OM-279248C 2020−05

Processes
MIG (GMAW) Welding
Pulsed MIG (GMAW-P)
Flux Cored (FCAW) Welding

Description

Wire Feeder

Intellx Pro
™

Wire Feeder

For product information, File: MIG (GMAW)

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

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_Thank1 2020−01
 TABLE OF CONTENTS

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

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Hazards For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Symboles utilisés . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . . 7
2-4. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-5. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-6. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-2. Software Licensing Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-3. Information About Default Weld Parameters And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-4. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-5. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-6. Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-1. Power Source And Wire Feeder Site Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-2. Connecting Weld Output Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5-3. Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5-4. Arranging Welding Cables To Reduce Welding Circuit Inductance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5-5. Control Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-6. Wire Feeder Lower Front Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-7. Weld Voltage Sense Connection (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-8. Connecting Shielding Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-9. Rotating Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-10. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5-11. Installing Wire Guides And Drive Rolls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5-12. Installing And Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-1. Wire Feeder User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6-2. Description Of Front Panel Controls (See Section 6-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6-3. Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-4. Jog/Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6-5. Arc Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-6. Memory 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-7. Trigger Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6-8. Trigger Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-9. Preflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-10. Postflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6-11. Operational Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
 TABLE OF CONTENTS

SECTION 6 − OPERATION (Continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6-12. Selecting Welding Arc, Wire Type, Size And Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6-13. MIG - Wire and Gas Selection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-14. Accu-Pulse - Wire and Gas Selection Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6-15. Accu-Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SECTION 7 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7-2. Cleaning Debris From Shielding Gas Filter Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7-3. Diagnostics Table For Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SECTION 8 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
WARRANTY
 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2020−02
7

Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.

1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if . Indicates special instructions.
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid
NOTICE − Indicates statements not related to personal injury. these hazards.

1-2. Arc Welding Hazards

D Properly install, ground, and operate this equipment according to
The symbols shown below are used throughout this manual its Owner’s Manual and national, state, and local codes.
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions D Always verify the supply ground − check and be sure that input
to avoid the hazard. The safety information given below is power cord ground wire is properly connected to ground terminal in
only a summary of the more complete safety information disconnect box or that cord plug is connected to a properly
found in the Principal Safety Standards listed in Section 1-5. grounded receptacle outlet.
Read and follow all Safety Standards. D When making input connections, attach proper grounding conduc-
tor first − double-check connections.
Only qualified persons should install, operate, maintain, and D Keep cords dry, free of oil and grease, and protected from hot metal
repair this equipment. A qualified person is defined as one and sparks.
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, train- D Frequently inspect input power cord and ground conductor for
ing and experience, has successfully demonstrated the damage or bare wiring – replace immediately if damaged – bare
ability to solve or resolve problems relating to the subject wiring can kill.
matter, the work, or the project and has received safety train- D Turn off all equipment when not in use.
ing to recognize and avoid the hazards involved.
D Do not use worn, damaged, undersized, or repaired cables.
During operation, keep everybody, especially children, away. D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
ELECTRIC SHOCK can kill.
D Do not touch electrode if you are in contact with the work, ground,
Touching live electrical parts can cause fatal shocks or another electrode from a different machine.
or severe burns. The electrode and work circuit is D Do not touch electrode holders connected to two welding ma-
electrically live whenever the output is on. The input chines at the same time since double open-circuit voltage will be
power circuit and machine internal circuits are also present.
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing, D Use only well-maintained equipment. Repair or replace damaged
and all metal parts touching the welding wire are parts at once. Maintain unit according to manual.
electrically live. Incorrectly installed or improperly D Wear a safety harness if working above floor level.
grounded equipment is a hazard.
D Keep all panels and covers securely in place.
D Do not touch live electrical parts. D Clamp work cable with good metal-to-metal contact to workpiece
D Wear dry, hole-free insulating gloves and body protection. or worktable as near the weld as practical.
D Insulate yourself from work and ground using dry insulating mats D Insulate work clamp when not connected to workpiece to prevent
or covers big enough to prevent any physical contact with the work contact with any metal object.
or ground. D Do not connect more than one electrode or work cable to any
D Do not use AC weld output in damp, wet, or confined spaces, or if single weld output terminal. Disconnect cable for process not in
there is a danger of falling. use.
D Use AC output ONLY if required for the welding process. D Use GFCI protection when operating auxiliary equipment in damp
D If AC output is required, use remote output control if present on or wet locations.
unit.
D Additional safety precautions are required when any of the follow- SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing electrically hazardous conditions are present: in damp ing power sources AFTER removal of input power.
locations or while wearing wet clothing; on metal structures such
D Turn off unit, disconnect input power, and discharge input capaci-
as floors, gratings, or scaffolds; when in cramped positions such
tors according to instructions in Manual before touching any parts.
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a HOT PARTS can burn.
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt- D Do not touch hot parts bare handed.
age. In most situations, use of a DC, constant voltage wire welder
D Allow cooling period before working on
is recommended. And, do not work alone!
equipment.
D Disconnect input power or stop engine before installing or
D To handle hot parts, use proper tools and/or wear heavy, insu-
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards). lated welding gloves and clothing to prevent burns.

