Miller Electric 852 Users Manual O222ad_mil

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OM-222

164 850AD

2007−03

Processes
TIG (GTAW) Welding
Stick (SMAW) Welding

Flux Cored (FCAW) Welding
Air Carbon Arc (CAC-A)
Cutting and Gouging

Description

Arc Welding Power Source

R

Gold Star Series

302, 452, 652 (60 Hz), 402, 602, 852 (50 Hz)

File: Stick (SMAW)
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
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001:2000 Quality Warranty and service information for your
System Standard.
particular model are also provided.

Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.

Mil_Thank 4/05

Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.

TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de l’appareil. . . . . . . . . . . .
2-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. General Precautionary Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Input Connection Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Electric Shock And Airflow Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Nameplate Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Selecting A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Dimensions And Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. 115 VAC Receptacle And Supplementary Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Connecting Weld Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Connecting Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Placing Jumper Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls (Non CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Controls (CE Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPTIONS AND ACCESSORIES
WARRANTY

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Declaration of Conformity for
European Community (CE) Products
NOTE

This information is provided for units with CE certification (see rating label on unit).

Manufacturer:

European Contact:

Miller Electric Mg. Co.
1635 W. Spencer St.
Appleton, WI 54914 USA
Phone: (920) 734-9821

Mr. Danilo Fedolfi,
Managing Director
ITW Welding Products Italy S.r.l.
Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39(02)98290-1
Fax: 39(02)98290203

European Contact Signature:

Declares that the product:

Goldstar® 402, 602, And 852

conforms to the following Directives and Standards:
Directives
Electromagnetic compatibility Directives: 89/336/EEC, 92/31/EEC
Low Voltage Directive: 73/23/EEC
Machinery Directives: 89/392/EEC, 91/368/EEC, 93/C 133/04, 93/68/EEC
Standards
Safety Requirements for Arc Welding Equipment part 1: EN 60974-1: 1990
Arc Welding Equipment Part 1: Welding Power Sources: IEC 974-1
(April 1995 − Draft revision)
Degrees of Protection provided by Enclosures (IP code): IEC 529: 1989
Insulation coordination for equipment within low-voltage systems:
Part 1: Principles, requirements and tests: IEC 664-1: 1992
Electromagnetic compatibility (EMC) Product standard for arc welding equipment:
EN50199: August 1995
dec_stat_6/05

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _3/05

Y Warning: Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
Y Marks a special safety message.

. Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.

1-2. Arc Welding Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard. The safety information given below is only
a summary of the more complete safety information found in
the Safety Standards listed in Section 1-5. Read and follow all
Safety Standards.
Y Only qualified persons should install, operate, maintain, and
repair this unit.

D
D
D
D
D
D

Y During operation, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic wire welding, the
wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.

D
D
D
D
D
D

Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly
with a separate cable.
Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
Do not connect more than one electrode or work cable to any
single weld output terminal.

SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.

FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
OM-222 Page 1

ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.

WELDING can cause fire or explosion.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.

FLYING METAL can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.

OM-222 Page 2

BUILDUP OF GAS can injure or kill.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.

HOT PARTS can cause severe burns.
D Do not touch hot parts bare handed.
D Allow cooling period before working on gun or
torch.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.

MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away.
D Wearers should consult their doctor before
going near arc welding, gouging, or spot
welding operations.

NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.

CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.

MOVING PARTS can cause injury.

D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.

D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors,
panels, covers, or guards for maintenance as
necessary.
D Reinstall doors, panels, covers, or guards
when maintenance is finished and before reconnecting input power.

FALLING UNIT can cause injury.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.

READ INSTRUCTIONS.
D Read Owner’s Manual before using or servicing unit.
D Use only genuine Miller/Hobart replacement
parts.

H.F. RADIATION can cause interference.

OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.

D
D

STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.

D
D

D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.

ARC WELDING can cause interference.

MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D

WELDING WIRE can cause injury.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.

D
D
D

D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)

For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.

Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
OM-222 Page 3

1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).

Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727 or in Toronto 416−747−4044, website: www.csa−international.org).

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, American Welding Society Standard
AWS F4.1 from Global Engineering Documents (phone:
1-877-413-5184, website: www.global.ihs.com).

Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website: www.ansi.org).

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (phone: 617−770−3000, website: www.nfpa.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, website: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).

1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:

OM-222 Page 4

1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
welding operations. If cleared by your doctor, then following the above
procedures is recommended.

SECTION 2 − CONSIGNES DE SÉCURITÉ − À LIRE AVANT
UTILISATION
som_fre 8/03

2-1. Signification des symboles
Signifie « Mise en garde. Faire preuve de vigilance. »
Cette procédure présente des risques identifiés par les
symboles adjacents aux directives.
Y Identifie un message de sécurité particulier.

. Signifie « NOTA » ; n’est pas relatif à la sécurité.

Ce groupe de symboles signifie « Mise en garde. Faire preuve de vigilance. » Il y a des dangers liés aux CHOCS ÉLECTRIQUES, aux
PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Se reporter
aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger.

2-2. Dangers relatifs au soudage à l’arc
Y Les symboles ci-après sont utilisés tout au long du présent
manuel pour attirer l’attention sur les dangers potentiels et les
identifier. Lorsqu’on voit un symbole, faire preuve de vigilance et
suivre les directives mentionnées afin d’éviter tout danger. Les
consignes de sécurité énoncées ci-après ne font que résumer le
contenu des normes de sécurité mentionnées à la section 2-4.
Lire et respecter toutes ces normes.
Y L’installation, l’utilisation, l’entretien et les réparations ne doivent être confiés qu’à des personnes qualifiées.
Y Pendant l’utilisation de l’appareil, tenir à l’écart toute personne,
en particulier les enfants.

