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-278174 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-278174 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-278174 Page 4 � Have the installation regularly checked and maintained. � Keep high-frequency source doors and panels tightly shut, keepspark gaps at correct setting, and use grounding and shielding tominimize the possibility of interference. ARC WELDING can cause interference. � Electromagnetic ...
Page 9 - Symboles utilisés; Dangers relatifs au soudage à l’arc; UNE DÉCHARGE ÉLECTRIQUE peut
OM-278174 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-278174 Page 7 � Ne pas couper ou souder des jantes ou des roues. Les pneus peu-vent exploser s’ils sont chauffés. Les jantes et les roues réparéespeuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans lesnormes de sécurité. � Ne pas effectuer le soudage sur des conteneurs fermés tels quedes ré...
Page 13 - Informations relatives aux CEM
OM-278174 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; SECTION 3 DEFINITIONS; Miscellaneous Symbols And Definitions; Notes
OM-278174 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
OM-278174 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-278174 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; A or V
OM-278174 Page 14 � Complete Parts List is available at www.MillerWelds.com 4-9. Duty Cycle And Overheating For MIG Duty Cycle is percentage of 10 minutes thatunit can weld at rated load without overheating. If unit overheats, output stops. Wait fifteenminutes for unit to cool. Reduce amperage ordut...
Page 19 - -10. Duty Cycle And Overheating For Stick
OM-278174 Page 15 � Complete Parts List is available at www.MillerWelds.com 4-10. Duty Cycle And Overheating For Stick Duty Cycle is percentage of 10 minutes thatunit can weld at rated load without overheating. If unit overheats, output stops. Wait fifteenminutes for unit to cool. Reduce amperage or...
Page 21 - SECTION 5 – INSTALLATION; Selecting A Location
OM-278174 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) 18 in. (460 mm) 2 Do...
Page 22 - Electrical Service Guide
OM-278174 Page 18 � Complete Parts List is available at www.MillerWelds.com 5-2. 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 23 - Connecting 1-Phase Input Power
OM-278174 Page 19 � Complete Parts List is available at www.MillerWelds.com 5-3. Connecting 1-Phase Input Power 2 1 L1 L2 1 =GND/PE Earth Ground 6 5 3 4 7 Installation must meet all Nationaland Local Codes—have only quali-fied persons make this installation. Disconnect and lockout/tagout in-put powe...
Page 24 - With Split-Phase 240 Volt Auxiliary Power; NGO’s
OM-278174 Page 20 � Complete Parts List is available at www.MillerWelds.com 5-4. Wiring Optional 240 Volt Plug (119172) For Connection To Miller Welder/Generator With Split-Phase 240 Volt Auxiliary Power Ref. 120 813-D / 907734 7 Green Or Green/Yel- low 2 3 4 5 6 240V 8 8 7 6 5 4 3 (Not Used) Plug F...
Page 25 - Generator Or Inverter Requirements; Selecting Cable Sizes
OM-278174 Page 21 � Complete Parts List is available at www.MillerWelds.com 5-5. Generator Or Inverter Requirements OM-253555 Page 1 1 2 Set Engine Control Switch to Runposition, not Run/Idle. Set generator Voltage/AmperageControl to 10 (or max) for maxi-mum auxiliary power. For maximum output, Mill...
Page 26 - Weld Output Terminals
OM-278174 Page 22 � Complete Parts List is available at www.MillerWelds.com 5-7. Weld Output Terminals 1 2 Turn off unit and disconnect inputpower before making connections. Do not use worn, damaged, under-sized, or repaired cables. 1 Positive (+) Weld Output Terminal 2 Negative (-) Weld Output Term...
Page 27 - MIG Welding Connections
OM-278174 Page 23 � Complete Parts List is available at www.MillerWelds.com 5-9. MIG Welding Connections MIG/FCAW-G − DCEP (Direct Current Electrode Positive) FCAW-S − DCEN (Direct Current Electrode Negative) 1 4 3 2 4 3 2 8 1 6 7 5 Turn off unit and disconnect inputpower before making connections. ...
Page 31 - MIG
OM-278174 Page 27 � Complete Parts List is available at www.MillerWelds.com 5-13. Connecting Shielding Gas Supply Ref. 804 654-A / 275168A / 280272C 1 2 3 Argon Gas CO 2 Gas 1 2 3 Mixed Gas 1 2 3 10 9 8 4 5 4 5 8 6 7 MIG TIG OM-222 Page 1 allen_wrench NGO’s tools/ flathead philips head wrench pliers...