OM-279248 Page 1
 D Do not cut or weld on tire rims or wheels. Tires can explode if heat-
FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR
1910.177 listed in Safety Standards.
Welding produces fumes and gases. Breathing D Do not weld on containers that have held combustibles, or on
these fumes and gases can be hazardous to your closed containers such as tanks, drums, or pipes unless they are
health. properly prepared according to AWS F4.1 and AWS A6.0 (see
D Keep your head out of the fumes. Do not breathe the fumes. Safety Standards).
D Ventilate the work area and/or use local forced ventilation at the arc D Do not weld where the atmosphere can contain flammable dust,
to remove welding fumes and gases. The recommended way to gas, or liquid vapors (such as gasoline).
determine adequate ventilation is to sample for the composition D Connect work cable to the work as close to the welding area as
and quantity of fumes and gases to which personnel are exposed. practical to prevent welding current from traveling long, possibly
D If ventilation is poor, wear an approved air-supplied respirator. unknown paths and causing electric shock, sparks, and fire
D Read and understand the Safety Data Sheets (SDSs) and the hazards.
manufacturer’s instructions for adhesives, coatings, cleaners, D Do not use welder to thaw frozen pipes.
consumables, coolants, degreasers, fluxes, and metals. D Remove stick electrode from holder or cut off welding wire at
D Work in a confined space only if it is well ventilated, or while contact tip when not in use.
wearing an air-supplied respirator. Always have a trained watch- D Wear body protection made from durable, flame−resistant material
person nearby. Welding fumes and gases can displace air and (leather, heavy cotton, wool). Body protection includes oil-free
lower the oxygen level causing injury or death. Be sure the breath- clothing such as leather gloves, heavy shirt, cuffless trousers, high
ing air is safe. shoes, and a cap.
D Do not weld in locations near degreasing, cleaning, or spraying op-
D Remove any combustibles, such as a butane lighter or matches,
erations. The heat and rays of the arc can react with vapors to form
from your person before doing any welding.
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or D After completion of work, inspect area to ensure it is free of sparks,
cadmium plated steel, unless the coating is removed from the weld glowing embers, and flames.
area, the area is well ventilated, and while wearing an air-supplied D Use only correct fuses or circuit breakers. Do not oversize or by-
respirator. The coatings and any metals containing these elements pass them.
can give off toxic fumes if welded. D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
ARC RAYS can burn eyes and skin. D Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners,
Arc rays from the welding process produce intense consumables, coolants, degreasers, fluxes, and metals.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the FLYING METAL or DIRT can injure eyes.
weld.
D Wear an approved welding helmet fitted with a proper shade of D Welding, chipping, wire brushing, and grinding
filter lenses to protect your face and eyes from arc rays and cause sparks and flying metal. As welds cool,
sparks when welding or watching (see ANSI Z49.1 and Z87.1 they can throw off slag.
listed in Safety Standards). D Wear approved safety glasses with side
D Wear approved safety glasses with side shields under your shields even under your welding helmet.
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc. BUILDUP OF GAS can injure or kill.
D Wear body protection made from durable, flame−resistant mate-
rial (leather, heavy cotton, wool). Body protection includes D Shut off compressed gas supply when not in use.
oil-free clothing such as leather gloves, heavy shirt, cuffless D Always ventilate confined spaces or use
trousers, high shoes, and a cap. approved air-supplied respirator.

WELDING can cause fire or explosion. ELECTRIC AND MAGNETIC FIELDS (EMF)
Welding on closed containers, such as tanks,
can affect Implanted Medical Devices.
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot D Wearers of Pacemakers and other Implanted
workpiece, and hot equipment can cause fires and Medical Devices should keep away.
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is D Implanted Medical Device wearers should consult their doctor
safe before doing any welding. and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
operations.
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.
NOISE can damage hearing.
D Be alert that welding sparks and hot materials from welding can Noise from some processes or equipment can
easily go through small cracks and openings to adjacent areas. damage hearing.
D Watch for fire, and keep a fire extinguisher nearby.
D Wear approved ear protection if noise lev-
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
el is high.
cause fire on the hidden side.

OM−279248 Page 2
 D Never weld on a pressurized cylinder − explosion will result.
CYLINDERS can explode if damaged.
D Use only correct compressed gas cylinders, regulators, hoses,
Compressed gas cylinders contain gas under high and fittings designed for the specific application; maintain them
pressure. If damaged, a cylinder can explode. Since and associated parts in good condition.
gas cylinders are normally part of the welding D Turn face away from valve outlet when opening cylinder valve. Do
process, be sure to treat them carefully. not stand in front of or behind the regulator when opening the valve.
D Protect compressed gas cylinders from excessive heat, mechani- D Keep protective cap in place over valve except when cylinder is in
cal shocks, physical damage, slag, open flames, sparks, and arcs. use or connected for use.
D Install cylinders in an upright position by securing to a stationary D Use the proper equipment, correct procedures, and sufficient
support or cylinder rack to prevent falling or tipping. number of persons to lift, move, and transport cylinders.
D Keep cylinders away from any welding or other electrical circuits. D Read and follow instructions on compressed gas cylinders,
D Never drape a welding torch over a gas cylinder. associated equipment, and Compressed Gas Association (CGA)
D Never allow a welding electrode to touch any cylinder. publication P-1 listed in Safety Standards.

1-3. Additional Hazards For Installation, Operation, And Maintenance

FIRE OR EXPLOSION hazard. MOVING PARTS can injure.

D Do not install or place unit on, over, or near D Keep away from moving parts.
combustible surfaces. D Keep away from pinch points such as drive
D Do not install unit near flammables. rolls.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
WELDING WIRE can injure.
FALLING EQUIPMENT can injure.
D Do not press gun trigger until instructed to do
so.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories. D Do not point gun toward any part of the body,
other people, or any metal when threading
D Use correct procedures and equipment of ade-
welding wire.
quate 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. BATTERY EXPLOSION can injure.
D Keep equipment (cables and cords) away from moving vehicles D Do not use welder to charge batteries or jump
when working from an aerial location. start vehicles unless it has a battery charging
D Follow the guidelines in the Applications Manual for the Revised feature designed for this purpose.
NIOSH Lifting Equation (Publication No. 94−110) when manu-
ally lifting heavy parts or equipment.
MOVING PARTS can injure.
OVERUSE can cause OVERHEATING
D Keep away from moving parts such as fans.
D Allow cooling period; follow rated duty cycle. D Keep all doors, panels, covers, and guards
D Reduce current or reduce duty cycle before closed and securely in place.
starting to weld again.
D Have only qualified persons remove doors, panels, covers, or
D Do not block or filter airflow to unit. guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
FLYING SPARKS can injure. finished and before reconnecting input power.

