O252203j Mil

OM-252203J 2016−02
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Wire Feeder
SuitCase ™
X-TREME 12VS
CE And Non-CE Models
File: MIG (GMAW)
Visit our website at

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 Quality System Warranty and service information for your
Standard. particular model are also provided.
Miller Electric manufactures a full line

of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Mil_Thank 2009−09
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 7
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-2. Unit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-3. Wire Type, Size, and Feed Speed Capability Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-4. Gun Recommendation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-5. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-1. Equipment Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-2. Installing Drive Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-3. Connecting Welding Gun And Voltage Sensing Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-4. Connecting Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-5. Connecting Weld Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-6. Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-7. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-8. Motor Control Board (PC1) DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-9. Meter Board (PC20) DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6-1. Controls With Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6-2. Controls Without Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-3. Wire Speed Dual Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-4. Wire Speed Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7-2. Overload Protection And Thermostat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7-3. Cleaning Debris From Shielding Gas Filter Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7-5. Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
WARRANTY
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product Stock Number

SUITCASE X‐TREME 12VS, HEAVY DUTY
300876
DRIVE
Council Directives:
• 2014/35/EU Low Voltage
• 2014/30/EU Electromagnetic Compatibility
• 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
• IEC 609745:2013 Arc Welding Equipment – Part 5: Wire feeders
• IEC 6097410:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Signatory:
February 18, 2016
_____________________________________ ___________________________________________
David A. Werba Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
259677B
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2015−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if Indicates special instructions.

not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.
1-2. Arc Welding Hazards
Always verify the supply ground − check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you
disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions
grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-5. Read and tor first − double-check connections.
follow all Safety Standards. Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and Frequently inspect input power cord and ground conductor for
repair this unit. damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
During operation, keep everybody, especially children, away. Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or repaired cables.
Do not drape cables over your body.
ELECTRIC SHOCK can kill.
If earth grounding of the workpiece is required, ground it directly
Touching live electrical parts can cause fatal shocks with a separate cable.
or severe burns. The electrode and work circuit is Do not touch electrode if you are in contact with the work, ground,
electrically live whenever the output is on. The input or another electrode from a different machine.
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic Do not touch electrode holders connected to two welding ma-
wire welding, the wire, wire reel, drive roll housing, chines at the same time since double open-circuit voltage will be
and all metal parts touching the welding wire are present.
electrically live. Incorrectly installed or improperly Use only well-maintained equipment. Repair or replace damaged
grounded equipment is a hazard.
parts at once. Maintain unit according to manual.
Do not touch live electrical parts. Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Wear dry, hole-free insulating gloves and body protection.
Insulate yourself from work and ground using dry insulating mats Clamp work cable with good metal-to-metal contact to workpiece
or covers big enough to prevent any physical contact with the work or worktable as near the weld as practical.
or ground. Insulate work clamp when not connected to workpiece to prevent
Do not use AC output in damp areas, if movement is confined, or if contact with any metal object.
there is a danger of falling. Do not connect more than one electrode or work cable to any
Use AC output ONLY if required for the welding process. single weld output terminal. Disconnect cable for process not in
use.
If AC output is required, use remote output control if present on
unit. Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
Additional safety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
SIGNIFICANT DC VOLTAGE exists in inverter weld-
as floors, gratings, or scaffolds; when in cramped positions such ing power sources AFTER removal of input power.
as sitting, kneeling, or lying; or when there is a high risk of unavoid- Turn Off inverter, disconnect input power, and discharge input
able or accidental contact with the workpiece or ground. For these capacitors according to instructions in Maintenance Section
conditions, use the following equipment in order presented: 1) a before touching any parts.
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder HOT PARTS can burn.
is recommended. And, do not work alone!
Do not touch hot parts bare handed.
Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to Allow cooling period before working on
OSHA 29 CFR 1910.147 (see Safety Standards). equipment.
Properly install, ground, and operate this equipment according to To handle hot parts, use proper tools and/or wear heavy, insu-
its Owner’s Manual and national, state, and local codes. lated welding gloves and clothing to prevent burns.
OM-252203 Page 1
Remove stick electrode from holder or cut off welding wire at
FUMES AND GASES can be hazardous. contact tip when not in use.
Wear body protection made from durable, flame−resistant material
Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free
these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high
health.
shoes, and a cap.
Keep your head out of the fumes. Do not breathe the fumes. Remove any combustibles, such as a butane lighter or matches,
If inside, ventilate the area and/or use local forced ventilation at the from your person before doing any welding.
arc to remove welding fumes and gases. The recommended way After completion of work, inspect area to ensure it is free of sparks,
to determine adequate ventilation is to sample for the composition glowing embers, and flames.
and quantity of fumes and gases to which personnel are exposed. Use only correct fuses or circuit breakers. Do not oversize or by-
If ventilation is poor, wear an approved air-supplied respirator. pass them.
Read and understand the Safety Data Sheets (SDSs) and the Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
manufacturer’s instructions for adhesives, coatings, cleaners, for hot work and have a fire watcher and extinguisher nearby.
consumables, coolants, degreasers, fluxes, and metals. Read and understand the Safety Data Sheets (SDSs) and the
Work in a confined space only if it is well ventilated, or while manufacturer’s instructions for adhesives, coatings, cleaners,
wearing an air-supplied respirator. Always have a trained watch- consumables, coolants, degreasers, fluxes, and metals.
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath- FLYING METAL or DIRT can injure eyes.
ing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying op- Welding, chipping, wire brushing, and grinding
erations. The heat and rays of the arc can react with vapors to form cause sparks and flying metal. As welds cool,
highly toxic and irritating gases. they can throw off slag.
Do not weld on coated metals, such as galvanized, lead, or Wear approved safety glasses with side
cadmium plated steel, unless the coating is removed from the weld shields even under your welding helmet.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements BUILDUP OF GAS can injure or kill.
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin. Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use
Arc rays from the welding process produce intense approved air-supplied respirator.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the ELECTRIC AND MAGNETIC FIELDS (EMF)
weld. can affect Implanted Medical Devices.
Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and Wearers of Pacemakers and other Implanted
sparks when welding or watching (see ANSI Z49.1 and Z87.1 Medical Devices should keep away.
listed in Safety Standards). Implanted Medical Device wearers should consult their doctor
Wear approved safety glasses with side shields under your and the device manufacturer before going near arc welding, spot
helmet. welding, gouging, plasma arc cutting, or induction heating
Use protective screens or barriers to protect others from flash, operations.
glare and sparks; warn others not to watch the arc.
Wear body protection made from durable, flame−resistant mate- NOISE can damage hearing.
rial (leather, heavy cotton, wool). Body protection includes Noise from some processes or equipment can
oil-free clothing such as leather gloves, heavy shirt, cuffless damage hearing.
trousers, high shoes, and a cap.
Wear approved ear protection if noise lev-
WELDING can cause fire or explosion. el is high.
Welding on closed containers, such as tanks, CYLINDERS can explode if damaged.

drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot Compressed gas cylinders contain gas under high
workpiece, and hot equipment can cause fires and pressure. If damaged, a cylinder can explode. Since
burns. Accidental contact of electrode to metal objects can cause gas cylinders are normally part of the welding
sparks, explosion, overheating, or fire. Check and be sure the area is process, be sure to treat them carefully.
safe before doing any welding.
Protect compressed gas cylinders from excessive heat, mechani-
Remove all flammables within 35 ft (10.7 m) of the welding arc. If cal shocks, physical damage, slag, open flames, sparks, and arcs.
this is not possible, tightly cover them with approved covers. Install cylinders in an upright position by securing to a stationary
Do not weld where flying sparks can strike flammable material. support or cylinder rack to prevent falling or tipping.
Protect yourself and others from flying sparks and hot metal. Keep cylinders away from any welding or other electrical circuits.
Be alert that welding sparks and hot materials from welding can Never drape a welding torch over a gas cylinder.
easily go through small cracks and openings to adjacent areas.
Never allow a welding electrode to touch any cylinder.
Watch for fire, and keep a fire extinguisher nearby.
Never weld on a pressurized cylinder − explosion will result.
Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side. Use only correct compressed gas cylinders, regulators, hoses,
Do not weld on containers that have held combustibles, or on and fittings designed for the specific application; maintain them
closed containers such as tanks, drums, or pipes unless they are and associated parts in good condition.
properly prepared according to AWS F4.1 and AWS A6.0 (see Turn face away from valve outlet when opening cylinder valve. Do
Safety Standards). not stand in front of or behind the regulator when opening the valve.
Do not weld where the atmosphere can contain flammable dust, Keep protective cap in place over valve except when cylinder is in
gas, or liquid vapors (such as gasoline). use or connected for use.
Connect work cable to the work as close to the welding area as Use the right equipment, correct procedures, and sufficient num-
practical to prevent welding current from traveling long, possibly ber of persons to lift and move cylinders.
unknown paths and causing electric shock, sparks, and fire Read and follow instructions on compressed gas cylinders,
hazards. associated equipment, and Compressed Gas Association (CGA)
Do not use welder to thaw frozen pipes. publication P-1 listed in Safety Standards.
OM-252203 Page 2
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard. MOVING PARTS can injure.

