Page 2 - From Miller to You; Thank you; To locate your nearest
From Miller to You Mil_Thank1 2019 01 Miller is the first welding equipment manufacturer in theU. S. A. to be registered to theISO 9001 Quality System Standard. Working as hard as you do −every power source from Miller is backed by the mosthassle-free warranty in thebusiness. From Miller to You Than...
Page 3 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1 Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING; Symbol Usage; Arc Welding Hazards; ELECTRIC SHOCK can kill.
OM-281426 Page 1 SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING 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 notavoided, will result in death or ...
Page 7 - Additional Hazards For Installation, Operation, And Maintenance
OM-281426 Page 3 CYLINDERS can explode if damaged. Compressed gas cylinders contain gas under highpressure. If damaged, a cylinder can explode.Since gas cylinders are normally part of the weld- ing process, be sure to treat them carefully. � Protect compressed gas cylinders from excessive heat, mech...
Page 8 - ARC WELDING can cause; California Proposition 65 Warnings; EMF Information
OM-281426 Page 4 ARC WELDING can cause interference. � Electromagnetic energy can interfere with sensitiveelectronic equipment such as microprocessors,computers, and computer-driven equipment such as robots. � Be sure all equipment in the welding area is electromagneticallycompatible. � To reduce po...
Page 9 - Symboles utilisés; Dangers relatifs au soudage à l’arc; UNE DÉCHARGE ÉLECTRIQUE peut
OM-281426 Page 5 SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relativesaux précautions de sécurité et au mode opératoire. 2-1. Symboles utilisés DANGER! – Indique un...
Page 11 - fonctionnement et la maintenance
OM-281426 Page 7 � Brancher le câble de masse sur la pièce le plus près possible dela zone de soudage pour éviter le transport du courant sur une lon-gue distance par des chemins inconnus éventuels en provoquantdes risques d’électrocution, d’étincelles et d’incendie. � Ne pas utiliser le poste de so...
Page 13 - Informations relatives aux CEM
OM-281426 Page 9 2-4. Proposition californienne 65 Avertissements AVERTISSEMENT – Ce produit peut vous exposer à des pro-duits chimiques tels que le plomb, reconnus par l’État deCalifornie comme cancérigènes et sources de malforma-tions ou d’autres troubles de la reproduction. Pour plus d’informatio...
Page 14 - SECTION 3 – DEFINITIONS; Additional Safety Symbol Definitions; Miscellaneous Symbols And Definitions
OM-281426 Page 10 � Complete Parts List is available at www.MillerWelds.com SECTION 3 – DEFINITIONS 3-1. Additional Safety Symbol Definitions Warning! Watch Out! There are possible hazards as shown by thesymbols. OM- Safe75 2017 04 Safe82 2012 07 Safe95 2012 05 Safe105 2012 09 Drive rolls can injure...
Page 16 - SECTION 4 – SPECIFICATIONS; Serial Number And Rating Label Location; Information About Default Weld Parameters And Settings
OM-281426 Page 12 � Complete Parts List is available at www.MillerWelds.com SECTION 4 – SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back of unit. Use rating label to determine input power requirementsand/or r...
Page 17 - Environmental Specifications; B. Temperature Specifications; Dimensions And Weight
OM-281426 Page 13 � Complete Parts List is available at www.MillerWelds.com 4-7. Environmental Specifications A. IP Rating IP Rating IP21 This equipment is designed for indoor use and is not intended to be used or stored outside. B. Temperature Specifications Operating Temperature Range * Storage/Tr...
Page 18 - Duty Cycle And Overheating For MIG (GMAW); A or V
OM-281426 Page 14 � Complete Parts List is available at www.MillerWelds.com 4-9. Duty Cycle And Overheating For MIG (GMAW) A complete Parts List is available at www.MillerWelds.com OM-281426 Page 5 1-4. Duty Cycle And Overheating For MIG (GMAW) 0 20 40 60 80 100 120 140 160 180 200 220 240 10 100 O ...
Page 19 - Duty Cycle And Overheating For TIG (GTAW)
OM-281426 Page 15 � Complete Parts List is available at www.MillerWelds.com 4-10. Duty Cycle And Overheating For TIG (GTAW) A complete Parts List is available at www.MillerWelds.com OM-281426 Page 6 1-5. Duty Cycle And Overheating For TIG (GTAW) 0 20 40 60 80 100 120 140 160 180 200 220 240 10 100 O...