LES DÉCHARGES ÉLECTRIQUES
peuvent être mortelles.
Un simple contact avec des pièces sous tension peut
causer une électrocution ou des blessures graves.
L’électrode et le circuit de soudage sont sous tension
dès que l’appareil est en fonctionnement. Le circuit
d’entrée et les circuits internes de l’appareil sont également sous tension.
En soudage semi−automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces métalliques en contact
avec le fil de soudage sont sous tension. Tout matériel mal installé ou mal
mis à la terre présente un danger.
D Ne jamais toucher aux pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs et exempts de
trous.
D S’isoler de la pièce et de la terre au moyen de tapis ou autres dispositifs isolants suffisamment grands pour empêcher tout contact
physique avec la pièce ou la terre.
D
D
D

Ne pas se servir d’une source de courant alternatif dans les zones humides, les endroits confinés ou là où on risque de tomber.
Ne se servir d’une source de courant alternatif QUE si le procédé de soudage l’exige.
Si l’utilisation d’une source de courant alternatif s’avère nécessaire, se servir de la fonction de télécommande si l’appareil en est équipé.

D Couper l’alimentation ou arrêter le moteur avant de procéder à l’installation, à la réparation ou à l’entretien de l’appareil. Couper/étiqueter
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir les normes de sécurité).
D Installer et mettre à la terre correctement l’appareil conformément à
son manuel d’utilisation et aux codes nationaux, provinciaux et
municipaux.
D 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 cordon est raccordée
à une prise correctement mise à la terre.
D Pour exécuter les branchements d’entrée, fixer d’abord le conducteur
de mise à la terre adéquat et contre−vérifier les connexions.
D Vérifier fréquemment le cordon d’alimentation et s’assurer qu’il n’est
ni endommagé ni dénudé ; le remplacer immédiatement s’il est endommagé − tout câble dénudé peut causer une électrocution.
D Mettre l’appareil hors tension quand on ne l’utilise pas.
D Ne pas utiliser de câbles usés, endommagés, de calibre insuffisant ou
mal épissés.
D Ne pas s’enrouler les câbles autour du corps.
D Si la pièce soudée doit être mise à la terre, le faire directement avec un
câble distinct.
D Ne pas toucher l’électrode quand on est en contact avec la pièce, la
terre ou une électrode d’une autre machine.

D N’utiliser que du matériel en bon état. Réparer ou remplacer sur−le−
champ les pièces endommagées. Entretenir l’appareil conformément
au présent manuel.
D Porter un harnais de sécurité quand on travaille en hauteur.
D Maintenir solidement en place tous les panneaux et capots.
D Fixer le câble de retour de façon à obtenir un bon contact métal sur
métal avec la pièce à souder ou la table de travail, le plus près possible
de la soudure.
D

Ne pas connecter plus d’une électrode ou plus d’un câble de masse à un
même terminal de sortie.

Il subsiste un COURANT CONTINU IMPORTANT
dans les convertisseurs après la suppression de
l’alimentation électrique.
D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions
énoncées à la section Entretien avant de toucher les pièces.

LES FUMÉES ET LES GAZ peuvent
être dangereux.
Le soudage génère des fumées et des gaz dont
l’inhalation peut être dangereuse pour la santé.

D Se tenir à distance des fumées et ne pas les inhaler.
D À l’intérieur, ventiler la zone et/ou utiliser un dispositif d’aspiration au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est insuffisante, utiliser un respirateur à adduction
d’air agréé.
D Lire les fiches techniques de santé−sécurité (FTSS) et les instructions du fabricant concernant les métaux, les consommables, les
revêtements, les nettoyants et les dégraisseurs.
D Ne travailler dans un espace clos que s’il est bien ventilé ou porter un
respirateur à adduction d’air. Demander toujours à un surveillant dûment formé de se tenir à proximité. Des fumées et des gaz de soudage
peuvent se substituer à l’air, abaisser la teneur en oxygène et causer
des lésions ou des accidents mortels. S’assurer que l’air est respirable.
D Ne pas souder à proximité d’opérations de dégraissage, de nettoyage
ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir en
présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder de métaux munis d’un revêtement, tels que la tôle
d’acier galvanisée, plombée ou cadmiée, à moins que le revêtement
n’ait été enlevé dans la zone de soudage, que l’endroit soit bien ventilé, et si nécessaire, porter un respirateur à adduction d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques lorsqu’on les soude.

OM-222 Page 5

LES RAYONS DE L’ARC peuvent causer des brûlures oculaires et cutanées.
Le rayonnement de l’arc génère des rayons visibles et
invisibles intenses (ultraviolets et infrarouges) susceptibles de causer des brûlures oculaires et cutanées.
Des étincelles sont projetées pendant le soudage.
D Porter un masque de soudage muni d’un filtre de la nuance adéquate
pour se protéger le visage et les yeux pendant le soudage ou pour regarder (voir les normes de sécurité ANSI Z49.1 et Z87.1).
D Porter des lunettes de sécurité à écrans latéraux sous le masque.
D Utiliser des écrans ou des barrières pour protéger les tiers de l’éclat
éblouissant ou aveuglant de l’arc ; leur demander de ne pas regarder
l’arc.
D Porter des vêtements de protection en matière durable et ignifuge
(cuir ou laine) et des chaussures de sécurité.

LE SOUDAGE peut causer un incendie ou une explosion.
Le soudage effectué sur des récipients fermés tels que
des réservoirs, des fûts ou des conduites peut causer
leur éclatement. Des étincelles peuvent être projetées
de l’arc de soudure. La projection d’étincelles, les
pièces chaudes et les équipements chauds peuvent causer des
incendies et des brûlures. Le contact accidentel de l’électrode avec tout
objet métallique peut causer des étincelles, une explosion, un surchauffement ou un incendie. Avant de commencer le soudage, vérifier et
s’assurer que l’endroit ne présente pas de danger.
D Se protéger et protéger les tiers de la projection d’étincelles et de métal chaud.
D Ne pas souder à un endroit où des étincelles peuvent tomber sur des
substances inflammables.
D Placer toutes les substances inflammables à une distance de 10,7 m
de l’arc de soudage. En cas d’impossibilité, les recouvrir soigneusement avec des protections agréées.
D Des étincelles et des matières en fusion peuvent facilement passer
même par des fissures et des ouvertures de petites dimensions.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à proximité.
D Le soudage effectué sur un plafond, un plancher, une paroi ou une
cloison peut déclencher un incendie de l’autre côté.
D Ne pas souder des récipients fermés tels que des réservoirs, des fûts
ou des conduites, à moins qu’ils n’aient été préparés conformément à
l’AWS F4.1 (voir les normes de sécurité).
D Brancher le câble sur la pièce le plus près possible de la zone de soudage pour éviter que le courant ne circule sur une longue distance, par
des chemins inconnus, et ne cause des risques d’électrocution et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porte−
électrode ou couper le fil au raz du tube−contact.
D Porter des vêtements de protection exempts d’huile tels que des
gants en cuir, une chemise en tissu épais, des pantalons sans revers,
des chaussures montantes et un masque.
D Avant de souder, retirer tout produit combustible de ses poches, tel
qu’un briquet au butane ou des allumettes.