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

Keep away from moving parts. ARC WELDING can cause interference.
Keep away from pinch points such as drive Electromagnetic energy can interfere with
rolls. sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
WELDING WIRE can injure. Be sure all equipment in the welding area is
electromagnetically compatible.
Do not press gun trigger until instructed to do
so. To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Do not point gun toward any part of the body,
other people, or any metal when threading Locate welding operation 100 meters from any sensitive elec-
welding wire. tronic equipment.
Be sure this welding machine is installed and grounded
BATTERY EXPLOSION can injure. according to this manual.
If interference still occurs, the user must take extra measures
Do not use welder to charge batteries or jump such as moving the welding machine, using shielded cables,
start vehicles unless it has a battery charging using line filters, or shielding the work area.
feature designed for this purpose.
OM-252203 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)
1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Safety in Welding, Cutting, and Allied Processes, CSA Standard
is available as a free download from the American Welding Society at W117.2, from Canadian Standards Association, Standards Sales, 5060
http://www.aws.org or purchased from Global Engineering Documents Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 1-877-413-5184, website: www.global.ihs.com). (phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
Safe Practices for the Preparation of Containers and Piping for Welding tion, ANSI Standard Z87.1, from American National Standards Institute,
and Cutting, American Welding Society Standard AWS F4.1, from Glob- 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
al Engineering Documents (phone: 1-877-413-5184, website: site: www.ansi.org).
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for Welding and Cutting Containers that have Held Com- Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: www.global.ihs.com). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
National Electrical Code, NFPA Standard 70, from National Fire Protec- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
www.nfpa.org and www. sparky.org). phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, Applications Manual for the Revised NIOSH Lifting Equation, The Na-
from Compressed Gas Association, 14501 George Carter Way, Suite tional Institute for Occupational Safety and Health (NIOSH), 1600
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga- Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
net.com). www.cdc.gov/NIOSH).
1-6. EMF Information

Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). The current from arc welding (and allied pro- welding circuit as possible.
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding 5. Connect work clamp to workpiece as close to the weld as
circuit. EMF fields can interfere with some medical implants, e.g. pace- possible.
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con- 6. Do not work next to, sit or lean on the welding power source.
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit: 7. Do not weld whilst carrying the welding power source or wire
feeder.
1. Keep cables close together by twisting or taping them, or using a
About Implanted Medical Devices:
cable cover.
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.
OM-252203 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés

DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
gers possibles sont montrés par les symboles joints ou Ce groupe de symboles veut dire Avertissement! Attention! DANGER
sont expliqués dans le texte. DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
AVIS − Indique des déclarations pas en relation avec des blessures afférant pour les actions nécessaires afin d’éviter le danger.
personnelles.
2-2. Dangers relatifs au soudage à l’arc

Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-
Les symboles représentés ci-dessous sont utilisés dans ce ma- stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
nuel pour attirer l’attention et identifier les dangers possibles. En l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor-
présence de l’un de ces symboles, prendre garde et suivre les mes de sécurité).
instructions afférentes pour éviter tout risque. Les instructions
Installez, mettez à la terre et utilisez correctement cet équipement
en matière de sécurité indiquées ci-dessous ne constituent
conformément à son Manuel d’Utilisation et aux réglementations
qu’un sommaire des instructions de sécurité plus complètes
nationales, gouvernementales et locales.
fournies dans les normes de sécurité énumérées dans la Sec-
tion 2-5. Lire et observer toutes les normes de sécurité. Toujours vérifier la terre du cordon d’alimentation. Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
Seul un personnel qualifié est autorisé à installer, faire fonc-
cordon est raccordée à une prise correctement mise à la terre.
tionner, entretenir et réparer cet appareil.
En effectuant les raccordements d’entrée, fixer d’abord le conduc-
teur de mise à la terre approprié et contre-vérifier les connexions.
Pendant le fonctionnement, maintenir à distance toutes les
personnes, notamment les enfants de l’appareil. Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques
chaudes.
UNE DÉCHARGE ÉLECTRIQUE peut Vérifier fréquemment le cordon d’alimentation et le conducteur de
entraîner la mort. mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
Le contact d’organes électriques sous tension peut le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraî-
provoquer des accidents mortels ou des brûlures ner la mort.
graves. Le circuit de l’électrode et de la pièce est sous L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
tension lorsque le courant est délivré à la sortie. Le
circuit d’alimentation et les circuits internes de la Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
machine sont également sous tension lorsque l’alimen- sante ou mal épissés.
tation est sur Marche. Dans le mode de soudage avec Ne pas enrouler les câbles autour du corps.
du fil, le fil, le dérouleur, le bloc de commande du Si la pièce soudée doit être mise à la terre, le faire directement
rouleau et toutes les parties métalliques en contact
avec le fil sont sous tension électrique. Un équipement avec un câble distinct.
installé ou mis à la terre de manière incorrecte ou Ne pas toucher l’électrode quand on est en contact avec la pièce,
impropre constitue un danger. la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
Ne pas toucher aux pièces électriques sous tension. en même temps à cause de la présence d’une tension à vide dou-
Porter des gants isolants et des vêtements de protection secs et blée.
sans trous. N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
S’isoler de la pièce à couper et du sol en utilisant des housses ou champ les pièces endommagées. Entretenir l’appareil conformé-
des tapis assez grands afin d’éviter tout contact physique avec la ment à ce manuel.
pièce à couper ou le sol. Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
Ne pas se servir de source électrique à courant électrique dans les S’assurer que tous les panneaux et couvercles sont correctement
zones humides, dans les endroits confinés ou là où on risque de en place.
tomber.
Fixer le câble de retour de façon à obtenir un bon contact métal-
Se servir d’une source électrique à courant électrique UNIQUE- métal avec la pièce à souder ou la table de travail, le plus près pos-
MENT si le procédé de soudage le demande. sible de la soudure.
Si l’utilisation d’une source électrique à courant électrique s’avère Isoler la pince de masse quand pas mis à la pièce pour éviter le
nécessaire, se servir de la fonction de télécommande si l’appareil contact avec tout objet métallique.
en est équipé. Ne pas raccorder plus d’une électrode ou plus d’un câble de
D’autres consignes de sécurité sont nécessaires dans les condi- masse à une même borne de sortie de soudage. Débrancher le
tions suivantes : risques électriques dans un environnement câble pour le procédé non utilisé.
humide ou si l’on porte des vêtements mouillés ; sur des structures Utiliser une protection différentielle lors de l’utilisation d’un équi-
métalliques telles que sols, grilles ou échafaudages ; en position
pement auxiliaire dans des endroits humides ou mouillés.
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou Il reste une TENSION DC NON NÉGLIGEABLE dans
le sol. Dans ces conditions, utiliser les équipements suivants,
dans l’ordre indiqué : 1) un poste à souder DC à tension constante
les sources de soudage onduleur UNE FOIS
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à l’alimentation coupée.
souder AC à tension à vide réduite. Dans la plupart des situations, Arrêter les convertisseurs, débrancher le courant électrique et
l’utilisation d’un poste à souder DC à fil à tension constante est re- décharger les condensateurs d’alimentation selon les instructions
commandée. En outre, ne pas travailler seul ! indiquées dans la partie Entretien avant de toucher les pièces.
OM-252203 Page 5
chauffement ou un incendie. Avant de commencer le soudage, vérifier
LES PIÈCES CHAUDES peuvent et s’assurer que l’endroit ne présente pas de danger.
provoquer des brûlures.
Déplacer toutes les substances inflammables à une distance de
Ne pas toucher à mains nues les parties chaudes. 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
Prévoir une période de refroidissement avant soigneusement avec des protections homologués.
de travailler à l’équipement. Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
Ne pas toucher aux pièces chaudes, utiliser les outils recomman- Se protéger et d’autres personnes de la projection d’étincelles et
dés et porter des gants de soudage et des vêtements épais pour de métal chaud.
éviter les brûlures. Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
LES FUMÉES ET LES GAZ peuvent fissures et des ouvertures.
être dangereux. Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
Le soudage génère des fumées et des gaz. Leur
Le soudage effectué sur un plafond, plancher, paroi ou séparation
inhalation peut être dangereux pour votre santé.
peut déclencher un incendie de l’autre côté.
Ne pas effectuer le soudage sur des conteneurs fermés tels que
Eloigner votre tête des fumées. Ne pas respirer les fumées.
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au préparés correctement conformément à AWS F4.1 et AWS A6.0
niveau de l’arc pour l’évacuation des fumées et des gaz de (voir les Normes de Sécurité).
soudage. Pour déterminer la bonne ventilation, il est recommandé Ne pas souder là où l’air ambiant pourrait contenir des poussières,
de procéder à un prélèvement pour la composition et la quantité
gaz ou émanations inflammables (vapeur d’essence, par
de fumées et de gaz auxquels est exposé le personnel.
exemple).
Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé. Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
Lire et comprendre les fiches de données de sécurité et les instruc-
longue distance par des chemins inconnus éventuels en provo-
tions du fabricant concernant les adhésifs, les revêtements, les
quant des risques d’électrocution, d’étincelles et d’incendie.
nettoyants, les consommables, les produits de refroidissement, les
dégraisseurs, les flux et les métaux. Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
lées.
Travailler dans un espace fermé seulement s’il est bien ventilé ou
En cas de non utilisation, enlever la baguette d’électrode du porte-
en portant un respirateur à alimentation d’air. Demander toujours à
électrode ou couper le fil à la pointe de contact.
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau Porter un équipement de protection pour le corps fait d’un matériau
d’oxygène provoquant des blessures ou des accidents mortels. résistant et ignifuge (cuir, coton robuste, laine). La protection du
S’assurer que l’air de respiration ne présente aucun danger. corps comporte des vêtements sans huile comme par ex. des
gants de cuir, une chemise solide, des pantalons sans revers, des
Ne pas souder dans des endroits situés à proximité d’opérations
chaussures hautes et une casquette.
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et for- Avant de souder, retirer toute substance combustible de vos po-
mer des gaz hautement toxiques et irritants. ches telles qu’un allumeur au butane ou des allumettes.
Ne pas souder des métaux munis d’un revêtement, tels que l’acier Une fois le travail achevé, assurez−vous qu’il ne reste aucune
galvanisé, plaqué en plomb ou au cadmium à moins que le revête- trace d’étincelles incandescentes ni de flammes.
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
bien ventilé, et en portant un respirateur à alimentation d’air. Les Ne pas augmenter leur puissance; ne pas les ponter.
revêtements et tous les métaux renfermant ces éléments peuvent Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
dégager des fumées toxiques en cas de soudage. NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
LES RAYONS DE L’ARC peuvent Lire et comprendre les fiches de données de sécurité et les instruc-
provoquer des brûlures dans les tions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement,
yeux et sur la peau. les dégraisseurs, les flux et les métaux.
Le rayonnement de l’arc du procédé de soudage génère
des rayons visibles et invisibles intenses (ultraviolets e DES PIECES DE METAL ou DES
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la SALETES peuvent provoquer des
peau. Des étincelles sont projetées pendant le soudage. blessures dans les yeux.
Porter un casque de soudage approuvé muni de verres filtrants
Le soudage, l’écaillement, le passage de la pièce à
approprié pour protéger visage et yeux pour protéger votre visage
la brosse en fil de fer, et le meulage génèrent des étincelles et des
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité). particules métalliques volantes. Pendant la période de ref-
roidissement des soudures, elles risquent de projeter du laitier.
Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque. Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas LES ACCUMULATIONS DE GAZ
regarder l’arc. risquent de provoquer des blessures
Porter un équipement de protection pour le corps fait d’un matériau ou même la mort.
résistant et ignifuge (cuir, coton robuste, laine). La protection du
Fermer l’alimentation du gaz comprimé en cas
corps comporte des vêtements sans huile comme par ex. des
de non utilisation.
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette. Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
LE SOUDAGE peut provoquer un Les CHAMPS ÉLECTROMAGNÉTIQUES
incendie ou une explosion. (CEM) peuvent affecter les implants mé-
Le soudage effectué sur des conteneurs fermés tels dicaux.
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent Les porteurs de stimulateurs cardiaques et
être projetées de l’arc de soudure. La projection d’étincelles, des autres implants médicaux doivent rester à
pièces chaudes et des équipements chauds peut provoquer des incen- distance.
dies et des brûlures. Le contact accidentel de l’électrode avec des Les porteurs d’implants médicaux doivent consulter leur médecin
objets métalliques peut provoquer des étincelles, une explosion, un sur- et le fabricant du dispositif avant de s’approcher de la zone où se
OM-252203 Page 6
déroule du soudage à l’arc, du soudage par points, du gougeage, Placer les bouteilles debout en les fixant dans un support station-
de la découpe plasma ou une opération de chauffage par naire ou dans un porte-bouteilles pour les empêcher de tomber ou
induction. de se renverser.
Tenir les bouteilles éloignées des circuits de soudage ou autres
LE BRUIT peut endommager l’ouïe. circuits électriques.
Ne jamais placer une torche de soudage sur une bouteille à gaz.
Le bruit des processus et des équipements peut
affecter l’ouïe. Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
Porter des protections approuvées pour les Ne jamais souder une bouteille pressurisée − risque d’explosion.
oreilles si le niveau sonore est trop élevé.
Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
LES BOUTEILLES peuvent exploser les maintenir ainsi que les éléments associés en bon état.
si elles sont endommagées. Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
Les bouteilles de gaz comprimé contiennent du de l’ouverture de la vanne.
gaz sous haute pression. Si une bouteille est Le couvercle du détendeur doit toujours être en place, sauf lorsque
endommagée, elle peut exploser. Du fait que la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
les bouteilles de gaz font normalement partie du procédé de
soudage, les manipuler avec précaution. Utiliser les équipements corrects, les bonnes procédures et suffi-
samment de personnes pour soulever et déplacer les bouteilles.
Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Lire et suivre les instructions sur les bouteilles de gaz comprimé,
des chocs mécaniques, des dommages physiques, du laitier, des l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
flammes ouvertes, des étincelles et des arcs. Association) mentionné dans les principales normes de sécurité.
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU D’EXPLOSION. LES CHARGES ÉLECTROSTATI-