Page 20 - Duty Cycle And Overheating For Stick (SMAW)
OM-281426 Page 16 � Complete Parts List is available at www.MillerWelds.com 4-11. Duty Cycle And Overheating For Stick (SMAW) A complete Parts List is available at www.MillerWelds.com OM-281426 Page 7 1-6. Duty Cycle And Overheating For Stick (SMAW) 0 20 40 60 80 100 120 140 160 180 200 220 240 10 1...
Page 21 - SECTION 5 – INSTALLATION; Selecting A Location
OM-281426 Page 17 � Complete Parts List is available at www.MillerWelds.com SECTION 5 – INSTALLATION 5-1. Selecting A Location Movement 1 A complete Parts List is available at www.MillerWelds.com OM-279299 Page 3 loc_smallmig2 2018-09 161-122 Location And Airflow 18 in. (460 mm) 2 18 in. (460 mm) Do...
Page 23 - Electrical Service Guide; Input Power Extension Cord Data
OM-281426 Page 19 � Complete Parts List is available at www.MillerWelds.com 5-3. Electrical Service Guide Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommen-dations are for an individual branch circuit sized for the rated ou...
Page 24 - Connecting 120 Volt Input Power
OM-281426 Page 20 � Complete Parts List is available at www.MillerWelds.com 5-5. Connecting 120 Volt Input Power A complete Parts List is available at www.MillerWelds.com OM-281426 Page 9 Input6 2011 03 275173A / Ref. 805 474-A 2-2. Connecting 120 Volt Input Power 1 2 Installation must meet all Nati...
Page 25 - Connecting 1-Phase Input Power For 240 VAC
OM-281426 Page 21 � Complete Parts List is available at www.MillerWelds.com 5-6. Connecting 1-Phase Input Power For 240 VAC A complete Parts List is available at www.MillerWelds.com OM-281426 Page 10 2-3. Connecting 1-Phase Input Power For 240 VAC input4 2012-05 803 766-C / Ref. 802 443-A / 275173A ...
Page 26 - Generator Requirements; Generator / Inverter Requirements
OM-281426 Page 22 � Complete Parts List is available at www.MillerWelds.com 5-7. Generator Requirements Generator settings, if applicable A complete Parts List is available at www.MillerWelds.com OM-281426 Page 11 2-4. Generator / Inverter Requirements Engine Control Switch must be setat "RUN...
Page 27 - Stick Welding Connections
OM-281426 Page 23 � Complete Parts List is available at www.MillerWelds.com 5-8. Stick Welding Connections A complete Parts List is available at www.MillerWelds.com OM-281426 Page 12 2-5. Stick Welding Connections Ref. 282724A 4 1 2 3 Turn off unit and disconnect inputpower before making connections...
Page 28 - TIG Welding Connections
OM-281426 Page 24 � Complete Parts List is available at www.MillerWelds.com 5-9. TIG Welding Connections A complete Parts List is available at www.MillerWelds.com OM-281426 Page 13 2-6. TIG Welding Connections Ref. 282724A / Ref. 282719A 2 1 3 4 5 6 7 8 Turn off unit and disconnect inputpower before...
Page 29 - MIG Welding Connections
OM-281426 Page 25 � Complete Parts List is available at www.MillerWelds.com 5-10. MIG Welding Connections A complete Parts List is available at www.MillerWelds.com OM-281426 Page 14 2-7. MIG Welding Connections Ref. 275172A / Ref. 275167A / Ref. 275168A 4 3 1 2 8 6 7 5 Turn off unit and disconnect i...
Page 31 - Connecting Shielding Gas Supply; MIG; NGO’s
OM-281426 Page 27 � Complete Parts List is available at www.MillerWelds.com 5-12. Connecting Shielding Gas Supply A complete Parts List is available at www.MillerWelds.com OM-281426 Page 16 2-9. Connecting Shielding Gas Supply Ref. 804 654-A / 282718A 1 2 3 1 2 4 1 2 10 12 11 9 5 6 5 6 9 7 8 MIG TIG...
Page 32 - -13. Installing Wire Spool And Adjusting Hub Tension; -10. Installing Wire Spool And Adjusting Hub Tension; -10. Installing Wire Spool And Adjusting Hub Tension
OM-281426 Page 28 � Complete Parts List is available at www.MillerWelds.com 5-13. Installing Wire Spool And Adjusting Hub Tension A complete Parts List is available at www.MillerWelds.com OM-281426 Page 17 2-10. Installing Wire Spool And Adjusting Hub Tension Ref. 282721A / 803 012 / 803 013 -B / Re...
