service Agent check Power switch.
Have Factory Authorized Service Agent check all board connections and main control board.
No Weld Output; wire feeds. Connect work clamp to get good metal to metal contact.
Replace contact tip (see welding gun Owner’s Manual.
HL.P 003 appears on meters, have Factory Authorized Service Agent check main control board and main
rectifier.
Low weld output. Connect unit to proper input voltage or check for low line voltage (see Section 4-13).
Check input voltage jumper links and correct position if necessary (see Section 4-11).
Have Factory Authorized Service Agent check main control board.
Fan motor does not run. Have Factory Authorized Service Agent check fan-on-demand circuit.
Low, high, or erratic wire speed. Readjust front panel settings (see Section 5-1).
Change to correct size drive rolls (see Section 6-3).
Readjust drive roll pressure (see Section 4-14).
Replace inlet guide, contact tip, and/or liner if necessary (see welding gun Owner’s Manual).
Check position of input jumper links (see Section 4-11).
OM-230 693 Page 29

Trouble Remedy
No wire feed. Turn Wire Speed control to higher setting (see Section 5-1).
Clear obstruction in gun contact tip or liner (see welding gun Owner’s Manual).
Readjust drive roll pressure (see Section 4-14).
Change to correct size drive rolls (see Section 6-3).
Rethread welding wire (see Section 4-14).
HL.P 002 appears on meters. Thermistor T is detecting an overheating condition. Wait for unit to cool
allowing the fan to run. After unit is cool, If HL.P 002 message remains, contact Factory Authorized
Service Agent (see Section 6-2).
HL.P 004 appears on meters. Reset message by releasing the trigger or removing stuck wire causing
short circuit (see Section 5-2) . If message remains, have Factory Authorized Service Agent check for
shorted trigger leads.
HL.P 005 appears on meters. Wire feed malfunction. Check wire feed delivery system.
Check gun trigger and leads. Repair or replace gun if necessary.
OM-230 693 Page 30

Notes
OM-230 693 Page 31

SECTION 7 − ELECTRICAL DIAGRAM
Figure 7-1. Circuit Diagram
OM-230 693 Page 32

229 485-A
OM-230 693 Page 33

SECTION 8 − MIG WELDING (GMAW) GUIDELINES
8-1. Typical MIG Process Connections

Y Weld current can damage
electronic parts in vehicles.
Disconnect both battery
cables before welding on a
vehicle. Place work clamp as
close to the weld as possible.
Regulator/
Flowmeter
Wire Feeder/
Power Source
Gun
Shielding Gas
Gas
Workpiece
Work Clamp
mig1 2007−05 / 801 909-A
OM-230 693 Page 34

8-2. Typical MIG Process Control Settings
. These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure
they comply to specifications.
Material thickness determines weld

parameters. 1/8 or
.125 in Convert Material
Thickness to
Amperage (A)
(.001 in = 1 ampere)
.125 in = 125 A
Wire Size Amperage Range

.035 in
.023 in 30 − 90 A
Select Wire Size
.030 in 40 − 145 A
.035 in 50 − 180 A
Wire Wire Speed Select Wire Speed

Recommendation (Amperage)
Size (Approx.)
.023 in 3.5 in per ampere 3.5 x 125 A = 437 ipm 125 A based on 1/8 in
.030 in 2 in per ampere 2 x 125 A = 250 ipm material thickness
.035 in 1.6 in per ampere 1.6 x 125 A = 200 ipm
ipm = inch per minute
Low voltage: wire stubs into work

High voltage: arc is unstable (spatter) Select Voltage
Set voltage midway between high/low voltage.
Voltage controls height and Wire speed (amperage) controls weld

width of weld bead. penetration (wire speed = burn-off rate)
OM-230 693 Page 35

8-3. Holding And Positioning Welding Gun
. Welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm)
past end of nozzle, and tip of wire is positioned correctly on seam.
1 1 Hold Gun and Control Gun