QUES peuvent endommager les cir-
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables. cuits imprimés.
Ne pas installer l’appareil à proximité de pro- Établir la connexion avec la barrette de terre
duits inflammables. avant de manipuler des cartes ou des pièces.
Ne pas surcharger l’installation électrique − s’assurer que Utiliser des pochettes et des boîtes antistatiques pour stocker,
l’alimentation est correctement dimensionnée et protégée avant déplacer ou expédier des cartes de circuits imprimes.
de mettre l’appareil en service.
Les PIÈCES MOBILES peuvent
causer des blessures.
Ne pas s’approcher des organes mobiles.
LA CHUTE DE L’ÉQUIPEMENT peut Ne pas s’approcher des points de coincement
provoquer des blessures. tels que des rouleaux de commande.
Utiliser l’anneau de levage uniquement pour
soulever l’appareil, NON PAS les chariots, les
LES FILS DE SOUDAGE peuvent
bouteilles de gaz ou tout autre accessoire. provoquer des blessures.
Ne pas appuyer sur la gâchette avant d’en
Utiliser un équipement de levage de capacité suffisante pour lever avoir reçu l’instruction.
l’appareil. Ne pas diriger le pistolet vers soi, d’autres
En utilisant des fourches de levage pour déplacer l’unité, s’assurer personnes ou toute pièce mécanique en engageant le fil de
que les fourches sont suffisamment longues pour dépasser du soudage.
côté opposé de l’appareil.
Tenir l’équipement (câbles et cordons) à distance des véhicules L’EXPLOSION DE LA BATTERIE
mobiles lors de toute opération en hauteur. peut provoquer des blessures.
Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage Ne pas utiliser l’appareil de soudage pour
manuelle de pièces ou équipements lourds. charger des batteries ou faire démarrer des
véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
L’EMPLOI EXCESSIF peut de charge de batterie destinée à cet usage.
SURCHAUFFER L’ÉQUIPEMENT.
Prévoir une période de refroidissement ; res- Les PIÈCES MOBILES peuvent
pecter le cycle opératoire nominal. causer des blessures.
Réduire le courant ou le facteur de marche S’abstenir de toucher des organes mobiles tels
avant de poursuivre le soudage. que des ventilateurs.
Ne pas obstruer les passages d’air du poste.
Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs de protection.
Lorsque cela est nécessaire pour des travaux d’entretien et de dé-
LES ÉTINCELLES PROJETÉES pannage, faire retirer les portes, panneaux, recouvrements ou
peuvent provoquer des blessures. dispositifs de protection uniquement par du personnel qualifié.
Remettre les portes, panneaux, recouvrements ou dispositifs de
Porter un écran facial pour protéger le visage et protection quand l’entretien est terminé et avant de rebrancher
les yeux. l’alimentation électrique.
Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exé- LIRE LES INSTRUCTIONS.
cuter dans un endroit sûr lorsque l’on porte l’équipement ho- Lire et appliquer les instructions sur les
mologué de protection du visage, des mains et du corps. étiquettes et le Mode d’emploi avant l’instal-
Les étincelles risquent de causer un incendie − éloigner toute lation, l’utilisation ou l’entretien de l’appareil.
substance inflammable. Lire les informations de sécurité au début du
manuel et dans chaque section.
OM-252203 Page 7
N’utiliser que les pièces de rechange recommandées par le
constructeur. LE SOUDAGE À L’ARC risque de
Effectuer l’installation, l’entretien et toute intervention selon les provoquer des interférences.
manuels d’utilisateurs, les normes nationales, provinciales et de L’énergie électromagnétique risque de
l’industrie, ainsi que les codes municipaux. provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
LE RAYONNEMENT HAUTE l’équipement commandé par ordinateur tel que
FRÉQUENCE (H.F.) risque de les robots.
provoquer des interférences.
Le rayonnement haute fréquence (H.F.) peut Veiller à ce que tout l’équipement de la zone de soudage soit com-
provoquer des interférences avec les équi- patible électromagnétiquement.
pements de radio−navigation et de communication, les services Pour réduire la possibilité d’interférence, maintenir les câbles de
de sécurité et les ordinateurs. soudage aussi courts que possible, les grouper, et les poser aussi
Demander seulement à des personnes qualifiées familiarisées avec bas que possible (ex. par terre).
des équipements électroniques de faire fonctionner l’installation. Veiller à souder à une distance de 100 mètres de tout équipement
L’utilisateur est tenu de faire corriger rapidement par un électricien électronique sensible.
qualifié les interférences résultant de l’installation. Veiller à ce que ce poste de soudage soit posé et mis à la terre
Si le FCC signale des interférences, arrêter immédiatement l’appareil. conformément à ce mode d’emploi.
Effectuer régulièrement le contrôle et l’entretien de l’installation. En cas d’interférences après avoir pris les mesures précédentes,
Maintenir soigneusement fermés les portes et les panneaux des il incombe à l’utilisateur de prendre des mesures supplémentaires
sources de haute fréquence, maintenir les éclateurs à une distan- telles que le déplacement du poste, l’utilisation de câbles blindés,
ce correcte et utiliser une terre et un blindage pour réduire les l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
interférences éventuelles. de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du
fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent
dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres
formations congénitales et, dans certains cas, des cancers. problèmes de procréation. Se laver les mains après
(Code de santé et de sécurité de Californie, chapitre 25249.5 utilisation.
et suivants)
2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
is available as a free download from the American Welding Society at (phone: 800-463-6727, website: www.csagroup.org).
http://www.aws.org or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec-
(phone: 1-877-413-5184, website: www.global.ihs.com). tion, ANSI Standard Z87.1, from American National Standards Institute,
Safe Practices for the Preparation of Containers and Piping for Welding 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
and Cutting, American Welding Society Standard AWS F4.1, from Glob- site: www.ansi.org).
al Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Safe Practices for Welding and Cutting Containers that have Held Com-
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184, OSHA, Occupational Safety and Health Standards for General Indus-
website: www.global.ihs.com). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
National Electrical Code, NFPA Standard 70, from National Fire Protec- and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
www.nfpa.org and www. sparky.org). (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, phone for Region 5, Chicago, is 312-353-2220, website:
from Compressed Gas Association, 14501 George Carter Way, Suite www.osha.gov).
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga- Applications Manual for the Revised NIOSH Lifting Equation, The Na-
net.com). tional Institute for Occupational Safety and Health (NIOSH), 1600
Safety in Welding, Cutting, and Allied Processes, CSA Standard Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
W117.2, from Canadian Standards Association, Standards Sales, 5060 www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM

Le courant électrique qui traverse tout conducteur génère des champs câbles d’un côté et à distance de l’opérateur.
électromagnétiques (CEM) à certains endroits. Le courant issu d’un 3. Ne pas courber et ne pas entourer les câbles autour de votre
soudage à l’arc (et de procédés connexes, y compris le soudage par corps.
points, le gougeage, le découpage plasma et les opérations de 4. Maintenir la tête et le torse aussi loin que possible du matériel du
chauffage par induction) crée un champ électromagnétique (CEM) circuit de soudage.
autour du circuit de soudage. Les champs électromagnétiques produits 5. Connecter la pince sur la pièce aussi près que possible de la
peuvent causer interférence à certains implants médicaux, p. ex. les soudure.
stimulateurs cardiaques. Des mesures de protection pour les porteurs 6. Ne pas travailler à proximité d’une source de soudage, ni
d’implants médicaux doivent être prises: Limiter par exemple tout accès s’asseoir ou se pencher dessus.
aux passants ou procéder à une évaluation des risques individuels pour 7. Ne pas souder tout en portant la source de soudage ou le
les soudeurs. Tous les soudeurs doivent appliquer les procédures dévidoir.
suivantes pour minimiser l’exposition aux CEM provenant du circuit de En ce qui concerne les implants médicaux :
soudage: Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
1. Rassembler les câbles en les torsadant ou en les attachant avec
points, de gougeage, du coupage plasma ou de chauffage par induc-
du ruban adhésif ou avec une housse.
tion. Si le médecin approuve, il est recommandé de suivre les
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les procédures précédentes.
OM-252203 Page 8
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions

Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not discard product (where applicable) with general waste.

Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Wear dry insulating gloves. Do not touch electrode (wire) with bare hand. Do not wear wet or damaged gloves.
Safe57 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe58 2012−06
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe59 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe60 2012−06
Use ventilating fan to remove fumes.
Safe61 2012−06
Keep flammables away from welding. Do not weld near flammables.
Safe62 2012−06
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe63 2012−06
OM-252203 Page 9
Do not weld on drums or any closed containers.
? Safe64 2012−06
Do not remove or paint over (cover) the label.
Safe20 2012−05
Drive rolls can injure fingers.
Safe32 2012−05
Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.
Safe33 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe66 2012−06
Become trained and read the instructions before working on the

machine or welding.
Safe65 2012−06
3-2. Miscellaneous Symbols And Definitions
Run-In Gas IN
I2 Rated Welding
Current
I1 Input Current Increase Off
Wire Feed
Constant Current On
Cold Jog (Inch)
Trigger Hold Off Increase Towards Work-
piece
Supplementary
Read Instructions Protector
Percent
Trigger Hold On
Filter
Trigger Hold Off

Purge By Gas
U1 Input Voltage
Constant Voltage
A Amperes
Trigger Hold On
IP Degree Of Protec-
tion
V Volts
I2 Rated Welding
Current
Input
Power Connection
OM-252203 Page 10
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located inside the door. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Unit Specifications

Welding
Type of Wire Max. Wire
Power Wire Feed Input Welding Overall
Input Diameter Spool Weight
Source Speed* Circuit Rating Dimensions
Power Range Capacity
Type
Solid Wire: Length: 21 in.

Constant
.023 - .052 in. 300 Amperes At (533 mm)
Open-Circuit/ Voltage (CV) 25 − 800 ipm
(0.6 To 1.3 mm) 100% Duty Cycle
Arc Voltage, Or Constant (0.64 − 20.3 45 lb (20.4 kg), Width: 9 in. 34.5 lb
14 − 110 Current (CC) mpm) Depending Flux Cored: 12 in. (304 mm) (229 mm) (15.6 kg)
.030 - 5/64 in. 425 Amperes At
Volts DC DC Power On Arc Voltage Height: 15-1/2 in.
(0.8 To 2 mm) 60% Duty Cycle
Source Only (394 mm)
*See Section 4-3 for detailed wire type, size, and rated speed range
4-3. Wire Type, Size, and Feed Speed Capability Table

Motor Speed Wire Type Wire Size Rated Speed Range*
.023 To 5/64 in. 50 to 780 ipm

Standard All
(0.6 To 2 mm) (1.3 -19.8 mpm)
*Rated speed range per IEC 60974-5
4-4. Gun Recommendation Table

Process Gun
GMAW − Hard or Cored Wires Bernard Q-Gun

Tregaskiss Tough Gun
Roughneck C-Series
FCAW − Self-Shielding Wires Bernard Dura-Flux Gun

Ironmate Series
4-5. Environmental Specifications

A. IP Rating
IP Rating
IP23
This equipment is designed for outdoor use. It may be stored, but is not intended to be used
for welding outside during precipitation unless sheltered.
IP23 2014−06
OM-252203 Page 11
B. Information On Electromagnetic Fields (EMF)
! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
C. Information On Electromagnetic Compatibility (EMC)
! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con-
ducted as well as radiated disturbances.
ce-emc 3 2014-07
SECTION 5 − INSTALLATION
5-1. Equipment Connection Diagram

! Turn Off wire feeder and
welding power source. Stop
engine on welding
generator.
! Do not move or operate
equipment where it could
tip.
! Use only with CC/CV DC
1 10 Power Sources.
1 Constant Current (CC) or
Constant Voltage (CV)
Welding Power Supply
2 Weld Cable To Feeder
3 Work Cable To Workpiece
Weld cable and work cable connec-
tions to power source (DCEN/
DCEP) are dependant on wire type.
Since feeder is not polarity sen-

sitive, there is no need for an
2 electrode polarity switch.
8 9 4 Workpiece
5 Voltage Sensing Clamp
3 Connect voltage sensing clamp to
workpiece.
6 Gun
7 7 Gun Trigger Receptacle
8 Wire Feeder
9 Gas Hose
4
5 10 Gas Cylinder
Use of shielding gas is dependant
on wire type.
Shielding gas pressure not to

6 exceed 100 psi (689 kPa).
Ref. 256 615-A
OM-252203 Page 12
5-2. Installing Drive Rolls
Installing Drive Rolls:
1 Drive Roll Securing Nut
2 Drive Roll Carrier
Installing Drive Rolls Turn nut one click until lobes of nut
line up with lobes of drive roll carrier.
3 Drive Roll
Slide drive roll onto drive roll carrier.
Turn nut one click.
2 Repeat procedure for top drive roll.
Cleaning Drive Rolls:
Remove drive rolls, and clean
grooves using a wire brush.
256 616-A
Notes
OM-252203 Page 13
5-3. Connecting Welding Gun And Voltage Sensing Clamp
welding power source.
Stop engine on welding
generator.
! Weld voltage is present at
5 voltage sensing clamp
2 when wire feeder and
welding power source are
on. This condition exists
even if wire feeder lights
5 and meters are off.
Turn off wire feeder or

welding power source be-
fore handling or moving
voltage sensing clamp.
1 Gun Securing Knob
2 Gun Block
3 Gun Power Pin
4 Power Pin Groove
5 Gun Locking Tab
Loosen gun securing knob, insert
1 gun power pin into gun block. Po-
sition power pin as close as pos-
Gun Locking Tab In Place sible to drive rolls without touch-
ing. Align the gun power pin
groove with the gun locking tab.
Tighten gun securing knob.
Gun Locking Tab Out Of Place
If the gun power pin does not
have a groove, loosen knob to ro-
tate the gun locking tab 180 de-
grees. This prevents the the gun
locking tab from interfering with
the gun power pin when inserted
into the gun block. Insert the gun
power pin into the gun block. Pos-
ition power pin as close as pos-
sible to drive rolls without touch-
ing them. Tighten gun securing
knob.
6 Gun Trigger Plug
7 Gun Trigger Receptacle
Connect gun trigger plug to gun
trigger receptacle.
See Section 6-3 to make wire
speed dual schedule connec-
tions to gun trigger receptacle.
8 Voltage Sensing Clamp
Internal Side View Connect voltage sensing clamp
3 4 to workpiece.
256 617-A / 256 619-A
OM-252203 Page 14
5-4. Connecting Shielding Gas
NOTICE − This feeder has a shield-
ing gas filter that requires special
attention when cleaning. See Sec-
tion 7-3 for proper cleaning instruc-
tions.
4 1 Gas Hose With 5/8-18
3 Right-hand Thread Fittings
Rear View (User−Supplied)
Tighten gas hose fitting to a
maximum of 100 in. lbs (12
N.m).
2 Shielding Gas Cylinder
2
Shielding gas pressure not to
exceed 100 psi (689 kPa).
3 Valve
4 Flowmeter
Close valve on cylinder when fin-
ished welding.
256 620-A
5-5. Connecting Weld Cable

engine on welding
generator.
1 User-Supplied Weld Cable
Follow wire manufacturer’s recom-
mendations for weld cable polarity.
2 Male Connector
3 User-Supplied Female
Connector
Connect male and female
connectors.
1 2
256 621-A
OM-252203 Page 15
5-6. Selecting Cable Sizes*
! Turn off power before connecting to weld output terminals.
! Do not use worn, damaged, undersized, or repaired cables.
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60%
60 − 100%
Welding Duty 10 − 100% Duty Cycle
Duty Cycle
Amperes Cycle AWG (mm2)
AWG (mm2)
AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-L 2015−02
Notes
OM-252203 Page 16
5-7. Installing And Threading Welding Wire
Installing Wire And Adjusting Hub
Tension:
1 Retaining Nut
2 Hub Tension Adjustment Knob
Remove retaining nut, and install spool
so hub pin fits spool hole. Reinstall re-
Hold wire tightly to keep it taining nut.
from unraveling.
Adjust tension knob so only a slight
force is needed to turn spool.
Do not over tighten tension knob. It

is not necessary to use any tools to
tighten the knob.
Threading Welding Wire:
3
3 Pressure Adjustment Knob
Lay gun cable out straight.
Open pressure assembly. Hold wire
tightly and cut off end. Guide wire
1 2 between alignment pins, into drive roll
grooves, and into gun liner.
Close pressure assembly and tighten
pressure adjustment knob enough to
feed wire. Press jog switch until wire
comes out of gun.
To set proper drive roll pressure, re-
lease the pressure on the drive rolls by
6 in. loosening the pressure adjustment
(150 mm) knob. Position gun at about a 45 degree
Pull and hold wire; cut off end. angle, with nozzle about two inches
from a wooden surface. While feeding
the wire against the wooden surface,
Tighten increase the pressure to one half turn
Clockwise past the point where the wire stops slip-
ping. If the wire slips at maximum
hand-tight pressure, there may be other
problems. Check the gun liner, spool
tension, contact tip and drive roll wear,
as all these can cause wire feeding
WOOD problems.
Cut off wire, and close door. 256 622-A
5-8. Motor Control Board (PC1) DIP Switch Settings

1 Motor Control Board (PC1)
2 DIP Switch SW1
3 LED5
DIP switch SW1 is used to match the
performance of PC1 to the character-
1 2 istics of the motor used in the feeder.
Setting SW1 as shown will help
ensure that PC1 and motor are
OPEN matched for optimal performance.
If protective coating is present, remove
before setting DIP switch. It is not neces-
sary to reapply the protective coating.
RC111 Set switch positions 1 and 2 so the de-
2 1 pressed section of both tabs are toward 1
and 2 as labeled on the switch. As shown
in illustration.
3
When feeder is powered up, LED 5 on the
Motor Control Board (PC1) will blink four
times. This blinking indicates everything
is working properly and the DIP switch is
set correctly.
After LED 5 is done blinking, it will be
either red or green. Red indicates that the
feeder is connected with electrode posit-
ive. Green indicates feeder is connected
247 678-B with electrode negative.
OM-252203 Page 17
5-9. Meter Board (PC20) DIP Switch Settings
Display Hold On
Displays will hold their last value for five seconds
1 2 3 4 5
after the trigger is released. After the hold times
out, the Voltmeter will show open circuit voltage or
weld voltage polarity. If the Wire Speed / Amper-
Meter Board (PC20) DIP Switch Settings age Meter is set to display Amps, the amperage
value will hold, after the hold times out, preset Wire
Shows switch in ON/DOWN (closed) position Speed will be displayed.
Shows switch in OFF/UP (open) position Display Hold Off

Displays will not hold values. Immediately, when
Indicates switch does not affect this function 1 2 3 4 5
the trigger is released, the Voltmeter will show
open circuit voltage or weld voltage polarity. The
Wire Speed / Amperage Meter will display preset
Wire Speed when the trigger is released.
Do Not Display Amperage

1 2 3 4 5 Wire Speed / Amperage Meter will display only
Wire Speed.
1 2 3 4 5
Display Amperage
Factory Default DIP Switch Settings To Wire Speed / Amperage Meter will display Amps
1 2 3 4 5
Display Wire Speed As Inches Per Minute while welding and Wire Speed while not welding.
If the hold function is enabled, Amps will be dis-
played during hold also.
Wire Speed − Inches per Minute