LES PARTICULES PROJETÉES peuvent blesser les yeux.
D Le soudage, le burinage, le passage de la pièce à
la brosse métallique et le meulage provoquent
l’émission d’étincelles et de particules métalliques. Pendant leur refroidissement, les soudures risquent de projeter du
laitier.
D

Porter des lunettes de sécurité à écrans latéraux agréés, même sous le
masque de soudage.

OM-222 Page 6

LES ACCUMULATIONS DE GAZ peuvent causer des blessures ou même
la mort.
Couper l’alimentation en gaz protecteur en cas de
non utilisation.
Veiller toujours à bien ventiler les espaces confinés ou porter un respirateur à adduction d’air agréé.
D

D

LES PIÈCES CHAUDES peuvent causer des brûlures graves.
D Ne pas toucher les pièces chaudes à main nue.
D Prévoir une période de refroidissement avant
d’utiliser le pistolet ou la torche.

LES CHAMPS MAGNÉTIQUES peuvent
perturber le fonctionnement des stimulateurs cardiaques.
D
D

Les personnes qui portent un stimulateur cardiaque
doivent se tenir à distance.
Ils doivent consulter leur médecin avant de s’approcher d’un lieu où on exécute des opérations de soudage à l’arc, de gougeage ou de soudage par points.

LE BRUIT peut affecter l’ouïe.
Le bruit de certains processus et équipements peut
affecter l’ouïe.
D

Porter des protecteurs d’oreille agréés si le niveau
sonore est trop élevé.

Les BOUTEILLES
peuvent exploser.

endommagées

Les bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Toute bouteille endommagée
peut exploser. Comme les bouteilles de gaz font
normalement partie du procédé de soudage, les
manipuler avec précaution.
D Protéger les bouteilles de gaz comprimé de la chaleur excessive, des
chocs mécaniques, du laitier, des flammes nues, des étincelles et des
arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire
ou dans un porte−bouteilles pour les empêcher de tomber ou de se
renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres circuits électriques.
D Ne jamais poser une torche de soudage sur une bouteille de gaz.
D Ne jamais mettre une électrode de soudage en contact avec une bouteille de gaz.
D Ne jamais souder une bouteille contenant du gaz sous pression − elle
risquerait d’exploser.
D N’utiliser que les bouteilles de gaz protecteur, régulateurs, tuyaux et
raccords adéquats pour l’application envisagée ; les maintenir en bon
état, ainsi que les pièces connexes.
D Détourner la tête lorsqu’on ouvre la soupape d’une bouteille.
D Laisser le capuchon protecteur sur la soupape, sauf en cas d’utilisation ou de branchement de la bouteille
D Lire et suivre les instructions concernant les bouteilles de gaz comprimé, les équipements associés et les publications P−1 de la CGA,
mentionnées dans les normes de sécurité.

2-3. Autres symboles relatifs à l’installation, au fonctionnement et à l’entretien de
l’appareil.
Risque D’INCENDIE OU D’EXPLOSION

LES ORGANES MOBILES peuvent
causer des blessures.

D Ne pas placer l’appareil sur une surface inflammable, ni au−dessus ou à proximité d’elle.

D Se tenir à l’écart des organes mobiles comme les
ventilateurs.
D Maintenir fermés et bien fixés les portes,
panneaux, recouvrements et dispositifs de
protection.

D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre
l’appareil en service.

LA CHUTE DE L’APPAREIL peut
blesser.
D N’utiliser que l’anneau de levage pour lever l’appareil. NE PAS utiliser le chariot, les bouteilles de
gaz ou tout autre accessoire.
D Utiliser un engin de capacité adéquate pour lever
l’appareil.
D Si on utilise un chariot élévateur pour déplacer l’unité, s’assurer que
les fourches sont suffisamment longues pour dépasser du côté opposé de l’appareil.

L’EMPLOI EXCESSIF peut FAIRE
SURCHAUFFER L’ÉQUIPEMENT.
D Prévoir une période de refroidissement ; respecter le cycle opératoire nominal.
D Réduire le courant ou le cycle opératoire avant de
reprendre le soudage.
D Ne pas obstruer les orifices ou filtrer l’alimentation en air du poste.

LES CHARGES ÉLECTROSTATIQUES peuvent endommager les circuits imprimés.
D Mettre un bracelet antistatique AVANT de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques
pour stocker, déplacer ou expédier des cartes de
circuits imprimés.

LES PIÈCES MOBILES peuvent causer des blessures.
D Se tenir à l’écart des pièces mobiles.
D Se tenir à l’écart des points de coincement tels
que les dévidoirs.

LES FILS DE SOUDAGE peuvent causer des blessures.
D Ne pas appuyer sur la gâchette avant d’en avoir
reçu l’instruction.
D Ne pas diriger le pistolet vers soi, vers d’autres
personnes ou vers toute pièce mécanique en engageant le fil de soudage.