Trigger
2 Workpiece
3 Work Clamp
3 4 Electrode Extension (Stickout)
2
1/4 to 1/2 in (6 To 13 mm)
5 Cradle Gun and Rest Hand on
Workpiece
5
0°-15°
90° 90°
End View Of Work Angle Side View Of Gun Angle

GROOVE WELDS
45° 0°-15°
45°
End View Of Work Angle Side View Of Gun Angle

FILLET WELDS S-0421-A
OM-230 693 Page 36

8-4. Conditions That Affect Weld Bead Shape
. Weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed
(weld current), and voltage.
10°
Push
10°
Perpendicular Drag
GUN ANGLES AND WELD BEAD PROFILES
Short Normal Long
ELECTRODE EXTENSIONS (STICKOUT)
Short Normal Long
FILLET WELD ELECTRODE EXTENSIONS (STICKOUT)
Slow Normal Fast
GUN TRAVEL SPEED

S-0634
OM-230 693 Page 37

8-5. Gun Movement During Welding
. Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps,
a weave bead or multiple stringer beads works better.
1 Stringer Bead − Steady

Movement Along Seam
1 2 2 Weave Bead − Side To Side
Movement Along Seam
3 Weave Patterns
Use weave patterns to cover a wide
area in one pass of the electrode.
S-0054-A
8-6. Poor Weld Bead Characteristics

1 Large Spatter Deposits
2 Rough, Uneven Bead
1
3 Slight Crater During Welding
4 Bad Overlap
5 Poor Penetration
2 3 4
5
S-0053-A
8-7. Good Weld Bead Characteristics

1 Fine Spatter
2 Uniform Bead
1 3 Moderate Crater During
Welding
Weld a new bead or layer for each
1/8 in (3.2 mm) thickness in metals
being welded.
4 No Overlap
5 Good Penetration into Base
Metal
2 3 4
5
S-0052-B
OM-230 693 Page 38

8-8. Troubleshooting − Excessive Spatter
Excessive Spatter − scattering of molten metal particles that

cool to solid form near weld bead.
S-0636
Possible Causes Corrective Actions
Wire feed speed too high. Select lower wire feed speed.
Voltage too high. Select lower voltage range.
Electrode extension (stickout) too long. Use shorter electrode extension (stickout).
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before welding.
Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Dirty welding wire. Use clean, dry welding wire.
Eliminate pickup of oil or lubricant on welding wire from feeder or liner.
8-9. Troubleshooting − Porosity
Porosity − small cavities or holes resulting from gas pockets

in weld metal.
S-0635
Insufficient shielding gas at welding arc. Increase flow of shielding gas at regulator/flowmeter and/or prevent drafts near welding arc.
Remove spatter from gun nozzle.
Check gas hoses for leaks.
Place nozzle 1/4 to 1/2 in (6-13 mm) from workpiece.
Hold gun near bead at end of weld until molten metal solidifies.
Wrong gas. Use welding grade shielding gas; change to different gas.
Dirty welding wire. Use clean, dry welding wire.
Eliminate pick up of oil or lubricant on welding wire from feeder or liner.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, and dirt from work surface before welding.
Use a more highly deoxidizing welding wire (contact supplier).
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
8-10. Troubleshooting − Excessive Penetration
Excessive Penetration − weld metal melting through base metal

and hanging underneath weld.
Excessive Penetration Good Penetration

S-0639
Excessive heat input. Select lower voltage range and reduce wire feed speed.
Increase travel speed.
OM-230 693 Page 39

8-11. Troubleshooting − Lack Of Penetration
Lack Of Penetration − shallow

fusion between weld metal and
base metal.
Lack of Penetration Good Penetration
S-0638
Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while
maintaining proper welding wire extension and arc characteristics.
Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration.
Keep arc on leading edge of weld puddle.
Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Insufficient heat input. Select higher wire feed speed and/or select higher voltage range.
Reduce travel speed.
8-12. Troubleshooting − Incomplete Fusion
Incomplete Fusion − failure of weld metal to fuse completely with

base metal or a preceeding weld bead.
S-0637
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, undercoating, and dirt from work surface before
welding.
Insufficient heat input. Select higher voltage range and/or adjust wire feed speed.
Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
Adjust work angle or widen groove to access bottom during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Keep arc on leading edge of weld puddle.
Use correct gun angle of 0 to 15 degrees.
8-13. Troubleshooting − Burn-Through
Burn-Through − weld metal melting completely through base metal

resulting in holes where no metal remains.
S-0640
Excessive heat input. Select lower voltage range and reduce wire feed speed.
Increase and/or maintain steady travel speed.
OM-230 693 Page 40