1 2 3 4 5 Displays Wire Speed in Inches per Minute.
Wire Speed − Meters per Minute

1 2 3 4 5 Displays Wire Speed in Meters per Minute.
1 2 3 4 5
Factory Default DIP Switch Settings To
Display Wire Speed As Meters Per Minute Information Off
1 2 3 4 5
Information is not displayed.
Information On
Indicates switch does 1 2 3 4 5 With switch in ON position, at feeder power up,
not affect this function feeder will display various sets of information.
Each set of information will be displayed for three
seconds.
Meter Board (PC20) Software Part Number
Top display will show the first three digits, bottom
display will show last three digits of the Meter
board (PC20) software revision level.
Motor Control Board (PC1) Software Part

Number
Top display will show the first three digits, bottom
display will show last three digits, of the Motor
Control Board (PC1) software revision level.
DIP switch is Accumulated Weld Time

located behind
This is the time the feeder has actually been used
front panel as
shown. for welding. This information will be displayed in
two halves. First being years and days, second in
hours and minutes. Top display will show years/
hours, bottom display will show days/minutes.
Weld Voltage Polarity

When the Voltmeter would normally display open
circuit voltage, the Voltmeter will display:
“EP” when connected as electrode positive. While
welding, and in Display Hold On mode, the Volt-
meter will display Weld Voltage.
“En.” when connected as electrode negative.
256 618-A
While welding, and in Display Hold On mode, the
Voltmeter will display Weld Voltage and the last
decimal point will remain lit. If Weld Voltage is
“23.4” the Voltmeter will display “23.4.”.
OM-252203 Page 18
SECTION 6 − OPERATION
6-1. Controls With Meters
1 Power Control Switch
2 Trigger Hold Switch
Trigger hold allows operator to weld without hold-
ing gun trigger.
To use trigger hold function, place trigger hold
switch in the ON position.
3 2 1 The operator must hold the trigger for a minimum
of 2 seconds, but no longer than 6 seconds be-
fore releasing it. Welding will continue when trig-
ger is released.
To stop welding, press and release the trigger.
4 3 Jog/Purge Switch
Pressing the Jog switch allows the operator to
jog wire without energizing the contactor or gas
valve.
5 Pressing the Purge switch allows the operator to
purge gas lines before welding and to preset gas
flow rate at the flowmeter.
4 Voltmeter
Displays actual arc voltage or open circuit volt-
6 age at the feeder.
5 Wire Speed / Amperage Meter
Displays preset wire speed. While welding in CC
mode, actual wire speed is dependant on arc
voltage. To set wire speed display to: Inches per
Minute or Meters per Minute, see Section 5-9.
Amperage displayed at the feeder is approxi-
mate. Refer to power source for actual amper-
age. To display Amperage, see Section 5-9.
6 Wire Speed Control
Use control to adjust wire speed within the speed
range selected by the wire speed range switch,
located on the inner control panel. Maximum
wire speed may be limited by arc voltage.
When using wire speed dual schedule, the re-
duced wire speed will be 87.5% of the standard
wire speed− See Section 6-3.
7 HI/LO Speed Range Switch
Use switch to select speed range. High range is
9 7 100 to 800 Inches per Minute (2.5 to 20.3 Meters
8 per Minute). Low range is 25 to 200 Inches per
Minute (0.6 to 5.1 Meters per Minute).
8 CC/CV Switch
Use switch to match feeder with the output of the
power source.
While welding in CC mode, actual wire speed is
Internal Control Panel dependent on arc voltage.
While welding in CV mode, the wire feeder re-
mains at constant speed and the wire speed is
not dependent on arc voltage. Maximum wire
speed may be limited by arc voltage.
9 Soft Start Switch
The Soft Start feature provides a smooth start
during most weld conditions. When the trigger is
pulled, the wire speed is approximately 50% of
Internal Side View the weld wire speed, as set by the wire speed
control knob. After an arc is established, the wire
speed increases to the weld wire speed.
When using small diameters wire, or with invert-
er power sources, it may be necessary to turn
soft start off to obtain smooth starts.
After adjusting the switches, close and latch the
door before welding.
Ref. 256 622-A / 252 210-B
OM-252203 Page 19
6-2. Controls Without Meters
1 Power Control Switch
2 Trigger Hold Switch
Trigger hold allows operator to weld without
holding gun trigger.
To use trigger hold function, place trigger
hold switch in the ON position.
3 2 The operator must hold the trigger for a mini-

1
mum of 2 seconds, but no longer than 6 sec-
onds before releasing it. Welding will contin-
ue when trigger is released.
To stop welding, press and release the trig-
ger.
3 Jog/Purge Switch
Pressing the Jog switch allows the operator
to jog wire without energizing the contactor
or gas valve.
Pressing the Purge switch allows the opera-
tor to purge gas lines before welding and to
preset gas flow rate at the flowmeter.
4 Wire Speed Control
Use control to adjust wire speed within the
4 speed range selected by the wire speed
range switch, located on the inner control
panel. Maximum wire speed may be limited
by arc voltage.
When using wire speed dual schedule, the
reduced wire speed will be 87.5% of the
standard wire speed− See Section 6-3.
5 CC/CV Switch
Use switch to match feeder with the output of
the power source.
While welding in CC mode, actual wire speed
is dependent on arc voltage.
While welding in CV mode, the wire feeder
remains at constant speed and the wire
speed is not dependent on arc voltage. Max-
imum wire speed may be limited by arc
voltage.
6 HI/LO Speed Range Switch
Use switch to select speed range. High
range is 100 to 800 Inches per Minute (2.5 to
20.3 Meters per Minute). Low range is 25 to
200 Inches per Minute (0.6 to 5.1 Meters per
7 6 Minute).
5 7 Soft Start Switch
The Soft Start feature provides a smooth
start during most weld conditions. When the
trigger is pulled, the wire speed is approxi-
mately 50% of the weld wire speed, as set by
the wire speed control knob. After an arc is
established, the wire speed increases to the
Internal Control Panel weld wire speed.
When using small diameters wire, or with in-
verter power sources, it may be necessary to
turn soft start off to obtain smooth starts.
After adjusting the switches, close and latch
the door before welding.
Internal Side View
Ref. 256 622-A / 252 260-B
OM-252203 Page 20
6-3. Wire Speed Dual Schedule
Wire Speed Dual Schedule allows the oper-
ator to switch between standard wire speed
and a reduced wire speed. When activated,
the reduced wire speed will be 87.5% of the
standard wire speed. Wire Speed Dual
Schedule may be activated any time before
or during the weld by using a gun with an in-
Weld Gun With Internal Mounted ternally mounted dual schedule switch, or a
Dual Schedule Switch gun with an added dual schedule switch. If
the feeder is equipped with Wire Speed
Meter it will display the active wire speed,
whether it is standard wire speed or reduced
wire speed.
Weld Gun With Internal Mounted Dual
Schedule Switch Comparable To
PipePro Dura−Flux Gun.
2 Gun Trigger Plug
Connect gun trigger plug to gun trigger
receptacle.
1 2
Weld Gun With External Mounted Dual

Schedule Switch Comparable To
DSS−9−15 (071833)
4 Dual Schedule Plug
5 Dual Schedule Switch Receptacle
6 Gun Trigger Plug
Weld Gun With External Mounted Connect gun trigger plug to dual schedule
Dual Schedule Switch switch receptacle . Connect dual schedule
plug to gun trigger receptacle.
3 4
5 6
258 996-A / 258 999-A
OM-252203 Page 21
6-4. Wire Speed Control Settings
Ref. 257 488-A
Notes
OM-252203 Page 22
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
7-1. Routine Maintenance
! Disconnect power Maintain more often during

before maintaining. severe conditions.
= Check = Change = Clean = Replace
Every
3 Replace
Damaged Replace
Months Damaged Gas
Or
Unreadable Hose

Labels
Repair Or Replace
Cracked Cables And
Cords

Every
6 Clean
Drive Blow Out Or
Months Vacuum Inside
Rolls

7-2. Overload Protection And Thermostat Protection

engine on welding
generator.
1 Supplementary Protector CB1
CB1 protects wire feeder from over-
1 load. Correct problem and reset
CB1.
Close and latch door.
Thermostat Protection
Unit has internal thermostat protec-
tion and will not feed wire if over-
heating occurs (see Section 7-4).
CB1
Internal Side View
Ref. 256 618-A
OM-252203 Page 23
7-3. Cleaning Debris From Shielding Gas Filter Fitting
! Disconnect power before
maintaining.
1 Shielding Gas Filter Fitting
Remove fitting from gas valve on
back panel of feeder.
Blow compressed air through the
threaded male end of fitting to dis-
lodge debris from internal mesh
screen.
if blowing compressed air

through fitting does not clear
obstructions replace fitting.
Reinstall fitting into gas valve.
Rear View of Feeder Tighten fitting to 250 in. lbs (28 N⋅m).
Tools Needed:
3/4 in. 256 623-A
OM-252203 Page 24
7-4. Troubleshooting
Trouble Remedy
Wire does not feed; open-circuit voltage Check power switch S1 and connections, and replace if necessary.
available.
Check supplementary protector CB1. Reset CB1.
Unit overheated. Allow unit to cool.
Check sensing lead connection.
Check gun trigger plug connection.
Check gun trigger. See gun Owner’s Manual.
Have Factory Authorized Service Agent check Motor Control Board (PC1).
Wire feeds erratically. Readjust hub tension (see Section 5-7).
Readjust drive roll pressure (see Section 5-7).
Clean or replace dirty or worn drive roll (see Section 5-2).
Remove weld spatter around gun nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Change to correct size and type drive roll (see Section 5-2)
Check that DIP switches on Motor Control Board (PC1) are set correctly (see Section 5-8)
Motor runs slowly. When soft start is on, motor will run slow until weld current is sensed by HD1.
Readjust hub tension (see Section 5-7).
Check if wire speed dual schedule switch is activated (if applicable, See Section 6-3)
Check and replace contact tip or liner if necessary. See gun Owner’s Manual
Check that DIP switches on Motor Control Board (PC1) are set correctly (see Section 5-8)
Unit does not switch out of Soft Start. Check transducer HD1 and connections, and replace if necessary.
Wire feeds when Jog switch is pressed Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s
but not when gun trigger is pressed. Manual.
Wire stubbing on low end using a con- Make sure CC/CV switch is in CC position (see Section 6-1 or 6-2).
stant current power source or feeder
resets.
Increase power source inductance setting if available.
Increase output setting of power source or decrease wire feed speed.
Gas does not flow or does not stop Clear blockage in gas hose or replace hose.
flowing; wire feeds.
Clear blockage in welding gun.
Clear blockage in filter (see Section 7-3).
Check gas valve.
Check coil voltage and connections of gas valve GS1. Check continuity of coil. Replace GS1 if necessary.
Wire remains energized after trigger is Check setting of trigger hold switch, if applicable.
released.
Check contactor W1 to see if contacts are frozen closed.
OM-252203 Page 25
Trouble Remedy
Gun trigger is pressed, gas does not If a welding arc is not established in 3 seconds, after the gun trigger is activated, the unit will feed wire
flow, wire is not energized, wire feeds. without energizing the contactor or gas valve. The unit will feed approximately 35 feet (10.7 meters) of
wire, then stop feeding. This is to prevent complete de-spooling of the wire, as in the case of a damaged
gun.
Display on meter board PC20 does not Have Factory Authorized Service Agent check Motor Control Board (PC1).
light.
Replace meter board PC20.
Segments on the meter board PC20 are Replace meter board PC20.
missing.
Arc voltage on meter board PC20 is not Arc voltage on the meter board PC20 will show weld voltage at the feeder. Due to voltage drops in the
accurate. weld cables, arc voltage at the feeder will not match arc voltage at the welding power source. Due to aver-
aging of arc voltage, if weld time is less than 8 seconds the displayed arc voltage at the feeder may not
be accurate.
Check Motor Control (PC1) and connections, replace if necessary.
Weld amperage on meter board PC20 is Amperage displayed at feeder is approximate. Refer to power source for actual amperage
(see Section 5-9).
not accurate.
Check DIP switch settings on meter board PC20 (see Section 5-9).
Check transducer HD1 and connections, and replace if necessary.
Software and weld time information on Check DIP switch settings on meter board PC20 (see Section 5-9).
meter board PC20 is not accurate.
7-5. Diagnostics
Error Indicators
Shown On (Optional) Display RED LED on Motor Control Board (PC1) Error
HLP 11 1 Blink Communication Error
HLP 12 2 Blinks Trigger Error
HLP 13 3 Blinks Tach Error
HLP 14 4 Blinks Motor