LE RAYONNEMENT HAUTE FRÉQUENCE (H. F.) risque de causer des
interférences.
D Le rayonnement haute fréquence peut causer
des interférences avec les équipements de radionavigation et de communication, les services de
sécurité et les ordinateurs.
D Ne demander qu’à des personnes qualifiées familiarisées avec les
équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences causées par l’installation.
D Si la Federal Communications Commission signale des interférences, arrêter immédiatement l’appareil.
D Faire régulièrement contrôler et entretenir l’installation.
D Maintenir soigneusement fermés les panneaux et les portes des sources de haute fréquence, maintenir le jeu d’éclatement au réglage
adéquat et utiliser une terre et un blindage pour réduire les interférences éventuelles.

LE SOUDAGE À L’ARC peut causer
des interférences.
D L’énergie électromagnétique peut causer des
interférences avec l’équipement électronique
sensible tel que les ordinateurs et l’équipement
commandé par ordinateur tel que les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit compatible au point de vue électromagnétique.
D Pour réduire la possibilité d’interférence, maintenir les câbles de soudage aussi courts que possible, les grouper, et les poser aussi bas
que possible (par ex. : à terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que le poste de soudage soit posé et mis à la terre conformément au présent manuel.
D En cas d’interférences après exécution des directives précédentes, il
incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de
travail.

LES CHAMPS MAGNÉTIQUES peuvent
affecter les stimulateurs cardiaques.
D Porteurs de stimulateur cardiaque, restez à distance.
D Les porteurs d’un stimulateur cardiaque doivent
d’abord consulter leur médecin avant de s’approcher des opérations de soudage à l’arc, de gougeage ou de soudage par points.

OM-222 Page 7

2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, norme ANSI Z49.1,
de l’American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126
(téléphone : (305) 443−9353, site Web : www.aws.org).

Rexdale, Rexdale (Ontario) Canada M9W 1R3 (téléphone : (800)
463−6727 ou à Toronto : (416) 747−4044, site Web : www.csa−international.org).

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping, norme American Welding Society AWS
F4.1, de l’American Welding Society, 550 N.W. LeJeune Rd, Miami, FL
33126 (téléphone : (305) 443−9353, site Web : www.aws.org).

Practice For Occupational And Educational Eye And Face Protection,
norme ANSI Z87.1, de l’American National Standards Institute, 11 West
42nd Street, New York, NY 10036−8002 (téléphone : (212) 642−4900,
site Web : www.ansi.org).

National Electrical Code, norme NFPA 70, de la National Fire Protection
Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101 (téléphone : (617) 770−3000, sites Web : www.nfpa.org et
www.sparky.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, norme NFPA 51B, de la National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (téléphone : (617) 770−3000, site Web : www.nfpa.org et www.sparky.org).

Safe Handling of Compressed Gases in Cylinders, brochure CGA P−1,
de la Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (téléphone : (703) 412−0900,
site Web : www.cganet.com).
Code for Safety in Welding and Cutting, norme CSA W117.2, de la Canadian Standards Association, Standards Sales, 178 boulevard

OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, de l’U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250 (il y a
10 bureaux régionaux − Téléphone pour la Région 5, Chicago : (312)
353−2220, site Web : www.osha.gov).

2-5. Information sur les champs électromagnétiques
Données sur le soudage électrique et les effets des champs magnétiques basse fréquence sur l’organisme
En parcourant les câbles de soudage, le courant crée des champs électromagnétiques. Les effets potentiels de tels champs restent
préoccupants. Cependant, après avoir examiné plus de 500 études qui
ont été faites pendant une période de recherche de 17 ans, un comité
de spécialistes du National Research Council a conclu : « L’accumulation de preuves n’a pas démontré que l’exposition aux champs
magnétiques et aux champs électriques à haute fréquence constitue un
risque pour la santé humaine ». Toutefois, les études et l’examen des
preuves se poursuivent. En attendant les conclusions finales de la recherche, il serait souhaitable de réduire l’exposition aux champs
électromagnétiques pendant le soudage ou le coupage.

OM-222 Page 8

Afin de réduire les champs électromagnétiques en milieu de travail, respecter les consignes suivantes :
1. Garder les câbles ensemble en les torsadant ou en les fixant avec du
ruban adhésif.
2. Mettre tous les câbles du côté opposé à l’opérateur.
3. Ne pas s’enrouler les câbles autour du corps.
4. Garder le poste de soudage et les câbles le plus loin possible de soi.
5. Placer la pince de masse le plus près possible de la zone de soudage.
Consignes relatives aux stimulateurs cardiaques :
Les personnes qui portent un stimulateur cardiaque doivent avant tout
consulter leur médecin. Si ce dernier les déclare aptes, il leur est recommandé de respecter les consignes ci-dessus.

. A complete Parts List is available at www.MillerWelds.com

SECTION 3 − DEFINITIONS
3-1. General Precautionary Label
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
1
1.1

1.2
1.3
2
2.1
2.2
2.3
3
3.1
3.2

3.3
4
4.1

5
6

Electric shock from welding
electrode or wiring can kill.
Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
Protect yourself from electric
shock by insulating yourself
from work and ground.
Disconnect input plug or
power before working on
machine.
Breathing welding fumes can
be hazardous to your health.
Keep your head out of the
fumes.
Use forced ventilation or local
exhaust to remove the fumes.
Use ventilating fan to remove
fumes.
Welding sparks can cause
explosion or fire.
Keep flammables away from
welding. Do not weld near
flammables.
Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
Do not weld on drums or any
closed containers.
Arc rays can burn eyes and
injure skin.
Wear hat and safety glasses.
Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
protection.
Become trained and read the
instructions before working on
the machine or welding.
Do not remove or paint over
(cover) the label.

OM-222 Page 9

. A complete Parts List is available at www.MillerWelds.com
3-2. Input Connection Label
1

2

3

4

1

Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring can
kill.
Disconnect input plug or
power before working on
machine.
Read the Owner’s Manual
before working on this
machine.
Consult rating label for input
power requirements, and
check power available at the
job site − they must match.
Read Owner’s Manual and
inside labels for connection
points and procedures.
Move jumper links as shown
on inside label to match
voltage at job site.
Having a loop of extra length,
connect grounding conductor
first.
Connect line input conductors
as shown on inside label −
double-check all connections,
jumper link positions, and
input voltage before applying
power.