D Wear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with READ INSTRUCTIONS.
proper guards in a safe location wearing proper
face, hand, and body protection.
D Read and follow all labels and the Owner’s
D Sparks can cause fires — keep flammables away. Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
STATIC (ESD) can damage PC boards. section.
D Put on grounded wrist strap BEFORE handling D Use only genuine replacement parts from the manufacturer.
boards or parts. D Perform installation, maintenance, and service according to the
D Use proper static-proof bags and boxes to Owner’s Manuals, industry standards, and national, state, and
store, move, or ship PC boards. local codes.

OM-279248 Page 3
 H.F. RADIATION can cause interference. ARC WELDING can cause interference.
D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with
navigation, safety services, computers, and sensitive electronic equipment such as
communications equipment. computers and computer-driven equipment
such as robots.
D Have only qualified persons familiar with electronic equipment
D Be sure all equipment in the welding area is electromagnetically
perform this installation.
compatible.
D The user is responsible for having a qualified electrician prompt-
D To reduce possible interference, keep weld cables as short as
ly correct any interference problem resulting from the installa-
possible, close together, and down low, such as on the floor.
tion.
D Locate welding operation 100 meters from any sensitive elec-
D If notified by the FCC about interference, stop using the
tronic equipment.
equipment at once.
D Be sure this welding machine is installed and grounded
D Have the installation regularly checked and maintained.
according to this manual.
D Keep high-frequency source doors and panels tightly shut, keep
D If interference still occurs, the user must take extra measures
spark gaps at correct setting, and use grounding and shielding to
such as moving the welding machine, using shielded cables,
minimize the possibility of interference.
using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings

WARNING: This product can expose you to chemicals in-

cluding lead, which are known to the state of California to
cause cancer and birth defects or other reproductive
harm.
For more information, go to www.P65Warnings.ca.gov.

1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, American Welding Safety in Welding, Cutting, and Allied Processes, CSA Standard
Society standard ANSI Standard Z49.1. Website: www.aws.org. W117.2 from Canadian Standards Association.
Safe Practice For Occupational And Educational Eye And Face Protec- Website: www.csagroup.org.
tion, ANSI Standard Z87.1 from American National Standards Institute. Standard for Fire Prevention During Welding, Cutting, and Other Hot
Website: www.ansi.org. Work, NFPA Standard 51B from National Fire Protection Association.
Safe Practices for the Preparation of Containers and Piping for Welding Website: www.nfpa.org.
and Cutting, American Welding Society Standard AWS F4.1 from Glob-
al Engineering Documents. Website: www.global.ihs.com. OSHA Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part
Safe Practices for Welding and Cutting Containers that have Held Com- 1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov.
bustibles, American Welding Society Standard AWS A6.0 from Global
Engineering Documents. Website: www.global.ihs.com. OSHA Important Note Regarding the ACGIH TLV, Policy Statement on
National Electrical Code, NFPA Standard 70 from National Fire Protection the Uses of TLVs and BEIs. Website: www.osha.gov.
Association. Website: www.nfpa.org and www. sparky.org. Applications Manual for the Revised NIOSH Lifting Equation from the
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1 National Institute for Occupational Safety and Health (NIOSH).
from Compressed Gas Association. Website:www.cganet.com. Website: www.cdc.gov/NIOSH.

1-6. EMF Information

Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). The current from arc welding (and allied pro- welding circuit as possible.
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding 5. Connect work clamp to workpiece as close to the weld as
circuit. EMF fields can interfere with some medical implants, e.g. pace- possible.
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con- 6. Do not work next to, sit or lean on the welding power source.
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit: 7. Do not weld whilst carrying the welding power source or wire
feeder.
1. Keep cables close together by twisting or taping them, or using a
About Implanted Medical Devices:
cable cover.
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.

OM−279248 Page 4
 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
som_2020−02_fre
7

Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.

2-1. Symboles utilisés

DANGER! − Indique une situation dangereuse qui si on . Indique des instructions spécifiques.
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dan-
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
gers possibles sont montrés par les symboles joints ou
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
sont expliqués dans le texte.
CHAUDES. Reportez−vous aux symboles et aux directives
AVIS − Indique des déclarations pas en relation avec des blessures ci−dessous afin de connaître les mesures à prendre pour éviter tout
personnelles. danger.