Page 34 - -15. Removing MIG Gun To Replace With A Spool Gun; -12. Removing MIG Gun To Replace With A Spool Gun
OM-281426 Page 30 � Complete Parts List is available at www.MillerWelds.com 5-15. Removing MIG Gun To Replace With A Spool Gun A complete Parts List is available at www.MillerWelds.com OM-281426 Page 19 2-12. Removing MIG Gun To Replace With A Spool Gun 282718A / Ref. 802982A / Ref. 282722A / Ref. 2...
Page 35 - SECTION 6 – OPERATION; Controls
OM-281426 Page 31 � Complete Parts List is available at www.MillerWelds.com SECTION 6 – OPERATION 6-1. Controls Rear View 1 Process Select Buttons Press the up and down buttons to select de-sired welding process. 2 Auto-Set Button Press button to turn Auto-Set On or Off. Au-to-Set is On when illumin...
Page 36 - Controls, TIG Aluminum Manual Mode; Accessing Control Panel Menu: AC TIG
OM-281426 Page 32 � Complete Parts List is available at www.MillerWelds.com 6-2. Controls, TIG Aluminum Manual Mode A complete Parts List is available at www.MillerWelds.com OM-281426 Page 21 3-2. Controls, TIG Aluminum Manual Mode Ref. 281252A 1 2 3 4 5 6 1 Auto-Set Button Press button to turn Auto...
Page 37 - Controls, TIG Steel/Stainless Manual Mode; Controls, Stick Manual Mode; Controls, TIG Steel/Stainless Manual Mode
OM-281426 Page 33 � Complete Parts List is available at www.MillerWelds.com 6-3. Controls, TIG Steel/Stainless Manual Mode A complete Parts List is available at www.MillerWelds.com OM-281426 Page 22 3-3. Controls, TIG Steel/Stainless Manual Mode Ref. 281252A 1 2 3 4 5 3-4. Controls, Stick Manual Mod...
Page 38 - Controls, MIG Manual Mode
OM-281426 Page 34 � Complete Parts List is available at www.MillerWelds.com 6-5. Controls, MIG Manual Mode A complete Parts List is available at www.MillerWelds.com OM-281426 Page 23 3-5. Controls, MIG Manual Mode Ref. 281252A 1 2 3 1 Auto-Set Button Press button to turn Auto-Set feature On orOff. A...
Page 39 - Welding Parameter Chart—120V; TIG Welding Parameters
OM-281426 Page 35 � Complete Parts List is available at www.MillerWelds.com 6-6. Welding Parameter Chart—120V 24 ga (V/WFS) 22 ga (V/WFS) 20 ga (V/WFS) 18 ga (V/WFS) 16 ga (V/WFS) 14 ga (V/WFS) 1/8” (V/WFS) 3/16” (V/WFS) 1/4” (V/WFS) 14.2/137 14.2/191 15.2/211 16.1/271 16.7/322 17.4/400 19.0/533 19....
Page 40 - Welding Parameter Chart—240V
OM-281426 Page 36 � Complete Parts List is available at www.MillerWelds.com 6-7. Welding Parameter Chart—240V 24 ga (V/WFS) 22 ga (V/WFS) 20 ga (V/WFS) 18 ga (V/WFS) 16 ga (V/WFS) 14 ga (V/WFS) 1/8” (V/WFS) 3/16” (V/WFS) 1/4” (V/WFS) 5/16” (V/WFS) 3/8” (V/WFS) 14.2/137 14.2/191 15.2/211 16.1/271 16....
Page 41 - Entering Setup Menu
OM-281426 Page 37 � Complete Parts List is available at www.MillerWelds.com 6-8. Entering Setup Menu A complete Parts List is available at www.MillerWelds.com OM-281426 Page 26 3-8. Entering Setup Menu Ref. 281252A 1 2 3 4 1 Wire/Rod/Tungsten Minus (-) Button 2 Material Thickness Minus (-) Button 3 ...