2
3
4

1

2

?

V

?

A

3

?

5

V

6

ÍÍÍ
ÍÍÍ
ÍÍÍ

ÍÍÍ
ÍÍÍ
5

6

7

5
3

8

4

S-179 290

7

8

9

9

1/96

3-3. Electric Shock And Airflow Label
1

2

1

3

2
3

S-179 563

Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from wiring and
exposed weld terminals can
kill.
Close door before turning on
unit.
1/96

3-4. Nameplate Safety Symbols
1
1

1

2
3

4
5

2

3

4

5

6

6

Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Electric shock from welding
electrode or wiring can kill.
Sparks from arcing electrode
can cause explosion or fire −
disconnect cable for process
not in use.
Read Owner’s Manual for
connection procedures.
Electric shock from wiring can
kill.
Disconnect input power
before working on unit or
making terminal strip
connections.
Nameplate D-179 389

OM-222 Page 10

. A complete Parts List is available at www.MillerWelds.com
3-5. Manufacturer’s Rating Labels For CE Products

. Match label to one on

unit. See Section 4-4.

OM-222 Page 11

. A complete Parts List is available at www.MillerWelds.com
3-6. Symbols And Definitions

Note

Some symbols are found only on CE products.

A

U0
I1

Amperes

Amperage Control/
Panel

Gas Tungsten Arc
Welding (GTAW)

Shielded Metal Arc
Welding (SMAW)

Temperature

Do Not Switch
While Welding

Arc Force (DIG)

Percent

Output

Circuit Breaker

Remote

Protective Earth
(Ground)

Positive

Negative

Input

On

Off

Hertz

Direct Current

Conventional Load
Voltage

Line Connection

Duty Cycle

Three-Phase
Transformer
Rectifier

KVA

Work Connection

Rated No Load
Voltage (Average)

U1

Primary Voltage

Primary Current

I2

Rated Welding
Current

IP

Degree Of
Protection

Three-Phase

Wire Feeder

Electrode
Connection

Hz
U2
X
S1

V

Volts

3-7. WEEE Label (For Products Sold Within The EU)
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.

OM-222 Page 12

. A complete Parts List is available at www.MillerWelds.com

SECTION 4 − INSTALLATION
4-1. Specifications

Rated
Welding
Output

Amp
Range DC

Maximum
OpenCircuit
Voltage DC

IP
Rating

300
Amp

300 A @
32 Volts
DC, 60%
Duty Cycle

15 − 395

68
(70)

450
Amp

450 A @
38 Volts
DC, 60%
Duty Cycle

20 − 590

650
Amp

650 A @
44 Volts
DC, 60%
Duty Cycle

50 − 850

Model

Amperes Input at Rated Load Output, 50 or 60 Hz,
Three-Phase
200 V

230 V

380 V

400 V

440 V

460 V

575 V

KVA

KW

21M

70
4.0*

61
3.6*

35
1.1*

33
1.1*

31
1.0*

31
3.1*

25
1.5*

24.5
1.3*

13.8
0.67*

71
(70)

21M

102
3.5*

89
3.1*

54
1.5*

51
1.4*

47
1.2*

45
1.5*

36
1.2*

35.5
1.2*

23.3
0.51*

71
(70)

21M

−−

124
5.2*

75
1.7*

71
1.6*

65
1.5*

62
2.6*

50
2.1*

49.4
2.1*

36
0.58*

*While idling
( ) Indicates specification differences for CE models

4-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
Y Exceeding duty cycle can
damage unit and void
warranty.

Example: 60% Duty Cycle =

6 Minutes Welding

Overheating

4 Minutes Resting

A

0
15
Minutes

OR
Reduce Duty Cycle

duty1 4/95 / Ref. SA-168 919

OM-222 Page 13

. A complete Parts List is available at www.MillerWelds.com
4-3. Volt-Ampere Curves

A. 300 Amp Model

Volt-ampere curves show minimum and maximum voltage and
amperage output capabilities of
unit. Curves of other settings fall between curves shown.

B. 450 Amp Model

C. 650 Amp Model

va_curve1 − 4/95 − SA-171 221 / SA-171 222 / SA-171 223

OM-222 Page 14

. A complete Parts List is available at www.MillerWelds.com
4-4. Selecting A Location
1
2

Lifting Eye
Lifting Forks

Use lifting eye or lifting forks to
move unit.
If using lifting forks, extend forks
beyond opposite side of unit.

Movement

3

1

Rating Label (Non CE Models
Only)

Use rating label to determine input
power needs. Label located under
front access door.
4

OR
2

5
Location And Airflow

Plate Label (CE Models Only)

Label located under front access
door.
Rating Label (CE Models
Only)

Use rating label to determine input
power needs. Label located on rear
access door (see Section 3-5).

6

3

6

Line Disconnect Device

Locate unit near correct input power supply.
18 in
(460 mm)

4

Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.

5

18 in
(460 mm)

OM-222 Page 15

. A complete Parts List is available at www.MillerWelds.com
4-5. Dimensions And Weights
Dimensions
300 Amp Models

450 Amp Models

650 Amp Models

A

30 in (762 mm) including lift eye

30 in (762 mm) including lift eye

30 in (762 mm) including lift eye

B

23 in (585 mm)

23 in (585 mm)

23 in (585 mm)

C

30-1/2 in (775 mm) including strain relief

38 in (966 mm) including strain relief

38 in (966 mm) including strain relief

D

27-1/2 in (699 mm)

35 in (889 mm)

35 in (889 mm)

E

3/4 in (19 mm)

1-1/4 in (32 mm)

1-1/4 in (32 mm)

F

21-1/8 in (537 mm)

21-1/8 in (537 mm)

21-1/8 in (537 mm)

G

1-1/8 in (29 mm)

1-1/8 in (29 mm)

1-1/8 in (29 mm)

H

7/16 in (11 mm) Dia

7/16 in (11 mm) Dia

7/16 in (11 mm) Dia

352 lb (160 kg)

404 lb (183 kg)

Weight
505 lb (229 kg)

F
G

H
4 Holes

A

D

B

C

E

Front

800 453-A / 801 530

OM-222 Page 16

. A complete Parts List is available at www.MillerWelds.com
4-6. Tipping
Y Be careful when placing or
moving unit over uneven
surfaces.