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

l’utilisation d’un poste à souder DC à fil à tension constante est re-
Les symboles représentés ci-dessous sont utilisés dans ce ma- commandée. En outre, ne pas travailler seul !
nuel pour attirer l’attention et identifier les dangers possibles. En
D Couper l’alimentation ou arrêter le moteur avant de procéder à l’in-
présence de l’un de ces symboles, prendre garde et suivre les
stallation, à la réparation ou à l’entretien de l’appareil. Déverrouiller
instructions afférentes pour éviter tout risque. Les consignes
l’alimentation selon la norme OSHA 29 CFR 1910.147 (voir nor-
de sécurité présentées ci−après ne font que résumer les in-
mes de sécurité).
formations contenues dans les principales normes de
sécurité énumérées à la section 2-5. Lire et observer toutes les D Installez, mettez à la terre et utilisez correctement cet équipement
normes de sécurité. conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
L’installation, l’utilisation, l’entretien et les réparations ne D Toujours vérifier la terre du cordon d’alimentation. Vérifier et
doivent être confiés qu’à des personnes qualifiées. Une per- s’assurer que le fil de terre du cordon d’alimentation est bien
sonne qualifiée est définie comme celle qui, par la raccordé à la borne de terre du sectionneur ou que la fiche du
possession d’un diplôme reconnu, d’un certificat ou d’un cordon est raccordée à une prise correctement mise à la terre.
statut professionnel, ou qui, par une connaissance, une for- D En effectuant les raccordements d’entrée, fixer d’abord le conduc-
mation et une expérience approfondies, a démontré avec teur de mise à la terre approprié et contre-vérifier les connexions.
succès sa capacité à résoudre les problèmes liés à la tâche, D Les câbles doivent être exempts d’humidité, d’huile et de graisse;
le travail ou le projet et a reçu une formation en sécurité afin protégez−les contre les étincelles et les pièces métalliques
de reconnaître et d’éviter les risques inhérents. chaudes.
D Vérifier fréquemment le cordon d’alimentation et le conducteur de
Pendant le fonctionnement, maintenir à distance toutes les
mise à la terre afin de s’assurer qu’il n’est pas altéré ou dénudé −,
personnes, notamment les enfants de l’appareil.
le remplacer immédiatement s’il l’est −. Un fil dénudé peut entraî-
UNE DÉCHARGE ÉLECTRIQUE peut ner la mort.
entraîner la mort. D L’équipement doit être hors tension lorsqu’il n’est pas utilisé.
Le contact d’organes électriques sous tension peut D Ne pas utiliser des câbles usés, endommagés, de grosseur insuffi-
provoquer des accidents mortels ou des brûlures sante ou mal épissés.
graves. Le circuit de l’électrode et de la pièce est sous D Ne pas enrouler les câbles autour du corps.
tension lorsque le courant est délivré à la sortie. Le D Si la pièce soudée doit être mise à la terre, le faire directement
circuit d’alimentation et les circuits internes de la avec un câble distinct.
machine sont également sous tension lorsque l’alimen-
tation est sur Marche. Dans le mode de soudage avec D Ne pas toucher l’électrode quand on est en contact avec la pièce,
du fil, le fil, le dérouleur, le bloc de commande du la terre ou une électrode provenant d’une autre machine.
rouleau et toutes les parties métalliques en contact D Ne pas toucher des porte électrodes connectés à deux machines
avec le fil sont sous tension électrique. Un équipement en même temps à cause de la présence d’une tension à vide dou-
installé ou mis à la terre de manière incorrecte ou blée.
impropre constitue un danger.
D N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-le-
D Ne pas toucher aux pièces électriques sous tension. champ les pièces endommagées. Entretenir l’appareil conformé-
D Porter des gants isolants et des vêtements de protection secs et ment à ce manuel.
sans trous. D Porter un harnais de sécurité si l’on doit travailler au-dessus du sol.
D S’isoler de la pièce à couper et du sol en utilisant des housses ou D S’assurer que tous les panneaux et couvercles sont correctement
des tapis assez grands afin d’éviter tout contact physique avec la en place.
pièce à couper ou le sol.
D Fixer le câble de retour de façon à obtenir un bon contact métal-
D Ne pas utiliser de sortie de soudage CA dans des zones humides métal avec la pièce à souder ou la table de travail, le plus près pos-
ou confinées ou s’il y a un risque de chute. sible de la soudure.
D Se servir d’une source électrique à courant électrique UNIQUE- D Isoler la pince de masse quand pas mis à la pièce pour éviter le
MENT si le procédé de soudage le demande. contact avec tout objet métallique.
D Si l’utilisation d’une source électrique à courant électrique s’avère
D Ne pas raccorder plus d’une électrode ou plus d’un câble de
nécessaire, se servir de la fonction de télécommande si l’appareil
masse à une même borne de sortie de soudage. Débrancher le
en est équipé.
câble pour le procédé non utilisé.
D D’autres consignes de sécurité sont nécessaires dans les condi-
D Utiliser une protection différentielle lors de l’utilisation d’un équi-
tions suivantes : risques électriques dans un environnement
pement auxiliaire dans des endroits humides ou mouillés.
humide ou si l’on porte des vêtements mouillés ; sur des structures
métalliques telles que sols, grilles ou échafaudages ; en position Il reste une TENSION DC NON NÉGLIGEABLE dans
coincée comme assise, à genoux ou couchée ; ou s’il y a un risque
élevé de contact inévitable ou accidentel avec la pièce à souder ou les sources de soudage onduleur UNE FOIS
le sol. Dans ces conditions, utiliser les équipements suivants, l’alimentation coupée.
dans l’ordre indiqué : 1) un poste à souder DC à tension constante D Éteignez l’unité, débranchez le courant électrique, et déchargez
(à fil), 2) un poste à souder DC manuel (électrode) ou 3) un poste à les condensateurs d’alimentation selon les instructions indiquées
souder AC à tension à vide réduite. Dans la plupart des situations, dans le manuel avant de toucher les pièces.
OM-279248 Page 5
 D Déplacer toutes les substances inflammables à une distance de
LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
provoquer des brûlures. soigneusement avec des protections homologués.
D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là où des étincelles peuvent tomber
D Prévoir une période de refroidissement avant sur des substances inflammables.
de travailler à l’équipement. D Se protéger et d’autres personnes de la projection d’étincelles et
D Ne pas toucher aux pièces chaudes, utiliser les outils recomman- de métal chaud.
dés et porter des gants de soudage et des vêtements épais pour D Des étincelles et des matériaux chauds du soudage peuvent
éviter les brûlures. facilement passer dans d’autres zones en traversant de petites
LES FUMÉES ET LES GAZ peuvent fissures et des ouvertures.
être dangereux. D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
Le soudage génère des fumées et des gaz. Leur D Le soudage effectué sur un plafond, plancher, paroi ou séparation
inhalation peut être dangereux pour votre santé. peut déclencher un incendie de l’autre côté.
D Eloigner votre tête des fumées. Ne pas respirer les fumées. D Ne pas couper ou souder des jantes ou des roues. Les pneus
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au peuvent exploser s’ils sont chauffés. Les jantes et les roues répa-