Page 42 - Internal Motor 24 Inch Calibration (Menu 1 Of 12); Internal Motor 24 Inch Calibration (Menu 1 Of 12)
OM-281426 Page 38 � Complete Parts List is available at www.MillerWelds.com 6-9. Internal Motor 24 Inch Calibration (Menu 1 Of 12) A complete Parts List is available at www.MillerWelds.com OM-281426 Page 27 3-9. Internal Motor 24 Inch Calibration (Menu 1 Of 12) Ref. 281252A 1 3 2 4 5 3-10. Internal ...
Page 49 - SECTION 7 – MAINTENANCE AND TROUBLESHOOTING; Routine Maintenance; Overload Protection
OM-281426 Page 45 � Complete Parts List is available at www.MillerWelds.com SECTION 7 – MAINTENANCE AND TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power before maintaining. � Maintain more often during severe conditions. � = Check ◇ = Change � = Clean � = Replace Every 3Months OM-249336 Pag...
Page 50 - Changing Drive Roll Or Wire Inlet Guide; Table 7–1. Drive Roll Grooves
OM-281426 Page 46 � Complete Parts List is available at www.MillerWelds.com 7-3. Changing Drive Roll Or Wire Inlet Guide 2 1 3 3 4 5 1 Inlet Wire Guide Remove guide by pressing on barbed areaor cutting off one end near housing and pull-ing it out of hole. Push new guide into holefrom rear until it s...
Page 51 - Error Messages
OM-281426 Page 47 � Complete Parts List is available at www.MillerWelds.com 7-4. Error Messages Message Error Remedy Overtemp-Please wait while the weld-er cools down. Internal temperature of welder has exceeded themaximum limit. Wait for unit to cool down. If the fan is not run-ning, contact Miller...
Page 52 - Troubleshooting
OM-281426 Page 48 � Complete Parts List is available at www.MillerWelds.com Message Error Remedy The secondary circuit thermistor is reading toohigh or too low for a valid temperature. The control board is damaged. Thermal error-Magnetic thermistorrange error. The magnetic circuit thermistor is unpl...
Page 53 - SECTION 8 – PARTS LIST; Recommended MIG Spare Parts; Recommended TIG Spare Parts
OM-281426 Page 49 � Complete Parts List is available at www.MillerWelds.com SECTION 8 – PARTS LIST 8-1. Recommended MIG Spare Parts Recommended Spare Parts Dia. Mkgs. Part No. Description Quantity 261167 Roll, Drive .024, .030–.035V Wire, .035VK Wire 1 202926 Roll, Drive VK .030–.035/.045 Wire 1 271...
Page 54 - SECTION 9 – ELECTRICAL DIAGRAMS
OM-281426 Page 50 SECTION 9 – ELECTRICAL DIAGRAMS 281418-A Figure 9-1. Circuit Diagram
Page 56 - SECTION 10 – HIGH FREQUENCY; 0-1. Welding Processes Requiring High Frequency; SECTION 1 HIGH FREQUENCY
OM-281426 Page 52 SECTION 10 – HIGH FREQUENCY 10-1. Welding Processes Requiring High Frequency OM- SECTION 1 HIGH FREQUENCY 1 TIG S-0694 13 9 8 7 1 2 4 5 6 3 10 11, 12 14 1 High-Frequency Voltage TIG – helps arc jump air gap between torchand workpiece and/or stabilize the arc. 10-2. Installation Sho...
Page 57 - 0-3. Recommended Installation To Reduce HF Interference
OM-281426 Page 53 10-3. Recommended Installation To Reduce HF Interference Best Practices Followed OM- 1 2 3 50 ft (15 m) 4 7 50 ft (15 m) 8 5 8 6 9 11 13 12 8 8 10 1 High-Frequency Source (welding powersource with built-in HF or separate HFunit) Ground metal machine case (clean paintfrom around hol...
Page 58 - A. Select Tungsten Electrode
OM-281426 Page 54 SECTION 11 – SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES 11-1. Selecting Tungsten Electrode Whenever possible and practical, use DC weld output instead of AC weld output. NOTICE – Wear clean gloves to prevent contamination of tungsten. A. Select T...
Page 59 - Welding With Inverter Machines
OM-281426 Page 55 11-2. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) Welding Or AC Welding With Inverter Machines Wrong Tungsten Preparation — Radial Grinding Causes Wandering Arc OM- 1-1. Preparing Tungsten Electrode For DC Electrode Negative (DCEN) WeldingOr AC Welding With Invert...