4-7. 115 VAC Receptacle And Supplementary Protectors
Y Turn Off power before
connecting to receptacle.
1

3
2

115 V 15 A AC Receptacle
RC9

Power is shared between RC9 and
Remote 14 receptacle RC8 (see
Section 4-11).
2
3

Supplementary Protector CB1
Supplementary Protector CB2

CB1 protects the 115 volts ac portion of RC8 and RC9 from overload.
CB2 protects the 24 volts ac portion
of RC8.

1

Press button to reset protector.

Ref. ST-800 101-D

OM-222 Page 17

. A complete Parts List is available at www.MillerWelds.com
4-8. Weld Output Terminals And Selecting Cable Sizes

Total Cable (Copper) Length In Weld Circuit Not Exceeding
100 ft (30 m) Or Less
YTurn Off power before
connecting to weld output
terminals

Electrode

Work

150 ft
(45 m)

200 ft
(60 m)

250 ft
(70 m)

300 ft
(90 m)

350 ft
(105 m)

400 ft
(120 m)

Welding
Amperes

10 − 60%
Duty
Cycle

60 − 100%
Duty Cycle

100

4

4

4

3

2

1

1/0

1/0

150

3

3

2

1

1/0

2/0

3/0

3/0

200

3

2

1

1/0

2/0

3/0

4/0

4/0

250

2

1

1/0

2/0

3/0

4/0

2-2/0

2-2/0

300

1

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

350

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-3/0

2-4/0

400

1/0

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

2-4/0

500

2/0

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-3/0

600

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-4/0

3-4/0

700

4/0

2-2/0

2-3/0

2-4/0

3-3/0

3-4/0

3-4/0

4-4/0

800

4/0

2-2/0

2-3/0

2-4/0

3-4/0

3-4/0

4-4/0

4-4/0

10 − 100% Duty Cycle

Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.

S-0007-D

4-9. Connecting Weld Output Cables

1

4

Do not place
anything between
weld cable terminal
and copper bar.

2

Tools Needed:

3

3/4 in (19 mm)
803 778-B

Correct Installation
Y Turn off power before connecting to
weld output terminals.

1

Weld Output Terminal

2

Supplied Weld Output Terminal Nut

Y Failure to properly connect weld
cables may cause excessive heat
and start a fire, or damage your machine.

3

Weld Cable Terminal

4

Copper Bar

OM-222 Page 18

Remove supplied nut from weld output ter-

Incorrect Installation
minal. Slide weld cable terminal onto weld
output terminal and secure with nut so that
weld cable terminal is tight against copper
bar. Do not place anything between weld
cable terminal and copper bar. Make
sure that the surfaces of the weld cable
terminal and copper bar are clean.

. A complete Parts List is available at www.MillerWelds.com
4-10. Remote 14 Receptacle Information
Socket

24 VOLTS AC

REMOTE OUTPUT CONTROL

115 VOLTS AC
GND

A

24 volts ac. Protected by supplementary protector CB2.

B

Contact closure to A completes 24 volts ac contactor control circuit.

C

Command reference; 0 to +10 volts dc.

D

Remote control circuit common.

E

0 to +10 volts dc input command signal from remote control.

F

Current feedback; 1 volt per 100 amperes.

H

Voltage feedback; 1 volt per 10 arc volts.

I

115 volts, 15 amperes, 60 Hz ac. Protected by supplementary protector CB1.

J

Contact closure to I completes 115 volts ac contactor control circuit.

K

Chassis common.

G

Circuit common for 24 and 115 volts ac circuits.

*

REMOTE POWER ON/OFF

To remote On/Off switch.
switch

*

REMOTE VOLTAGE SENSING

Information

*

Voltage sensing signal from Negative (-) weld output terminal.

*

Voltage sensing signal from Positive (+) weld output terminal.

* Not Used

4-11. Connecting Remote Control
1

Remote 14 Receptacle RC8

Connect remote control to RC8.

1
A
B

K

J

I

H
C L N
D M
G
E F

OR

OR
Ref. ST-800 101-D / ST-141 127-D

OM-222 Page 19

. A complete Parts List is available at www.MillerWelds.com
4-12. Electrical Service Guide
60 Hertz Models

300 Amp Model

450 Amp Model

650 Amp Model

Input Voltage

200

230

460

575

200

230

460

575

230

460

575

Input Amperes At Rated Output

70

61

31

25

102

89

45

36

124

62

50

Time-Delay 2

80

70

35

30

125

110

50

45

150

70

60

Normal Operating 3

110

90

45

35

150

125

70

50

175

90

70

6

8

10

12

4

4

8

10

3

8

8

149
(45)

131
(40)

356
(108)

342
(104)

136
(41)

180
(55)

319
(97)

335
(102)

144
(44)

210
(64)

328
(100)

6

8

10

12

6

6

8

10

6

8

8

Max Recommended Standard Fuse
Rating In Amperes 1

Min Input Conductor Size In AWG 4
Max Recommended Input Conductor
Length In Feet (Meters)
Min Grounding Conductor Size In
AWG 4

Reference: 2005 National Electrical Code (NEC)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

300 Amp Model

50 Hertz Models

450 Amp Model

650 Amp Model

Input Voltage

380

400

440

380

400

440

380

400

440

Input Amperes At Rated Output

35

33

31

54

51

47

75

71

65

Time-Delay 2

40

40

35

60

60

50

90

80

80

Normal Operating 3

60

50

50

80

80

70

125

110

100

10

10

10

8

8

8

6

6

6

243
(74)

269
(82)

326
(99)

218
(66)

241
(73)

292
(89)

219
(67)

242
(74)

293
(89)

10

10

10

8

8

8

6

6

8

Max Recommended Standard Fuse Rating In
Amperes 1

Min Input Conductor Size In AWG 4
Max Recommended Input Conductor Length
In Feet (Meters)
Min Grounding Conductor Size In AWG 4

Reference: 2005 National Electrical Code (NEC)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” .
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amp), and UL class “H” ( 65 amp and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

OM-222 Page 20

. A complete Parts List is available at www.MillerWelds.com
4-13. Placing Jumper Links
Y Disconnect and lockout/tagout input power before
installing or moving jumper
links.
Check input voltage available at
site.
1

Jumper Link Label

Check label − only one is on unit.
2

Jumper Links

Move jumper links to match input
voltage.
Close and secure access door, or
go on to Section 4-14.