niveau de l’arc pour l’évacuation des fumées et des gaz de rées peuvent défaillir. Voir OSHA 29 CFR 1910.177 énuméré dans
soudage. Pour déterminer la bonne ventilation, il est recommandé les normes de sécurité.
de procéder à un prélèvement pour la composition et la quantité de D Ne pas effectuer le soudage sur des conteneurs fermés tels que
fumées et de gaz auxquelles est exposé le personnel. des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs préparés correctement conformément à AWS F4.1 et AWS A6.0
approuvé. (voir les Normes de Sécurité).
D Lire et comprendre les fiches de données de sécurité et les instruc-
D Ne pas souder là où l’air ambiant pourrait contenir des poussières,
tions du fabricant concernant les adhésifs, les revêtements, les
nettoyants, les consommables, les produits de refroidissement, les gaz ou émanations inflammables (vapeur d’essence, par exemple).
dégraisseurs, les flux et les métaux. D Brancher le câble de masse sur la pièce le plus près possible de la
D Travailler dans un espace fermé seulement s’il est bien ventilé ou zone de soudage pour éviter le transport du courant sur une
en portant un respirateur à alimentation d’air. Demander toujours à longue distance par des chemins inconnus éventuels en provo-
un surveillant dûment formé de se tenir à proximité. Des fumées et quant des risques d’électrocution, d’étincelles et d’incendie.
des gaz de soudage peuvent déplacer l’air et abaisser le niveau D Ne pas utiliser le poste de soudage pour dégeler des conduites ge-
d’oxygène provoquant des blessures ou des accidents mortels. lées.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations D En cas de non utilisation, enlever la baguette d’électrode du porte-
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et électrode ou couper le fil à la pointe de contact.
les rayons de l’arc peuvent réagir en présence de vapeurs et for- D Porter un équipement de protection pour le corps fait d’un matériau
mer des gaz hautement toxiques et irritants. résistant et ignifuge (cuir, coton robuste, laine). La protection du
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier corps comporte des vêtements sans huile comme par ex. des
galvanisé, plaqué en plomb ou au cadmium à moins que le revête- gants de cuir, une chemise solide, des pantalons sans revers, des
ment n’ait été enlevé dans la zone de soudure, que l’endroit soit chaussures hautes et une casquette.
bien ventilé, et en portant un respirateur à alimentation d’air. Les
D Avant de souder, retirer toute substance combustible de vos po-
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage. ches telles qu’un allumeur au butane ou des allumettes.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune
LES RAYONS DE L’ARC peuvent trace d’étincelles incandescentes ni de flammes.
provoquer des brûlures dans les D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
yeux et sur la peau. Ne pas augmenter leur puissance; ne pas les ponter.
Le rayonnement de l’arc du procédé de soudage génère D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
des rayons visibles et invisibles intenses (ultraviolets e NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la extincteur à proximité.
peau. Des étincelles sont projetées pendant le soudage. D Lire et comprendre les fiches de données de sécurité et les instruc-
D Porter un casque de soudage approuvé muni de verres filtrants tions du fabricant concernant les adhésifs, les revêtements, les
approprié pour protéger visage et yeux pour protéger votre visage nettoyants, les consommables, les produits de refroidissement,
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 les dégraisseurs, les flux et les métaux.
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque. DES PIECES DE METAL ou DES
D Avoir recours à des écrans protecteurs ou à des rideaux pour SALETES peuvent provoquer des
protéger les autres contre les rayonnements les éblouissements blessures dans les yeux.
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc. D Le soudage, l’écaillement, le passage de la pièce à
D Porter un équipement de protection pour le corps fait d’un matériau la brosse en fil de fer, et le meulage génèrent des étincelles et des
résistant et ignifuge (cuir, coton robuste, laine). La protection du particules métalliques volantes. Pendant la période de ref-
corps comporte des vêtements sans huile comme par ex. des
roidissement des soudures, elles risquent de projeter du laitier.
gants de cuir, une chemise solide, des pantalons sans revers, des
chaussures hautes et une casquette. D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels LES ACCUMULATIONS DE GAZ
que des réservoirs, tambours ou des conduites peut risquent de provoquer des blessures
provoquer leur éclatement. Des étincelles peuvent ou même la mort.
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des incen- D Fermer l’alimentation du gaz comprimé en cas
dies et des brûlures. Le contact accidentel de l’électrode avec des de non utilisation.
objets métalliques peut provoquer des étincelles, une explosion, un sur-
chauffement ou un incendie. Avant de commencer le soudage, vérifier D Veiller toujours à bien aérer les espaces confinés ou se servir d’un
et s’assurer que l’endroit ne présente pas de danger. respirateur d’adduction d’air homologué.
OM-279248 Page 6
 Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support station-
D Les porteurs de stimulateurs cardiaques et
naire ou dans un porte-bouteilles pour les empêcher de tomber ou
autres implants médicaux doivent rester à
de se renverser.
distance.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
D Les porteurs d’implants médicaux doivent consulter leur médecin circuits électriques.
et le fabricant du dispositif avant de s’approcher de la zone où se
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
déroule du soudage à l’arc, du soudage par points, du gougeage,
de la découpe plasma ou une opération de chauffage par D Une électrode de soudage ne doit jamais entrer en contact avec
induction. une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
LE BRUIT peut endommager l’ouïe.
D Utiliser seulement des bouteilles de gaz comprimé, régulateurs,
Le bruit des processus et des équipements peut tuyaux et raccords convenables pour cette application spécifique;
affecter l’ouïe. les maintenir ainsi que les éléments associés en bon état.
D Porter des protections approuvées pour les D Tourner le dos à la sortie de vanne lors de l’ouverture de la vanne
oreilles si le niveau sonore est trop élevé. de la bouteille. Ne pas se tenir devant ou derrière le régulateur lors
de l’ouverture de la vanne.
LES BOUTEILLES peuvent exploser D Le couvercle du détendeur doit toujours être en place, sauf lorsque
si elles sont endommagées. la bouteille est utilisée ou qu’elle est reliée pour usage ultérieur.
D Utilisez les équipements corrects, les bonnes procédures et suffi-
Les bouteilles de gaz comprimé contiennent du samment de personnes pour soulever, déplacer et transporter les
gaz sous haute pression. Si une bouteille est bouteilles.
endommagée, elle peut exploser. Du fait que D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
les bouteilles de gaz font normalement partie du procédé de l’équipement connexe et le dépliant P-1 de la CGA (Compressed Gas
soudage, les manipuler avec précaution. Association) mentionné dans les principales normes de sécurité.