Overload Error
HLP 15 5 Blinks Bus Bar

Overheat Error
Error Indications - Error conditions are indicated by a “HLP” message on the display, or by the blinking of the Red LED on Motor Control Board
(PC1). To view the Red LED, turn Off power source, remove shroud, and turn power source On. The number of blinks in this period indicates the
type of error. If an error condition does not exist on the Motor Control Board (PC1), the Red LED is on steady.
Communication Error - The communication error occurs 2.5 seconds after a loss of communication between the Motor Control Board (PC1) and
the meter board PC20. The user may continue to weld with this error. The error may be cleared by turning power Off, waiting a minimum of two
seconds, and turning power On.
Trigger Error - The trigger error occurs if the user has fed approximately 35 feet (10.7 meters) of wire without striking an arc. The error may be
cleared by releasing the trigger.
Motor Overload Error - The motor overload error can indicate that the motor has been drawing too much current for too long, To remedy this,
reduce the wire feed speed or the wire feeder torque load/duty cycle. The error may be cleared by turning power Off, waiting a minimum of two
seconds, and turning power On.
Bus Bar Overheat Error - The bus bar overheat error can be caused by the arc drawing too much current for too long. To remedy this, reduce
the weld amperage or duty cycle.
Tach Error - May indicate motor is overloaded. If a tach error occurs, feeder will continue to function. When the trigger is released, a tach error
will be indicated on the front panel, or red LED blinks on Motor Control Board (PC1). The tach error will be cleared when the feeder is re-triggered.
If error persists, have feeder serviced. Tach error may also be generated if DIP switch SW1 on Motor Control Board (PC1) is set incorrectly (See
Section 5-8).
OM-252203 Page 26
SECTION 8 − ELECTRICAL DIAGRAM
252 200-D
Figure 8-1. Circuit Diagram For Wire Feeder

OM-252203 Page 27
SECTION 9 − PARTS LIST
5
14
20
15
22
16 7 6
8
48
33
26
30 13
24 25 31
21 28 10
19 27 9
23
18
17 29
13
32
11
34 12
13
41
47
35 38
46
45
44 43
37 39,40
36
42 41
3 256 891-C
Figure 9-1. Complete Assembly
Item Diagram Part

No. marking No. Description Quantity
Figure 9-1. Complete Assembly
1 . . . . . . . . . . . . . . . . . . Fig 9-2 . . Panel Assembly Front (Without Meters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 . . . . . . . . . . . . . . . . . . Fig 9-3 . . Panel Assembly Front (With Meters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-252203 Page 28
Item Dia. Part
No. Mkgs No. Description Quantity
.
Figure 9-1. Complete Assembly (Continued)
3 . . . . . . . . . . . . . . . . . . Fig 9-4 . . Drive Assembly, Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 . . . . . . . . . . . . . . . . . . 252170 . . Case, Control Feeder Machined Blk Sc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
5 . . . . . . . . . . . . . . . . . . 208015 . . Handle, Rubberized Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
6 . . . . . . . . CB1 . . . . . 083432 . . Supplementary Pro, Man Reset 1P 10A 250VAC Frict . . . . . . . . . . . . . . . . 1
7 . . . . . . . . . . . . . . . . . . 255703 . . Panel, Inner 12 WCC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
8 . . . . . . . . . . . . . . . . . . 256203 . . Plate, Inner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9 . . . . . S3, S5, S6 . . 217932 . . Switch, Rocker Spst .4VA 28VDC On-None-Off .187 Ter . . . . . . . . . . . . . . 3
10 . . . . . . . . . . . . . . . . . 147195 . . Nut, 375-27 .54Hex .25H Nyl Flange .62D . . . . . . . . . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . . . . . . . . . . . 252177 . . Chassis, Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12 . . . . . . . . . . . . . . . . . 256594 . . Grommet, Scr No 8/10 Panel Hole .309X.315 .125H . . . . . . . . . . . . . . . . . 2
13 . . . . . . . . . . . . . . . . . 256595 . . Grommet, Scr No 8/10 Panel Hole .270X.290 .062H . . . . . . . . . . . . . . . . . 5
14 . . . . . . . . . . . . . . . . . 222103 . . Support, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
15 . . . . . . . . . . . . . . . . . 222294 . . Clip, Wire/Cord .380 Bundle .250Hole .105 Thk Blk . . . . . . . . . . . . . . . . . . 2
16 . . . . . . . . . . . . . . . . . 252186 . . Shroud, Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17 . . . . . . . . . . . . . . . . . 235607 . . Nut, Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
18 . . . . . . . . . . . . . . . . . 237843 . . Knob, Brake Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
19 . . . . . . . . . . . . . . . . . 172918 . . Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
20 . . . . . . . . . . . . . . . . . 231211 . . Washer, Anti-Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
21 . . . . . . . . . . . . . . . . . 235608 . . Hub, Spool 12 Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22 . . . . . . . . . . . . . . . . . 058424 . . Washer, Fiber (Brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
23 . . . . . . . . . . . . . . . . . 210133 . . Bracket, Capacitor Support SC12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
24 . . . . . C1, C2 . . . . 200606 . . Capacitor, Elctlt 1200 Uf 300 VDC Can 1.39 Dia . . . . . . . . . . . . . . . . . . . . . 2
25 . . . . . . . . . . . . . . . . . 207678 . . Insulator, Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
26 . . . . . . . . . . . . . . . . . 211989 . . Fitting, W/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
27 . . . . . . . . . . . . . . . . . 215980 . . Bushing, Strain Relief .709/.984 Id X1.375 Mtg Hole . . . . . . . . . . . . . . . . . 1
28 . . . . . . . . . . . . . . . . . 221346 . . Weld Cable Assembly, 4/0 (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 600324 . . . . Cable, Weld Cop Strd No 4/0 Ep Rubber Jacket 600V . . . . . . . . . . . . 22 in.
. . . . . . . . . . . . . . . . . . . . 009800 . . . . Term, Ring Tng 375 Stud Solistrand 4/0 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
29 . . . . . . . . . . . . . . . . . 259416 . . Clip, Snap In .250 Hole .062−.857 Pnl Thk Blk . . . . . . . . . . . . . . . . . . . . . . . 1
30 . . . . . . . . . . . . . . . . . 252194 . . Insulator, Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
31 . . . . . . . . . . . . . . . . . 252196 . . Bushing Gas Valve Opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
32 . . . . . . . . . . . . . . . . . 234126 . . Nut, Conduit 1.000 Npt Knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
33 . . . . . . . . . . . . . . . . . 253430 . . Terminal, Connector Friction 0.406 Id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
34 . . . . . . . PC1 . . . . . 238276 . . Circuit Card Assy, Motor Control Board W/Program . . . . . . . . . . . . . . . . . . 1
35 . . . . . . . HD1 . . . . . 218339 . . Transducer, Current 600A Module Supply V +5V . . . . . . . . . . . . . . . . . . . . 1
36 . . . . . . . . . . . . . . . . . 183387 . . Washer, Cone .380idx .860odx.109T Stl Pld 4000Lbs . . . . . . . . . . . . . . . . 2
37 . . . . . . . W1 . . . . . 255627 . . Contactor Assy, Service Kit SC HDD (Includes) . . . . . . . . . . . . . . . . . . . . . 1
38 . . . . . . PLG5 . . . . 201665 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
39 . . . . . . . . . . . . . . . . . 183387 . . . . Washer, Cone .380idx .860odx.109T Stl Pld 4000Lbs . . . . . . . . . . . . . . . 2
40 . . . . . . . . . . . . . . . . . 232295 . . . . Nut, M10−1.5 17Hex 10H Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
41 . . . . TP1, TP2 . . . 230471 . . . . Thermostat, Nc Open 140C Close 110C Snap Action . . . . . . . . . . . . . . . 2
42 . . . . . . . . . . . . . . . . . 252252 . . Bracket, Mtg Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
43 . . . . . . . . . . . . . . . . . 134834 . . Hose, SAE .187 Id X .410 Od XCoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 in.
44 . . . . . . . . . . . . . . . . . 149332 . . Clamp, Hose .405 − .485 Clp Dia Slfttng Olive Dra . . . . . . . . . . . . . . . . . . . 1
45 . . . . . . . GS1 . . . . . 226819 . . Valve, 12VDC 1Way .750−14 Thd 2mm Orf 100PSI . . . . . . . . . . . . . . . . . . 1
46 . . . . . . . . . . . . . . . . . 252254 . . Bracket, Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
47 . . . . . . . . . . . . . . . . . 220805 . . Nut, 750-14 Knurled 1.68Dia .41H Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
48 . . . . . . . . . . . . . . . . . 242250 . . Conn, TW LK Insul Male (Tweco/Lenco Type) HD 3/0−4/0 . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 252393 . . Label, Warn Gen Precaution Suitcase CE/Domestic . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 196956 . . Label, Warning Electric Shock And Pinch Wordless . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . 222320 . . Label, Warning X−TREME 12VS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . PLG3 . . . . 115093 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG10 . . . . 131052 . . Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG17 . . . . 222397 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . PLG9, 21 . . . 131055 . . Housing Rcpt+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . PLG22 . . . . 115092 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG111 . . . 256953 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-252203 Page 29
2 Hardware is common and
not available unless listed.
3 1
8
7
6
5
4
10
257 057-B
Figure 9-2. Front Panel Assembly without Meters
Item Dia. Part