200 VOLTS

230 VOLTS

460 VOLTS

Ref. S-174 976-B

230 VOLTS

460 VOLTS

575 VOLTS

Ref. S-174 973-B

1

220 VOLTS

380 VOLTS

400 VOLTS

440 VOLTS

(FACTORY OPTION)

Ref. S-174 975-B

2

Tools Needed:
3/8 in
3/8 in

Do not overtighten
jumper link nuts.
Ref. ST-800 103-A

OM-222 Page 21

. A complete Parts List is available at www.MillerWelds.com
4-14. Connecting Input Power
Y Installation must meet all National
and Local Codes − have only qualified persons make this installation.

3

Y Disconnect and lockout/tagout input power before connecting input
conductors from unit.

9

= GND/PE Earth Ground

Y Make input power connections to
the welding power source first.

8

Y Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
See rating label on unit and check input
voltage available at site.

11

1

10

Input Power Conductors (Customer
Supplied Cord)

Select size and length of conductors using
Section 4-12. Conductors must comply
with national, state, and local electrical
codes. If applicable, use lugs of proper
amperage capacity and correct hole size.

2
4
7

Welding Power Source Input Power
Connections
2

3
4

IMPORTANT
6

3
Input Contactor

L1 (U)

7 L2 (V)
L3 (W)

4

5

7
4

3
= GND/ PE Earth Ground

Machine Grounding Terminal
Green Or Green/Yellow Grounding
Conductor
Reed Switch (Ground Current
Sensor) (Optional)

Connect green or green/yellow grounding
conductor to welding power source
grounding terminal first. If unit is equipped
with optional ground current sensor, route
grounding conductor through reed switch
two times and connect to grounding terminal.
6

5

Strain Relief

Route conductors (cord) through strain relief and tighten screws.

1

Welding Power Source Line
Terminals
Input Conductors L1 (U), L2 (V) And
L3 (W)

Connect input conductors L1 (U), L2 (V)
and L3 (W) to welding power source line
terminals.
Close and secure access door on welding
power source.
Disconnect Device Input Power Connections
8
9

Disconnect Device (switch shown in
OFF position)
Disconnect Device (Supply)
Grounding Terminal

Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.

Tools Needed:
3/8 in
3/8 in

10 Disconnect Device Line Terminals
Connect input conductors L1 (U), L2 (V)
And L3 (W) to disconnect device line
terminals.
11 Over-Current Protection
Select type and size of over-current
protection using Section 4-12 (fused disconnect switch shown).
Close and secure door on line disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
800 103-C / Ref. 801 116-A

OM-222 Page 22

. A complete Parts List is available at www.MillerWelds.com

SECTION 5 − OPERATION
5-1. Controls (Non CE Models)
300 Amp Model Shown
1

2

9

3

8

5

4

7

6

Ref. ST-165 596-D

short arc length without sticking the electrode.
1

Polarity Selector Switch (Optional On 50
Hz Models)
To change polarity on models not equipped
with a Polarity Selector switch, reverse work
and electrode cables at the weld output terminals (see Section 4-8).
Y Turn Off Power before reversing
cables.
2 Arc Force (Dig) Control
Control increases SMAW short-circuit amperage which allows the operator to use a very

Set control at 0 for normal welding amperage.
Turn clockwise to increase short-circuit
amperage.
3 Hot Start Switch
Turn switch On for SMAW and Off for GTAW
welding.
4 Amperage Adjustment Control
5 Digital Meters (Optional)
6 Power Switch With Indicator Light
7 High Temperature Shutdown Light

8 Remote Amperage Control Switch
For front panel control, place switch in Panel
position. For remote control, place switch in
Remote position, and connect remote device
(see Section 4-11).
9 Output Switch (Contactor)
For front panel control of output, place switch
in Panel position. For remote control of output,
place switch in Remote position, and connect
remote device (see Section 4-11).
Y Turn Off power before connecting remote device.

OM-222 Page 23

. A complete Parts List is available at www.MillerWelds.com
5-2. Controls (CE Models)
300 Amp Model Shown

2

1

9

3

4

5

8

7

6
Ref. ST-173 450-B

short arc length without sticking the electrode.
1

Polarity Selector Switch (Optional On 50
Hz Models)
To change polarity on models not equipped
with a Polarity Selector switch, reverse work
and electrode cables at the weld output terminals (see Section 4-8).
Y Turn Off Power before reversing
cables.
2 Arc Force (Dig) Control
Control increases SMAW short-circuit amperage which allows the operator to use a very

Set control at 0 for normal welding amperage.
Turn clockwise to increase short-circuit
amperage.
3 Hot Start Switch
Turn switch On for SMAW and Off for GTAW
welding.
4 Amperage Adjustment Control
5 Digital Meters (Optional)
6 Power Switch With Indicator Light
7 High Temperature Shutdown Light

8 Remote Amperage Control Switch
For front panel control, place switch in Panel
position. For remote control, place switch in
Remote position, and connect remote device
(see Section 4-11).
9 Output Switch (Contactor)
For front panel control of output, place switch
in Panel position. For remote control of output,
place switch in Remote position, and connect
remote device (see Section 4-11).
Y Turn Off power before connecting remote device.

SECTION 6 − MAINTENANCE AND TROUBLESHOOTING
6-1. Routine Maintenance
Y Disconnect power before maintaining.

3 Months

Replace
unreadable
labels.

Repair or
replace
cracked
weld cable.