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

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

QUES peuvent endommager les cir-
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables. cuits imprimés.
D Ne pas installer l’appareil à proximité de pro- D Établir la connexion avec la barrette de terre
duits inflammables. avant de manipuler des cartes ou des pièces.
D Ne pas surcharger l’installation électrique − s’assurer que
l’alimentation est correctement dimensionnée et protégée avant D Utiliser des pochettes et des boîtes antistatiques pour stocker, dé-
de mettre l’appareil en service. placer ou expédier des cartes de circuits imprimes.
Les PIÈCES MOBILES peuvent
LA CHUTE DE L’ÉQUIPEMENT peut causer des blessures.
provoquer des blessures. D Ne pas s’approcher des organes mobiles.
D Utiliser l’anneau de levage uniquement pour D Ne pas s’approcher des points de coincement
soulever l’appareil, NON PAS les chariots, les tels que des rouleaux de commande.
bouteilles de gaz ou tout autre accessoire.
D Utilisez les procédures correctes et des équipements d’une capa- LES FILS DE SOUDAGE peuvent
cité appropriée pour soulever et supporter l’appareil. provoquer des blessures.
D En utilisant des fourches de levage pour déplacer l’unité, s’assurer D Ne pas appuyer sur la gâchette avant d’en
que les fourches sont suffisamment longues pour dépasser du avoir reçu l’instruction.
côté opposé de l’appareil.
D Ne pas diriger le pistolet vers soi, d’autres
D Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur. personnes ou toute pièce mécanique en engageant le fil de
soudage.
D Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94–110) lors du levage
manuelle de pièces ou équipements lourds. L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT. D Ne pas utiliser l’appareil de soudage pour
D Prévoir une période de refroidissement ; res- charger des batteries ou faire démarrer des
pecter le cycle opératoire nominal. véhicules à l’aide de câbles de démarrage,
sauf si l’appareil dispose d’une fonctionnalité
D Réduire le courant ou le facteur de marche de charge de batterie destinée à cet usage.
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
Les PIÈCES MOBILES peuvent
causer des blessures.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures. D S’abstenir de toucher des organes mobiles tels
que des ventilateurs.
D Porter un écran facial pour protéger le visage et D Maintenir fermés et verrouillés les portes,
les yeux. panneaux, recouvrements et dispositifs de protection.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exé- D Lorsque cela est nécessaire pour des travaux d’entretien et de dé-
cuter dans un endroit sûr lorsque l’on porte l’équipement ho- pannage, faire retirer les portes, panneaux, recouvrements ou
mologué de protection du visage, des mains et du corps. dispositifs de protection uniquement par du personnel qualifié.
D Les étincelles risquent de causer un incendie − éloigner toute D Remettre les portes, panneaux, recouvrements ou dispositifs de
substance inflammable. protection quand l’entretien est terminé et avant de rebrancher
l’alimentation électrique.
OM-279248 Page 7
 D Effectuer régulièrement le contrôle et l’entretien de l’installation.
LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des
D Lire et appliquer les instructions sur les sources de haute fréquence, maintenir les éclateurs à une distan-
étiquettes et le Mode d’emploi avant l’instal- ce correcte et utiliser une terre et un blindage pour réduire les
lation, l’utilisation ou l’entretien de l’appareil. interférences éventuelles.
Lire les informations de sécurité au début du
manuel et dans chaque section. LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D N’utiliser que les pièces de rechange recommandées par le
constructeur. D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
D Effectuer l’installation, l’entretien et toute intervention selon les
électronique sensible tel que les ordinateurs et
manuels d’utilisateurs, les normes nationales, provinciales et de l’équipement commandé par ordinateur tel que
l’industrie, ainsi que les codes municipaux. les robots.
LE RAYONNEMENT HAUTE D Veiller à ce que tout l’équipement de la zone de soudage soit com-
FRÉQUENCE (H.F.) risque de patible électromagnétiquement.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
provoquer des interférences. soudage aussi courts que possible, les grouper, et les poser aussi
D Le rayonnement haute fréquence (H.F.) peut bas que possible (ex. par terre).
provoquer des interférences avec les équi- D Veiller à souder à une distance de 100 mètres de tout équipement
pements de radio−navigation et de communication, les services électronique sensible.
de sécurité et les ordinateurs. D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D Demander seulement à des personnes qualifiées familiarisées avec D En cas d’interférences après avoir pris les mesures précédentes,
des équipements électroniques de faire fonctionner l’installation. il incombe à l’utilisateur de prendre des mesures supplémentaires
D L’utilisateur est tenu de faire corriger rapidement par un électricien telles que le déplacement du poste, l’utilisation de câbles blindés,
qualifié les interférences résultant de l’installation. l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
D Si le FCC signale des interférences, arrêter immédiatement l’appareil. de travail.