8-14. Troubleshooting − Waviness Of Bead
Waviness Of Bead − weld metal that is not parallel and does not cover
joint formed by base metal.
S-0641
Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle.
Unsteady hand. Support hand on solid surface or use two hands.
8-15. Troubleshooting − Distortion

Distortion − contraction of weld metal during welding that forces
base metal to move.
Base metal moves
in the direction of
the weld bead.
S-0642
Excessive heat input. Use restraint (clamp) to hold base metal in position.
Make tack welds along joint before starting welding operation.
Select lower voltage range and/or reduce wire feed speed.
Increase travel speed.
Weld in small segments and allow cooling between welds.
OM-230 693 Page 41

8-16. Common MIG Shielding Gases
This is a general chart for common gases and where they are used. Many different combinations (mixtures) of
shielding gases have been developed over the years. The most commonly used shielding gases are listed in the
following table.
Application
Gas Short Circuiting

Spray Arc Steel Short Circuiting Steel Aluminum
Stainless Steel
Argon X
Argon + 25% CO2 X
80% or greater Argon +
X X1
balance CO2 or Oxygen
100% CO2 X
Tri-Mix2 X
1 Limited short circuiting use
2 90% HE + 7-1/2% AR + 2-1/2% CO2
8-17. Troubleshooting Guide For Semiautomatic Welding Equipment
Problem Probable Cause Remedy

Wire feed motor operates, but Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls.
wire does not feed.
Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to match
wire size and type if necessary.
Wire spool brake pressure too high. Decrease brake pressure on wire spool.
Restriction in the gun and/or assembly. Check and replace cable, gun, and contact tip if
damaged. Check size of contact tip and cable liner,
replace if necessary.
Wire curling up in front of the Too much pressure on wire feed rolls. Decrease pressure setting on wire feed rolls.
wire feed rolls (bird nesting).
Incorrect cable liner or gun contact tip size. Check size of contact tip and check cable liner length
and diameter, replace if necessary.
Gun end not inserted into drive housing properly. Loosen gun securing bolt in drive housing and push gun
end into housing just enough so it does not touch wire
feed rolls.
Dirty or damaged (kinked) liner. Replace liner.
Wire feeds, but no gas flows. Gas cylinder empty. Replace empty gas cylinder.
Gas nozzle plugged. Clean or replace gas nozzle.
Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate.
Restriction in gas line. Check gas hose between flowmeter and wire feeder, and
gas hose in gun and cable assembly.
Loose or broken wires to gas solenoid. Have Factory Authorized Service Agent repair wiring.
Gas solenoid valve not operating. Have Factory Authorized Service Agent replace gas
solenoid valve.
Incorrect primary voltage connected to welding power Check primary voltage and relink welding power source
source. for correct voltage.
OM-230 693 Page 42

Problem Probable Cause Remedy
Welding arc not stable. Wire slipping in drive rolls. Adjust pressure setting on wire feed rolls. Replace worn
drive rolls if necessary.
Wrong size gun liner or contact tip. Match liner and contact tip to wire size and type.
Incorrect voltage setting for selected wire feed speed on Readjust welding parameters.
welding power source.
Loose connections at the gun weld cable or work cable. Check and tighten all connections.
Gun in poor shape or loose connection inside gun. Repair or replace gun as necessary.
OM-230 693 Page 43

SECTION 9 − PARTS LIST
9-1. Drive Roll And Wire Guide Kits
Note Base selection of drive rolls upon the following recommended usages:
1 V-Grooved rolls for hard wire.
2 U-Grooved rolls for soft and soft shelled cored wires.
3 U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
4 V-Knurled rolls for hard shelled cored wires.
5 Drive roll types may be mixed to suit particular requirements (example: V-Knurled roll in combination
with U-Grooved).
Wire Diameter Drive Roll Inlet