Page 60 - SECTION 12 – GMAW WELDING (MIG) GUIDELINES
OM-281426 Page 56 SECTION 12 – GMAW WELDING (MIG) GUIDELINES 12-1. Typical GMAW (MIG) Process Connections OM- 1 2 3 4 5 6 7 1/16 in. (0.0625 in.) 2 1 3 4 Weld current can damage electronicparts in vehicles. Disconnect bothbattery cables before welding on avehicle. Place work clamp as closeto the wel...
Page 61 - 2-3. Holding And Positioning Welding Gun; SECTION 1 GMAW WELDING (MIG) GUIDELINES WHEN; Holding And Positioning Welding Gun
OM-281426 Page 57 Wire Size Amperage Range Recommended Wire Feed Speed Wire Feed Speed * 0.023 in. (0.58 mm) 30-90 A 3.5 in. (89 mm) per amp 3.5 x 62.5 A = 219 ipm (5.56 mpm) 0.030 in. (0.76 mm) 40-145 A 2 in. (51 mm) per amp 2 x 62.5 A = 125 ipm (3.19 mpm) 0.035 in. (0.89 mm) 50-180 A 1.6 in. (41 m...
Page 62 - 2-4. Conditions That Affect Weld Bead Shape
OM-281426 Page 58 12-4. Conditions That Affect Weld Bead Shape Gun Angles and Weld Bead Profiles 4 5 6 4 5 6 10 ° 10 ° 7 8 9 1 2 3 Electrode Extensions (Stickout) 4 5 6 4 5 6 10 ° 10 ° 7 8 9 1 2 3 Fillet Weld Electrode Extensions (Stickout) 4 5 6 4 5 6 10 ° 10 ° 7 8 9 1 2 3 Gun Travel Speed 4 5 6 4 ...
Page 68 - SECTION 13 – STICK WELDING (SMAW) GUIDELINES
OM-281426 Page 64 SECTION 13 – STICK WELDING (SMAW) GUIDELINES 13-1. Stick Welding Procedure Tools Needed: OM-222 Page 1 allen_wrench NGO’s tools/ flathead philips head wrench pliers knife heavy-duty workclamp light-duty workclamp wirecutter frontcutter allen_set needlenose steelbrush nutdriver chip...
Page 69 - 3-2. Electrode And Amperage Selection Chart
OM-281426 Page 65 13-2. Electrode And Amperage Selection Chart OM- 3/32 1/8 5/323/167/32 1/4 1/165/643/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/167/32 1/4 3/32 1/8 5/323/163/32 1/8 5/32 6010 & 6011 6013 7014 7018 7024 Ni-Cl 308L 5 0 1 0 0 1 5 0 2...
Page 71 - 3-7. Conditions That Affect Weld Bead Shape
OM-281426 Page 67 13-7. Conditions That Affect Weld Bead Shape Electrode Angle OM- 10 ° - 30 ° 1 2 3 4 5 6 7 8 9 10 11 Arc Length 10 ° - 30 ° 1 2 3 4 5 6 7 8 9 10 11 Travel Speed 10 ° - 30 ° 1 2 3 4 5 6 7 8 9 10 11 � Weld bead shape is affected by elec- trode angle, arc length, travel speed,and thic...
Page 73 - Welding Lap Joints
OM-281426 Page 69 13-11. Welding T-Joints 1-1. Welding Lap Joints ≤ 30 ° ≤ 30 ° 1 1 2 3 1-2. Welding Groove (Butt) Joints 30 ° 2 1 1/16 in. (1.6 mm) 3 4 1-3. Welding T-Joints ≤ 45 ° 1 2 1 3 2 1-4. Weld Test 2 3 in. 1/4 in. 3 2 1 2 3 in. 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 1 Electrode 2 Fillet Weld ...
Page 76 - Notes
Page 79 - ranties expressed or implied.
Effective January 1, 2023 (Equipment with a serial number preface of ND or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war- ranties expressed or implied. LIMITED WARRANTY - Subject to the terms andconditions below, Miller Electr...
Page 80 - Miller Electric Mfg. LLC; Owner’s Record; Please complete and retain with your personal records.; For Service; Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Miller Electric Mfg. LLC An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 USA International Headquarters–USA USA Phone: 920-735-4505USA & Canada FAX: 920-735-4134International FAX: 920-735-4125 For International Locations Visitwww.MillerWelds.com ORIGINAL INSTRUCTIONS – P...