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 de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.

2-5. Principales normes de sécurité

Safety in Welding, Cutting, and Allied Processes, American Welding Safety in Welding, Cutting, and Allied Processes, CSA Standard
Society standard ANSI Standard Z49.1. Website: www.aws.org. W117.2 from Canadian Standards Association.
Safe Practice For Occupational And Educational Eye And Face Protec- Website: www.csagroup.org.
tion, ANSI Standard Z87.1 from American National Standards Institute. Standard for Fire Prevention During Welding, Cutting, and Other Hot
Website: www.ansi.org. Work, NFPA Standard 51B from National Fire Protection Association.
Safe Practices for the Preparation of Containers and Piping for Welding Website: www.nfpa.org.
and Cutting, American Welding Society Standard AWS F4.1 from Glob-
al Engineering Documents. Website: www.global.ihs.com. OSHA Occupational Safety and Health Standards for General Industry,
Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part
Safe Practices for Welding and Cutting Containers that have Held Com- 1910 Subpart Q, and Part 1926, Subpart J. Website: www.osha.gov.
bustibles, American Welding Society Standard AWS A6.0 from Global
Engineering Documents. Website: www.global.ihs.com. OSHA Important Note Regarding the ACGIH TLV, Policy Statement on
National Electrical Code, NFPA Standard 70 from National Fire Protection the Uses of TLVs and BEIs. Website: www.osha.gov.
Association. Website: www.nfpa.org and www. sparky.org. Applications Manual for the Revised NIOSH Lifting Equation from the
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1 National Institute for Occupational Safety and Health (NIOSH).
from Compressed Gas Association. Website:www.cganet.com. Website: www.cdc.gov/NIOSH.

2-6. Informations relatives aux CEM

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

OM-279248 Page 8
 SECTION 3 − DEFINITIONS

3-1. Additional Safety Symbols And Definitions

. Some symbols are found only on CE products.

Warning! Watch Out! There are possible hazards as shown by the symbols.

Safe1 2012−05

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

Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2017−04

Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

Safe2 2017−04

Protect yourself from electric shock by insulating yourself from work and ground.

Safe3 2017−04

Disconnect input plug or power before working on machine.

Safe5 2017−04

Keep your head out of the fumes.

Safe6 2017−04

Use forced ventilation or local exhaust to remove the fumes.

Safe60 2012−06

Use ventilating fan to remove fumes.

Safe61 2012−06

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

Safe62 2012−06

OM-279248 Page 9
 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Safe63 2012−06

Do not weld on drums or any closed containers.

Safe16 2017−04

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

Safe20 2017−04

Drive rolls can injure fingers.

Safe32 2012−05

Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.

Safe33 2017−04

Pinch points can injure.

Safe102 2012−09

Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.

Safe66 2012−06

Become trained and read the instructions before working on the

machine or welding.

Safe65 2012−06

Notes

OM-279248 Page 10
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.

A Amperes
Gas Preflow U1 Primary Voltage

V Volts
Gas Postflow
Filter
Direct Current
(DC)

IP Degree Of
Protection
I2 Rated Welding
Current
Wire Type

Arc Control
Increase Line Connection

Read Instructions
Gas Input Wire Diameter

Cold Jog (Inch) Pulse

Input Towards
Workpiece

Output Trigger Hold On Done

Percent Gas Type Voltage Sense

Input
Gas Metal Arc
Purge By Gas Welding (GMAW)
Gun

Notes

OM-279248 Page 11
 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. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.

4-2. Software Licensing Agreement

The End User License Agreement and any third-party notices and terms and conditions pertaining to third-party software can be found at
https://www.millerwelds.com/eula and are incorporated by reference herein.

4-3. Information About Default Weld Parameters And Settings

NOTICE − Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding
parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference
purposes only; and final weld results can be affected by other variables and application-specific circumstances. The appropriateness of all parameters
and settings should be evaluated and modified by the end user as necessary based upon application-specific requirements. The end user is solely
responsible for selection and coordination of appropriate equipment, adoption or adjustment of default weld parameters and settings, and ultimate
quality and durability of all resultant welds. Miller Electric expressly disclaims any and all implied warranties including any implied warranty of fitness
for a particular purpose.

4-4. Specifications

Welding Power Welding Circuit Overall

Input Power Wire Feed Speed Range* Wire Diameter Range Weight
Source Type Rating Dimensions

50 VDC Deltaweld 350 Standard: .023 To 5/64 in. 113 Volts DC Height:
Deltaweld 500 50−780 ipm (0.6 To 2 mm) 16-1/4 in.
600 Amperes,
(1.3−19.8mpm) (413 mm)
Max Spool Capacity: 60% Duty
Width:
18 in. (457 mm) Cycle 44.8 lb
12-3/8 in.
Max Spool Weight: (314 mm) (20.3 kg)
60 lb (27 kg) Length:
27-7/8 in.
(708 mm)

4-5. Environmental Specifications

A. IP Rating
IP Rating
IP2X
This equipment is designed for indoor use and is not intended to be used or stored outside.
IP2X 2014−06

B. Temperature Specifications
Operating Temperature Range Storage Temperature Range

14 to 104 °F (−10 to 40°C) −4 to 131 °F (−20 to 55°C)

Temp_2016- 07

4-6. Duty Cycle

Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
60% Duty Cycle At 600 Amperes NOTICE − Exceeding duty cycle
can damage unit and void warranty.