Kit No. Wire Guide
Fraction Decimal Metric Part No. Type
.023/.025 in. .023/.025 in. 0.6 mm 087 131 087 130 V-Grooved 056 192
.030/.035 in. .030/.035 in. 0.8/0.9 mm 204 579 203 526 V-Grooved 056 192
.030 in. .030 in. 0.8 mm 079 594 053 695 V-Grooved 056 192
.035 in. .035 in. 0.9 mm 079 595 053 700 V-Grooved 056 192
.045 in. .045 in. 1.2 mm 079 596 053 697 V-Grooved 056 193
Ref. S-0026-B/7-91
OM-230 693 Page 44

Notes
Notes
Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
Warranty Questions? guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions * Induction Heating Coils and Blankets, Cables, and
Call below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to Non-Electronic Controls
1-800-4-A-MILLER its original retail purchaser that new Miller equipment sold after
the effective date of this limited warranty is free of defects in
* APT & SAF Model Plasma Cutting Torches
for your local material and workmanship at the time it is shipped by Miller. THIS * Remote Controls
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
Miller distributor. WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Accessory (Kits)
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Replacement Parts (No labor)
Within the warranty periods listed below, Miller will repair or * Spoolmate Spoolguns
Your distributor also gives replace any warranted parts or components that fail due to such * Canvas Covers
you ... defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which Miller’s True Blue® Limited Warranty shall not apply to:
Service time Miller will provide instructions on the warranty claim 1. Consumable components; such as contact tips,
You always get the fast, procedures to be followed. cutting nozzles, contactors, brushes, slip rings, relays
reliable response you Miller shall honor warranty claims on warranted equipment listed or parts that fail due to normal wear. (Exception:
need. Most replacement below in the event of such a failure within the warranty time brushes, slip rings, and relays are covered on Bobcat,
parts can be in your periods. All warranty time periods start on the delivery date of the Trailblazer, and Legend models.)
hands in 24 hours. equipment to the original end-user purchaser, and not to exceed 2. Items furnished by Miller, but manufactured by others, such
one year after the equipment is shipped to a North American as engines or trade accessories. These items are covered
Support distributor or eighteen months after the equipment is shipped to by the manufacturer’s warranty, if any.
Need fast answers to the an International distributor.
tough welding questions? 3. Equipment that has been modified by any party other than
1. 5 Years Parts — 3 Years Labor Miller, or equipment that has been improperly installed,
Contact your distributor.
The expertise of the * Original main power rectifiers improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
distributor and Miller is 2. 3 Years — Parts and Labor
necessary maintenance, or equipment which has been
there to help you, every * Transformer/Rectifier Power Sources used for operation outside of the specifications for the
step of the way. * Plasma Arc Cutting Power Sources equipment.
* Process Controllers MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Semi-Automatic and Automatic Wire Feeders USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Inverter Power Sources (Unless Otherwise Stated) MAINTENANCE OF WELDING EQUIPMENT.
* Water Coolant Systems (Integrated)
In the event of a warranty claim covered by this warranty, the
* Intellitig exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Engine Driven Welding Generators replacement; or, where authorized in writing by Miller in
(NOTE: Engines are warranted separately by the appropriate cases, (3) the reasonable cost of repair or
engine manufacturer.) replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
3. 1 Year — Parts and Labor Unless Specified depreciation based upon actual use) upon return of the goods at
* Motor Driven Guns (w/exception of Spoolmate customer’s risk and expense. Miller’s option of repair or
Spoolguns) replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
* Positioners and Controllers Miller. Therefore no compensation or reimbursement for
* Automatic Motion Devices transportation costs of any kind will be allowed.
* RFCS Foot Controls TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Induction Heating Power Sources, Coolers, and PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
Electronic REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
Controls/Recorders DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Water Coolant Systems (Non-Integrated)
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
* Flowgauge and Flowmeter Regulators (No Labor) OTHER LEGAL THEORY.
* HF Units ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Grids ANY IMPLIED WARRANTY, GUARANTY OR
* Spot Welders REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
* Load Banks OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Arc Stud Power Sources & Arc Stud Guns PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Racks OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING ANY IMPLIED WARRANTY OF
* Running Gear/Trailers MERCHANTABILITY OR FITNESS FOR PARTICULAR
* Plasma Cutting Torches (except APT & SAF PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
Models) FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
* Field Options BY MILLER.
(NOTE: Field options are covered under True Blue® Some states in the U.S.A. do not allow limitations of how long an
for the remaining warranty period of the product they implied warranty lasts, or the exclusion of incidental, indirect,
are installed in, or for a minimum of one year — special or consequential damages, so the above limitation or
whichever is greater.) exclusion may not apply to you. This warranty provides specific
* Bernard-Branded Mig Guns (No Labor) legal rights, and other rights may be available, but may vary from
state to state.
* Weldcraft-Branded TIG Torches (No Labor)
In Canada, legislation in some provinces provides for certain
* Subarc Wire Drive Assemblies
additional warranties or remedies other than as stated herein,
4. 6 Months — Batteries and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
5. 90 Days — Parts provides specific legal rights, and other rights may be available,
* MIG Guns/TIG Torches and Subarc (SAW) Guns but may vary from province to province.
miller_warr 2007−01
Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
European Headquarters −
United Kingdom
Welding Process Handbooks Phone: 44 (0) 1204-593493
To locate a Distributor or Service Agency visit FAX: 44 (0) 1204-598066
www.millerwelds.com or call 1-800-4-A-Miller www.MillerWelds.com
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
PRINTED IN USA © 2007 Miller Electric Mfg. Co. 2007−01