.
Figure 9-2. Front Panel Assembly without Meters (Figure 9-1 Item 1)
. . 1 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Without Meters (Order By Model And Serial Number) . . . . . . . 1

. . 2 . . . . . . . . . . . . . . 252209 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . . . R1 . . . . . 208399 . . Pot, Cp Std Slot 1T 2. W 10K Linear W/Fricttabs . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 171007 . . Knob, Pointer 1.670 Dia X .250 Id W/Set Screwsplstc . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 604645 . . Nut, 375−32 .56Hex .09H Stl Pld Use W/Pots . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . S2 . . . . . 266614 . . Switch, Rocker SPDT 8A 125VAC (On)−Off−(On) .187T . . . . . . . . . . . . . . . 1
. . 7 . . . . . S4 . . . . . 217932 . . Switch, Rocker SPST .4VA 28VDC On−None−Off .187Ter . . . . . . . . . . . . . . 1
. . 8 . . . . . S1 . . . . . 267296 . . Switch, Rocker SPST 15A 250VAC On−Off Visi Red Rock . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 252262 . . Cable, Trigger 25in W/Strain Relief (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 139042 . . . . Bushing, Strain Relief .270/.470 Id X .804 Mtg Hole . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG6 . . . . 115094 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 079531 . . . . Conn, Circ CPC Clamp Str Rlf Size 11 .453OD . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RC2 . . . . . 080328 . . . . Rcpt W/Skts, Free Hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 604571 . . . . Cable, Port NO 18 4/C Type Sjo Nprn Jkt Re . . . . . . . . . . . . . . . . . . . . . 25 in.
. . 10 . . . . . . . . . . . . . 252212 . . Cable, Sensing W/Strain Relief (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 208820 . . . . Clamp, Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 258058 . . . . Wire, Strd 10Ga Blk 600V 125C 105x30 Poe .216od . . . . . . . . . . . . . . . . 16 Ft
. . . . . . . . . . . . . . . . . . . 261163 . . . . Label, Warning Electric Shock/Volt Sense Clamp . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-252203 Page 30
3
2 Hardware is common and
8
5 7
6
10
257 055-A
Figure 9-3. Front Panel Assembly with Meters
Item Dia. Part

.
Figure 9-3. Front Panel Assembly with Meters (Figure 9-1 Item 2)
. . 1 . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, With Meters (Order By Model And Serial Number) . . . . . . . . . . 1

. . 2 . . . . . . . . . . . . . . 252209 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 3 . . . PC20 . . . . 258989 . . Circuit Card Assy, Meter Suitcase w/Program . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 4 . . . . . . . . . . . . . . 179851 . . Knob, Pointer 1.670 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . . . . . . 1
. . 5 . . . . . . . . . . . . . . 604645 . . Nut, 375−32 .56Hex .09H Stl Pld Use W/Pots . . . . . . . . . . . . . . . . . . . . . . . . 1
. . 6 . . . . . S2 . . . . . 266614 . . Switch, Rocker SPDT 8A 125VAC (On)−Off−(On) .187T . . . . . . . . . . . . . . . 1
. . 7 . . . . . S4 . . . . . 217932 . . Switch, Rocker SPST .4VA 28VDC On−None−Off .187 Ter . . . . . . . . . . . . . 1
. . 8 . . . . . S1 . . . . . 267296 . . Switch, Rocker SPST 15A 250VAC On−Off Visi Red Rock . . . . . . . . . . . . . 1
. . 9 . . . . . . . . . . . . . . 252262 . . Cable, Trigger 25in W/Strain Relief (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG6 . . . . 115094 . . . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 079531 . . . . . . Conn, Circ CPC Clamp Str Rlf Size 11 .453OD . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . RC2 . . . . . 080328 . . . . Rcpt W/Skts, Free Hanging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 604571 . . . . Cable, Port NO 18 4/C Type Sjo Nprn Jkt Re . . . . . . . . . . . . . . . . . . . . . 25 in.
. . 10 . . . . . . . . . . . . . 252212 . . Cable, Sensing W/Strain Relief (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 208820 . . . . Clamp, Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . 258058 . . . . Wire, Strd 10Ga Blk 600V 125C 105x30 Poe .216od . . . . . . . . . . . . . . . . 16 Ft
. . . . . . . . . . . . . . . . . . . 261163 . . . . Label, Warning Electric Shock/Volt Sense Clamp . . . . . . . . . . . . . . . . . . . . 1
To Maintain The Factory Original Performance Of Your Equipment, Use Only Manufacturer’S Suggested
Replacement Parts. Model And Serial Number Required When Ordering Parts From Your Local Distributor.
OM-252203 Page 31
Hardware is common and
2 1
15
16
11
3
10
17 9
18 12
13
14 5
19 4
8
10 27
22 26
21
20
29
30 7
31
32 6
33
24
42
36 23
13 40
45 25
34 35
44 39
38
41
43 37
46
28
257 016-B
Figure 9-4. Drive Assembly, Wire

OM-252203 Page 32
Item Dia. Part
.
Figure 9-4. Drive Assembly, Wire (Figure 9-1 Item 3)
1 . . . . . . . . M1 . . . . . 252214 . . Motor, Right Angle 24VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 . . . . . . . PLG4 . . . . 131054 . . Housing Plug+Skts, (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3 .................. 252229 . . Insulator, Motor/Drive/Tach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
4 .................. 149332 . . Clamp, Hose .405 − .485 Clp Dia Slfttng Olive Dra . . . . . . . . . . . . . . . . . . . 1
5 .................. 134834 . . Hose, SAE .187 Id X .410 Od Xcoil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 In.
6 .................. 263858 . . Module, Tach Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
7 .................. 231181 . . Screw, 004−40x .37 Soc Hd−Hex Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8 .................. 174610 . . Screw, M 6−1.0x 20 Soc Hd Button Cap Blk . . . . . . . . . . . . . . . . . . . . . . . . . 3
.................... 256035 . . Casting Assembly, Drive (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
9 .................. 079634 . . . . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 . . . . . . . . . . . . . . . . . 151828 . . . . Pin, Cotter Hair .042 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
11 . . . . . . . . . . . . . . . . . 252235 . . . . Lever, Mtg Pressure Gear Machined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
12 . . . . . . . . . . . . . . . . . 252238 . . . . Stand−Off, Drive Roll Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 . . . . . . . . . . . . . . . . . 172075 . . . . Carrier, Drive Roll W/Components 24 Pitch . . . . . . . . . . . . . . . . . . . . . . . . 2
14 . . . . . . . . . . . . . . . . . 228562 . . . . Screw, 006−32x .25 Pan Hd−Phl W/Ext Washer (Sems) Stl . . . . . . . . . 1
15 . . . . . . . . . . . . . . . . . 196895 . . . . Knob, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
16 . . . . . . . . . . . . . . . . . 252243 . . . . Spring, Cprsn Big . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17 . . . . . . . . . . . . . . . . . 241856 . . . . Cup, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
18 . . . . . . . . . . . . . . . . . 085244 . . . . Washer, Cupped .328idx .812odx16gax.125 Lip . . . . . . . . . . . . . . . . . . . . 1
19 . . . . . . . . . . . . . . . . . 267899 . . . . Fastener, Pinned Machined . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
20 . . . . . . . . . . . . . . . . . 010224 . . . . Pin, Spring Cs .187 X 1.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
21 . . . . . . . . . . . . . . . . . 222159 . . . . Spring, Torsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
22 . . . . . . . . . . . . . . . . . 253655 . . . . Insulator, Screw Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
23 . . . . . . . . . . . . . . . . . 253513 . . . . Housing, Wire Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
24 . . . . . . . . . . . . . . . . . 166072 . . . . Spacer, Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
25 . . . . . . . . . . . . . . . . . 273794 . . . . Screw, 250−20x1.38 Soc Hd−Hex Gr8 Pln . . . . . . . . . . . . . . . . . . . . . . . . 1
26 . . . . . . . . . . . . . . . . . 264611 . . . . O−Ring, .187 Id X .312 Od X .063 Cs 75 Duro Fluor . . . . . . . . . . . . . . . . 1
27 . . . . . . . . . . . . . . . . . 144172 . . . . Ftg, Hose Brs Barbed M 3/16 TBG X .250-20 . . . . . . . . . . . . . . . . . . . . . . 1
28 . . . . . . . . . . . . . . . . . 263877 . . . . Wire Drive Bus Bar (Service Kit) (Includes) . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 259857 . . . . . . Screw, 375−16X .87 Hex Hd−Pln Gr5 Pld Blk . . . . . . . . . . . . . . . . . . . . 1
.................... 231223 . . . . . . Nut, 375−16 .56Hex .34H Stl Pld Clr . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
.................... 183387 . . . . . . Washer, Cone .380idx .860odx.109T Stl Pld 4000lbs . . . . . . . . . . . . . . 2
.................... 252232 . . . . . . Bolt, Crg Stl .375−16 X 1.000 Gr5 Pl Fnsh . . . . . . . . . . . . . . . . . . . . . . . 1
29 . . . . . . . . . . . . . . . . . 252230 . . Grommet, Motor Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
30 . . . . . . . . . . . . . . . . . 252786 . . Drive, Pinion 10mm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
31 . . . . . . . . . . . . . . . . . 252220 . . Key, Stl 3mm/3mm X 10mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
32 . . . . . . . . . . . . . . . . . 602237 . . Washer, Flat .172idx0.500od X .048t Stl Pld Blk . . . . . . . . . . . . . . . . . . . . . 1
33 . . . . . . . . . . . . . . . . . 174609 . . Screw, M 4− .7x 12 Cheese Hd Blk Din 84 . . . . . . . . . . . . . . . . . . . . . . . . . . 1
34 . . . . . . . . . . . . . . . . . 133308 . . Ring, Rtng Ext .375 Shaft X .025 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
35 . . . . . . . . . . . . . . . . . 168825 . . Drive, Pinion Sntr 22T 24P .376 Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
36 . . . . . . . . . . . . . . . . . 252222 . . Screw, 010−32x .75 Soc Hd−Hex Stl Gr8 Pld Lkg Patch . . . . . . . . . . . . . . 4
37 . . . . . . . . . . . . . . . . . 124778 . . Knob, T 2.000 Bar W/.312-18 Stud 1.000 Lg Plstc . . . . . . . . . . . . . . . . . . . 1
38 . . . . . . . . . . . . . . . . . 237188 . . Lock, Pin Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
39 . . . . . . . . . . . . . . . . . 234074 . . Clamp, Pin Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
40 . . . . . . . . . . . . . . . . . 234073 . . Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
41 . . . . . . . . . . . . . . . . . 151828 . . Pin, Cotter Hair .042 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
42 . . . . . . . . . . . . . . . . . 252785 . . Cover, Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
43 . . . . . . . . . . . . . . . . . 258838 . . Screw, 008−32x .37 Pan Hd−Phl Stl Pld Zc Lkg Patch . . . . . . . . . . . . . . . . 3
44 . . . . . . . . . . . . . . . . . 253404 . . Screw, 008−32x .75 Soc Hd−Hex Stl Pld Lkg Patch . . . . . . . . . . . . . . . . . . 1
45 . . . . . . . . . . . . . . . . . 252322 . . Block, Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
46 . . . . . . . . . . . . . . . . . 252323 . . Pin, Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
To Maintain The Factory Original Performance Of Your Equipment, Use Only Manufacturer’S Suggested
Replacement Parts. Model And Serial Number Required When Ordering Parts From Your Local Distributor.
OM-252203 Page 33
Table 9-1. Drive Roll Guide
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 (2 Required)