Page 32 - -14. Installing Wire Spool And Adjusting Hub Tension
OM-278174 Page 28 � Complete Parts List is available at www.MillerWelds.com 5-14. Installing Wire Spool And Adjusting Hub Tension Installing 8 in. (203 mm) Wire Spool Hand tighten knob clockwise. When a slightforce is needed to turn spool, tension is set Removing 8 in. (203 mm) Spool Hub And Spool N...
Page 37 - -19. Threading Welding Wire For Spoolmate 200
OM-278174 Page 33 � Complete Parts List is available at www.MillerWelds.com 5-19. Threading Welding Wire For Spoolmate 200 Ref. 243 740-C 8 1 2 9 3 4 6 5 7 OM-222 Page 1 allen_wrench NGO’s tools/ flathead philips head wrench pliers knife heavy-duty workclamp light-duty workclamp wirecutter frontcutt...
Page 40 - SECTION 6 – OPERATION; Controls
OM-278174 Page 36 � Complete Parts List is available at www.MillerWelds.com SECTION 6 – OPERATION 6-1. Controls 277656-C 1 2 3 4 7 6 5 9 8 11 10 1 MIG Button Press to select MIG process. 2 Stick Button Press to select Stick process. 3 TIG Button Press to select TIG process. 4 Auto-Set Button Press t...
Page 41 - Special Features
OM-278174 Page 37 � Complete Parts List is available at www.MillerWelds.com 6-2. Special Features MIG Mode In MIG mode, the left knob is used to adjust welding voltage within a range of 12 to 32 volts. The right knob is usedto adjust wire feed speed within a range of 50 to 800 IPM. Refer to weld cha...
Page 42 - Elite
OM-278174 Page 38 � Complete Parts List is available at www.MillerWelds.com 6-3. Using Auto-Set ™ Elite 277656-C 1 2 3 9 4 10 5 6 7 8 11 12 13 1 Process Buttons Select desired welding process. 2 Auto-Set Button Press to turn Auto-Set On or Off. 3 Pulse Button Press to turn Pulse On or Off for MIG or...
Page 43 - Using Manual Mode
OM-278174 Page 39 � Complete Parts List is available at www.MillerWelds.com 6-4. Using Manual Mode 277656-C 1 2 3 8 4 9 5 6 7 1 Process Button Use to select desire welding process. 2 Auto-Set Button Press to turn Auto-Set On or Off. 3 Pulse Button Press to turn Pulse On or Off for MIG or TIGprocess....
Page 44 - Manual MIG Set-Up Mode
OM-278174 Page 40 � Complete Parts List is available at www.MillerWelds.com 6-5. Manual MIG Set-Up Mode 277656-C 1 2 3 4 1 Set-Up Button 2 Left Knob 3 Right Knob 4 Home Button To enter the Setup menu from the ManualMode home screen, press Setup. Once in the Setup menu, rotate the left knobto find a ...
Page 45 - Manual Stick Set-Up Mode
OM-278174 Page 41 � Complete Parts List is available at www.MillerWelds.com 6-6. Manual Stick Set-Up Mode 277656-C 1 2 3 4 1 Set-Up Button 2 Left Knob 3 Right Knob 4 Home Button To enter the Setup menu from the ManualMode home screen, press Setup. Once in the Setup menu, rotate the left knobto find ...
Page 46 - Manual TIG Set-Up Mode
OM-278174 Page 42 � Complete Parts List is available at www.MillerWelds.com 6-7. Manual TIG Set-Up Mode 277656-C 1 2 3 4 1 Set-Up Button 2 Left Knob 3 Right Knob 4 Home Button To enter the Setup menu from the ManualMode home screen, press Setup. Once in the Setup menu, rotate the left knobto find a ...
Page 47 - Setting Crater Time
OM-278174 Page 43 � Complete Parts List is available at www.MillerWelds.com 6-8. Setting Crater Time 277656-C 1 2 3 1 Left Knob 2 Right Knob 3 Home Button The crater setting is the amount of time thewelding arc stays on after the welding guntrigger is released. This feature is used to fillthe void o...
Page 48 - Manual Program Mode
OM-278174 Page 44 � Complete Parts List is available at www.MillerWelds.com 6-9. Manual Program Mode 1 3 4 5 2 1 Program Button 2 Program Soft Keys 3 Left Knob 4 Right Knob 5 Home Button The unit can store four programs for MIG,four for Stick, and four for TIG. The pro-grams have default setting sav...