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OM-230 693B 2007−07

Arc Welding Power Source

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Miller Electric manufactures a full line

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

SECTION 8 − MIG WELDING (GMAW) GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1-1. Symbol Usage

This group of symbols means Warning! Watch Out! possible

1-2. Arc Welding Hazards

WELDING can cause fire or explosion.

OM-230 693 Page 2

FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury.

H.F. RADIATION can cause interference.

ARC WELDING can cause interference.

1-4. California Proposition 65 Warnings

1-6. EMF Information

OM-230 693 Page 4

2-1. Symboles utilisés

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

OM-230 693 Page 6

Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent

2-4. Proposition californienne 65 Avertissements

2-6. Information EMF

OM-230 693 Page 8

Wire Feed Output

V Volts Increase On Off

Gas Metal Arc

Voltage Input Press To Reset U0 Rated No-Load

OM-230 693 Page 9

4-2. Welding Power Source Duty Cycle And Overheating

6 Minutes Welding 4 Minutes Resting 4 Minutes Welding 6 Minutes Resting

duty1 4/95 − 150 215-A

4-3. Volt-Ampere Curves

OM-230 693 Page 10

4-4. Connecting To Weld Output Terminals

4-5. Installing Work Cable And Clamp

OM-230 693 Page 11

4-6. Connecting Spoolmatic) 15A Or 30A Gun

OM-230 693 Page 12

4-7. Connecting XR Aluma-Pro, XR Edge, XR-A Gun, Or XR-A Python

. If Aluma-Pro push/pull gun has

. Be sure to trim liner to proper extension.

Ref. 804 910-A / 804 936-A

OM-230 693 Page 13

4-8. Setting Gun Polarity For Wire Type

Wire Drive Work Clamp Lead

+ Positive Terminal - Negative Terminal

Shown as shipped − Electrode Positive (DCEP): For

4-9. Installing Gas Supply

OM-230 693 Page 14

4-10. Installing Wire Spool And Adjusting Hub Tension

Installing 1 Or 2 lb Wire Spool To install either a 1 lb or 2 lb wire

Order extra spring

4-11. Positioning Jumper Links

153 980-D / 144 916-E / 804 911-A

OM-230 693 Page 15

4-12. Electrical Service Guide

Reference: 2005 National Electrical Code (NEC) (including article 630)

OM-230 693 Page 16