6 Months

Blow out or
vacuum inside.
During heavy
service, clean monthly.
OM-222 Page 24

OR

Clean and
tighten weld
terminals.

. A complete Parts List is available at www.MillerWelds.com
6-2. Fuse F1
Y Turn Off power before opening rear access door.
1
1

Fuse F1 (See Parts List For
Rating)

Fuse F1 protects control transformer from overload. If F1 opens, weld
output and fan motor stops. Replace F1.
Close and secure access door.

Tools Needed:
3/8 in

Ref. ST-800 101-C

6-3. Troubleshooting

Trouble
No weld output; unit completely inoperative.

Remedy
Place line disconnect switch in On position (see Section 4-14).
Check fuse F1, and replace if necessary (see Section 6-2).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-14).
Check for proper input power connections (see Section 4-14).
Check for proper jumper link position (see Section 4-13).

No weld output; Power switch pilot light
on; fan on.

If using remote control, place Output (Contactor) switch in Remote 14 position, and connect remote
control (see Section 4-11). If remote is not being used, place switch in On position.
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 4-2).
Have Factory Authorized Service Agent check control board PC1.

No weld output; Power switch pilot light Check for proper input power connections (see Section 4-14).
on; fan off.
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-14).
Have Factory Authorized Service Agent check SCR’s.
Unit provides only maximum or minimum weld output.

Have Factory Authorized Service Agent check control board PC1 and hall device HD1.

Erratic or improper weld output.

Use proper size and type of weld cable (see Section 4-8).
Clean and tighten all weld connections.
Check position of Polarity selector switch (see Section 5-1).
Have Factory Authorized Service Agent check control board PC1 and hall device HD1.

No 115 volts ac output at duplex receptacle, Remote 14 receptacle.

Reset supplementary protector CB1 (see Section 4-7).

No 24 volts ac output at Remote 14 receptacle.

Reset supplementary protector CB2 (see Section 4-7).

Fan not operating. NOTE: fan only
runs when cooling is necessary.

Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor.
OM-222 Page 25

SECTION 7 − ELECTRICAL DIAGRAM

Figure 7-1. Circuit Diagram
OM-222 Page 26

218 518-A

OM-222 Page 27

SECTION 8 − PARTS LIST
NOTE

A complete Parts List is available on-line at www.MillerWelds.com.

http://www.millerwelds.com/service/replacementparts.html
Choose Genuine Select to review spare parts requirements such
as filters, spark plugs, and fuses.
Choose Service Parts to download complete parts listing.

Notes

OM-222 Page 28

Notes

Notes

Effective January 1, 2007
(Equipment with a serial number preface of “LH” or newer)
Warranty Questions?

Call
1-800-4-A-MILLER
for your local
Miller distributor.
Your distributor also gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.

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
* Induction Heating Coils and Blankets, Cables, and
below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to
Non-Electronic Controls
its original retail purchaser that new Miller equipment sold after
* APT & SAF Model Plasma Cutting Torches
the effective date of this limited warranty is free of defects in
* Remote Controls
material and workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
* Accessory (Kits)
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
* Replacement Parts (No labor)
WARRANTIES OF MERCHANTABILITY AND FITNESS.
* Spoolmate Spoolguns
Within the warranty periods listed below, Miller will repair or
* Canvas Covers
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.

Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the delivery date of the
equipment to the original end-user purchaser, and not to exceed
one year after the equipment is shipped to a North American
distributor or eighteen months after the equipment is shipped to
an International distributor.
1.

5 Years Parts — 3 Years Labor

2.

3 Years — Parts and Labor

*
*
*
*
*
*
*
*
*

3.

Original main power rectifiers
Transformer/Rectifier Power Sources
Plasma Arc Cutting Power Sources
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Inverter Power Sources (Unless Otherwise Stated)
Water Coolant Systems (Integrated)
Intellitig
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)

1 Year — Parts and Labor Unless Specified

*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*

*
*
*

Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Automatic Motion Devices
RFCS Foot Controls
Induction Heating Power Sources, Coolers, and
Electronic
Controls/Recorders
Water Coolant Systems (Non-Integrated)
Flowgauge and Flowmeter Regulators (No Labor)
HF Units
Grids
Spot Welders
Load Banks
Arc Stud Power Sources & Arc Stud Guns
Racks
Running Gear/Trailers
Plasma Cutting Torches (except APT & SAF
Models)
Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Bernard-Branded Mig Guns (No Labor)
Weldcraft-Branded TIG Torches (No Labor)
Subarc Wire Drive Assemblies

4.

6 Months — Batteries

5.

90 Days — Parts

*

MIG Guns/TIG Torches and Subarc (SAW) Guns

Miller’s True Blue® Limited Warranty shall not apply to:
1.

Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings, relays
or parts that fail due to normal wear. (Exception:
brushes, slip rings, and relays are covered on Bobcat,
Trailblazer, and Legend models.)

2.

Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.

3.

Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.

MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
Some states in the U.S.A. do not allow limitations of how long an
implied warranty lasts, or the exclusion of incidental, indirect,
special or consequential damages, so the above limitation or
exclusion may not apply to you. This warranty provides specific
legal rights, and other rights may be available, but may vary from
state to state.
In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations and
exclusions set out above may not apply. This Limited Warranty
provides specific legal rights, and other rights may be available,
but may vary from province to province.

miller_warr 2007−01

Owner’s Record
Please complete and retain with your personal records.
Model Name

Serial/Style Number

Purchase Date

(Date which equipment was delivered to original customer.)

Distributor
Address
City
State

Zip

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.
Contact your Distributor for:

Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair

Miller Electric Mfg. Co.

Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
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.

PRINTED IN USA

© 2007 Miller Electric Mfg. Co. 2007−01

An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA

International Headquarters−USA
USA Phone: 920-735-4505 Auto-Attended
USA & Canada FAX: 920-735-4134
International FAX: 920-735-4125
European Headquarters −
United Kingdom
Phone: 44 (0) 1204-593493
FAX: 44 (0) 1204-598066
www.MillerWelds.com



---

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