Fraction Decimal Metric Part No. Type
.023/.025 in. .023/.025 in. 0.6 mm 087130 V-Grooved
.030 in. .030 in. 0.8 mm 053695 V-Grooved
.035 in. .035 in. 0.9 mm 053700 V-Grooved
.040 in. .040 in. 1.0 mm 053696 V-Grooved
.045 in. .045 in. 1.2 mm 053697 V-Grooved
.052 in. .052 in. 1.3 mm 053698 V-Grooved
1/16 in. .062 in. 1.6 mm 053699 V-Grooved
.035 in. .035 in. 0.9 mm 072000 U-Grooved
.045 in. .045 in. 1.2 mm 053701 U-Grooved
.052 in. .052 in. 1.3 mm 053702 U-Grooved
1/16 in. .062 in. 1.6 mm 053706 U-Grooved
5/64 in. .079 in. 2.0 mm 053704 U-Grooved
.035 in. .035 in. 0.9 mm 132958 V-Knurled
.045 in. .045 in. 1.2 mm 132957 V-Knurled
.052 in. .052 in. 1.3 mm 132956 V-Knurled
1/16 in. .062 in. 1.6 mm 132955 V-Knurled
.068-.072 in. .068-.072 in. 1.8 mm 132959 V-Knurled
5/64 in. .079 in. 2.0 mm 132960 V-Knurled
.045 in. .045 in. 1.2 mm 083489 U-Cogged
.052 in. .052 in. 1.3 mm 083490 U-Cogged
1/16 in. .062 in. 1.6 mm 053708 U-Cogged
5/64 in. .079 in. 2.0 mm 053710 U-Cogged
S-0859
OM-252203 Page 34
Effective January 1, 2016
(Equipment with a serial number preface of MG or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Call Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original * Batteries
retail purchaser that new Miller equipment sold after the effective * Bernard Guns (No Labor)
1-800-4-A-MILLER date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
for your local EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
Miller distributor. OR IMPLIED, INCLUDING THE WARRANTIES OF * Accessory (Kits)
MERCHANTABILITY AND FITNESS. * Canvas Covers
Within the warranty periods listed below, Miller will repair or replace * Induction Heating Coils and Blankets, Cables, and
any warranted parts or components that fail due to such defects in Non-Electronic Controls
Your distributor also gives material or workmanship. Miller must be notified in writing within * M-Guns
you ... thirty (30) days of such defect or failure, at which time Miller will * MIG Guns and Subarc (SAW) Torches
provide instructions on the warranty claim procedures to be * Remote Controls and RFCS-RJ45
Service followed. If notification is submitted as an online warranty claim, the
You always get the fast, * Replacement Parts (No labor)
claim must include a detailed description of the fault and the
reliable response you * Roughneck Guns
troubleshooting steps taken to identify failed components and the
need. Most replacement cause of their failure. * Spoolmate Spoolguns
parts can be in your Miller’s True Blue® Limited Warranty shall not apply to:
Miller shall honor warranty claims on warranted equipment listed
hands in 24 hours. below in the event of such a failure within the warranty time periods. 1. Consumable components; such as contact tips,
All warranty time periods start on the delivery date of the equipment cutting nozzles, contactors, brushes, relays, work
Support to the original end-user purchaser, and not to exceed twelve months station table tops and welding curtains, or parts that
Need fast answers to the after the equipment is shipped to a North American distributor or fail due to normal wear. (Exception: brushes and
tough welding questions? eighteen months after the equipment is shipped to an International relays are covered on all engine-driven products.)
Contact your distributor. distributor. 2. Items furnished by Miller, but manufactured by others,
The expertise of the 1. 5 Years Parts — 3 Years Labor such as engines or trade accessories. These items are
distributor and Miller is * Original Main Power Rectifiers Only to Include SCRs, covered by the manufacturer’s warranty, if any.
there to help you, every Diodes, and Discrete Rectifier Modules 3. Equipment that has been modified by any party other than
step of the way. 2. 3 Years — Parts and Labor Miller, or equipment that has been improperly installed,
* Auto-Darkening Helmet Lenses (Except Classic improperly operated or misused based upon industry
Series) (No Labor) standards, or equipment which has not had reasonable
* Engine Driven Welder/Generators and necessary maintenance, or equipment which has
(NOTE: Engines are Warranted Separately by the been used for operation outside of the specifications for
Engine Manufacturer.) the equipment.
* Inverter Power Sources (Unless Otherwise Stated) MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Plasma Arc Cutting Power Sources USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Process Controllers MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Transformer/Rectifier Power Sources exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
3. 2 Years — Parts and Labor replacement; or, where authorized in writing by Miller in appropriate
* Auto-Darkening Helmet Lenses − Classic Series Only cases, (3) the reasonable cost of repair or replacement at an
(No Labor) authorized Miller service station; or (4) payment of or credit for the
* Fume Extractors − Capture 5, Filtair 400 and Industrial purchase price (less reasonable depreciation based upon actual
Collector Series use) upon return of the goods at customer’s risk and expense.
Miller’s option of repair or replacement will be F.O.B., Factory at
4. 1 Year — Parts and Labor Unless Specified Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
* Automatic Motion Devices as determined by Miller. Therefore no compensation or
* CoolBelt and CoolBand Blower Unit (No Labor) reimbursement for transportation costs of any kind will be allowed.
* Desiccant Air Dryer System TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* External Monitoring Equipment and Sensors PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Field Options REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
(NOTE: Field options are covered for the remaining DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
warranty period of the product they are installed in, CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
or for a minimum of one year — whichever is
LEGAL THEORY.
greater.)
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
* RFCS Foot Controls (Except RFCS-RJ45) IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
* Fume Extractors − Filtair 130, MWX and SWX Series TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
* HF Units CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
* ICE/XT Plasma Cutting Torches (No Labor) BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
* Induction Heating Power Sources, Coolers OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
(NOTE: Digital Recorders are Warranted Separately DEALING, INCLUDING ANY IMPLIED WARRANTY OF
by the Manufacturer.) MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* LiveArc Welding Performance Management System
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
* Load Banks MILLER.
* Motor-Driven Guns (except Spoolmate Spoolguns) Some states in the U.S.A. do not allow limitations of how long an
* PAPR Blower Unit (No Labor) implied warranty lasts, or the exclusion of incidental, indirect,
* Positioners and Controllers special or consequential damages, so the above limitation or
* Racks exclusion may not apply to you. This warranty provides specific
* Running Gear/Trailers legal rights, and other rights may be available, but may vary from
* Spot Welders state to state.
* Subarc Wire Drive Assemblies In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
* Water Coolant Systems
the extent that they may not be waived, the limitations and
* TIG Torches (No Labor) exclusions set out above may not apply. This Limited Warranty
* Wireless Remote Foot/Hand Controls and Receivers provides specific legal rights, and other rights may be available, but
* Work Stations/Weld Tables (No Labor) may vary from province to province. miller_warr 2016-01
Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Miller Electric Mfg. Co.
Replacement Parts An Illinois Tool Works Company
1635 West Spencer Street
Training (Schools, Videos, Books) Appleton, WI 54914 USA
International Headquarters−USA
Technical Manuals (Servicing Information USA Phone: 920-735-4505 Auto-Attended
and Parts) USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
Circuit Diagrams
For International Locations Visit
www.MillerWelds.com
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2016 Miller Electric Mfg. Co. 2016−01

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

Product Stock Number

February 18, 2016

MANAGER, PRODUCT DESIGN COMPLIANCE

1-1. Symbol Usage

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

1-2. Arc Welding Hazards

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

FIRE OR EXPLOSION hazard. MOVING PARTS can injure.

MOVING PARTS can injure.

1-5. Principal Safety Standards

1-6. EMF Information

2-1. Symboles utilisés

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

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

Risque D’INCENDIE OU D’EXPLOSION. LES CHARGES ÉLECTROSTATI-

2-4. Proposition californienne 65 Avertissements

2-5. Principales normes de sécurité

2-6. Informations relatives aux CEM

3-1. Additional Safety Symbols And Definitions

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

Disconnect input plug or power before working on machine.

Keep your head out of the fumes.

Use forced ventilation or local exhaust to remove the fumes.

Use ventilating fan to remove fumes.

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

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

Drive rolls can injure fingers.

Become trained and read the instructions before working on the

3-2. Miscellaneous Symbols And Definitions

I1 Input Current Increase Off

Trigger Hold Off

4-2. Unit Specifications

Solid Wire: Length: 21 in.

4-3. Wire Type, Size, and Feed Speed Capability Table

.023 To 5/64 in. 50 to 780 ipm

*Rated speed range per IEC 60974-5

4-4. Gun Recommendation Table

GMAW − Hard or Cored Wires Bernard Q-Gun

FCAW − Self-Shielding Wires Bernard Dura-Flux Gun

4-5. Environmental Specifications

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

C. Information On Electromagnetic Compatibility (EMC)

5-1. Equipment Connection Diagram

Since feeder is not polarity sen-

Shielding gas pressure not to

Ref. 256 615-A

Turn off wire feeder or

256 617-A / 256 619-A

5-5. Connecting Weld Cable

Do not over tighten tension knob. It

5-8. Motor Control Board (PC1) DIP Switch Settings

Shows switch in OFF/UP (open) position Display Hold Off

Do Not Display Amperage

Wire Speed − Inches per Minute

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

= Check = Change = Clean = Replace