Page 49 - Gun In Program Mode
OM-278174 Page 45 � Complete Parts List is available at www.MillerWelds.com 6-10. Using Optional MDX-250 EZ-Select ™ Gun In Program Mode Ref. 800797-A 1 2 1 Trigger Switch 2 Program LEDS The optional MDX-250 EZ-Select gun givesthe operator the ability to change weld pro-grams at the gun. When the MD...
Page 50 - Mode
OM-278174 Page 46 � Complete Parts List is available at www.MillerWelds.com 6-11. Pulsed MIG Auto-Set ™ Mode 277656-C 1 3 4 5 2 6 7 8 Pulsed MIG is a spray transfer that producesless heat input than conventional spraytransfer, resulting in less warping, distortion,and spatter. Pulsed MIG is often us...
Page 58 - -17. Welding Parameter Chart – Stick And TIG
OM-278174 Page 54 � Complete Parts List is available at www.MillerWelds.com 6-17. Welding Parameter Chart – Stick And TIG
Page 60 - SECTION 7 – MAINTENANCE AND TROUBLESHOOTING; Routine Maintenance; SECTION 17 MAINTENANCE & TROUBLESHOOTING; Changing Drive Roll Or Wire Inlet Guide
OM-278174 Page 56 � 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 61 - Aligning Drive Rolls And Wire Guide
OM-278174 Page 57 � Complete Parts List is available at www.MillerWelds.com 7-4. Aligning Drive Rolls And Wire Guide Correct Incorrect 4 3 2 1 5 Turn Off Power. View is from top of drive rolls looking downwith pressure assembly open. 1 Drive Roll Securing Nut 2 Drive Roll 3 Wire Guide 4 Welding Wire...
Page 62 - Error Messages
OM-278174 Page 58 � Complete Parts List is available at www.MillerWelds.com 7-5. Error Messages Message Error Remedy Overtemp-Please wait while the weld-er cools down. Boost Module* Inverter Module * Out-put Rectifier * Secondary Magnetics Internal temperature of welder has exceeded themaximum limit...
Page 64 - Troubleshooting
OM-278174 Page 60 � Complete Parts List is available at www.MillerWelds.com Message Error Remedy Free tungsten to clear error Tungsten has contacted workpiece for more thanfive seconds without starting an arc. Cable error — Connect wire feedhousing cable to clear error. A process that requires a wel...
Page 65 - SECTION 8 – PARTS LIST; MDX-250 MIG Gun Consumables And Recommended Spare Parts
OM-278174 Page 61 � Complete Parts List is available at www.MillerWelds.com SECTION 8 – PARTS LIST 8-1. MDX-250 MIG Gun Consumables And Recommended Spare Parts See OM-282976 (shipped with this product) for information on replacement consumables for the MDX welding gun. 8-2. Drive Roll And Wire Guide...
Page 66 - SECTION 9 – ELECTRICAL DIAGRAMS
OM-278174 Page 62 SECTION 9 – ELECTRICAL DIAGRAMS Figure 9-1. Circuit Diagram
Page 68 - SECTION 10 – GMAW WELDING (MIG) GUIDELINES
OM-278174 Page 64 SECTION 10 – GMAW WELDING (MIG) GUIDELINES 10-1. 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 69 - 0-3. Holding And Positioning Welding Gun; SECTION 1 GMAW WELDING (MIG) GUIDELINES WHEN; Holding And Positioning Welding Gun
OM-278174 Page 65 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 70 - 0-4. Conditions That Affect Weld Bead Shape
OM-278174 Page 66 10-4. 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 76 - SECTION 11 – STICK WELDING (SMAW) GUIDELINES
OM-278174 Page 72 SECTION 11 – STICK WELDING (SMAW) GUIDELINES 11-1. 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 77 - 1-2. Electrode And Amperage Selection Chart
OM-278174 Page 73 11-2. 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 79 - 1-7. Conditions That Affect Weld Bead Shape
OM-278174 Page 75 11-7. 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 81 - Welding Lap Joints
OM-278174 Page 77 11-11. 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 84 - A. Select Tungsten Electrode
OM-278174 Page 80 SECTION 12 – SELECTING AND PREPARING A TUNGSTEN FOR DC OR AC WELDING WITH INVERTER MACHINES 12-1. 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 85 - Welding With Inverter Machines
OM-278174 Page 81 12-2. 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 87 - (Equipment with a serial number preface of NB or newer); Call
Effective January 1, 2021 (Equipment with a serial number preface of NB or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, Miller Electri...
Page 88 - 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...