6 Minutes Welding 4 Minutes Resting

duty1 4/95 − SA-181560 / 263638-A

OM-279248 Page 12
 SECTION 5 − INSTALLATION
5-1. Power Source And Wire Feeder Site Selection

Movement

! Do not put feeder where ! Do not move or operate

welding wire hits cylinder. unit where it could tip.

1 OR

Location And Airflow ! Special installation may be required

where gasoline or volatile liquids are
present − see NEC Article 511 or CEC
Section 20.
! Do not move or operate equipment
where it could tip.
1 Hand Cart
3 Use cart or similar device to move unit.
2 Lifting Forks
Use lifting eye or lifting forks to move unit.
If using lifting forks, extend forks beyond
opposite side of unit.
3 Line Disconnect Device

18 in. Locate unit near correct input power supply.

(460 mm)

18 in.
(460 mm)

281831-A

OM-279248 Page 13
 5-2. Connecting Weld Output Cable
! Turn off power before connecting to
weld terminal or receptacle.
! Failure to properly connect weld
cables may cause excessive heat
Tools Needed:
and start a fire, or damage your
machine.
9/16 in.
Ensure all connections are tight.
Weld Cable Connection

. Do not place anything between weld

cable terminal and weld terminal. Make
sure that all surfaces are clean.
1 Weld Terminal
2 Weld Terminal Bolt
Wire Feeder Side View
with Door Open 3 Weld Cable Terminal
4 Supplied Nut
Remove supplied nut from weld terminal.
Install cable on weld terminal bolt. Screw
nut onto bolt and tighten to 250 in lb
(28.2 N·m).

2
3
4

Ref. 281839-A

Notes

OM-279248 Page 14
5-3. Connection Diagram

8
1
11

6
2

5 10
3

12

281832-A
4

! Turn off power before making 6 Welding Gun Use of shielding gas is dependant on Wire
connections. 7 Wire Feeder Type.
1 Wire Feeder Cable 8 Gas Hose
2 Positive (+) Weld Output Terminal 9 Gas Cylinder . The connection diagram illustrates
3 Negative (−) Weld Output Terminal 10 Welding Power Source DCEP (reverse polarity) suitable for
all wires except self-shielded FCAW.
4 Work Cable 11 Electrode Cable The majority of self-shielded FCAW
5 Workpiece 12 Volt Sense Lead (Optional) wires require DCEN (straight polarity).

OM-279248 Page 15
5-4. Arranging Welding Cables To Reduce Welding Circuit Inductance
1 Welding Power Source
2 Electrode Cable
3 Feeder Cable
4 Work Cable
Bad
5 Voltage Sense Lead
1 6 Wire Feeder
2
3 7 Workpiece
The arrangement of the cables has an
effect that is significant to the welding
properties. As an example, Accupulse
welding process can produce high
6 welding circuit inductance depending
on cable length and arrangement. This
can result in limited current rise during
droplet transfer into the welding puddle.
4 The work sense lead connects to the
rear of the wire feeder. This work
5
sense lead automatically compen-
sates for work cable voltage drop
when connected.
Do not coil excess cables. Use cables
that are the appropriate length for the
7
application. Whenever using long weld
cables [longer than 50 ft (15 m)] try to
arrange positive and negative weld
cables together to reduce the magnetic
Better field surrounding the cables. Avoid
1 coupling the feeder and work sense
leads with the weld cables.

3 2
6

5
7

Best 1

2
3
6

5
7

Ref. 283401-A

OM-279248 Page 16
5-5. Control Cable Connections
! Turn off power before connecting
control cable.
1 Remote ArcConnect Receptacle
RC2
2 Remote ArcConnect Receptacle
RC1
Connect control cable between recepta-
cle RC2 on front of welding power source
to receptacle RC1 on rear of wire feeder.

Wire Feeder
Welding Power Source Rear View
Front View
Ref. 280823-A / Ref. 281841-A

5-6. Wire Feeder Lower Front Panel Connections

1 4-Socket Gun Trigger
Receptacle RC2
Connect gun trigger plug to recep-
tacle RC2 on lower front panel on
wire feeder.

1
Ref. 281841-A

OM-279248 Page 17
5-7. Weld Voltage Sense Connection (Optional)
1 Weld Voltage Sense
Receptacle RC3
Connect voltage sense lead from
weld voltage sense receptacle RC3
on rear of wire feeder to work piece
(see Sections 5-3 and 5-4) for more
information.

. Connecting sense lead is

optional as required by desired
weld process.

Wire Feeder Rear View

Ref. 281839-A

5-8. Connecting Shielding Gas

NOTICE − This feeder has a shield-
ing gas filter that requires special
attention when cleaning. See Sec-
tion 7-2 for proper cleaning instruc-
tions.
1 Gas Hose With 5/8-18
Right-hand Thread Fittings
(Customer Supplied)

3
4 Wire Feeder Rear View . Tighten gas hose fitting to a
maximum of 100 in. lbs (12
N.m).
2 Shielding Gas Cylinder
. Shielding gas pressure not to
exceed 100 psi (689 kPa).
3 Valve
2 4 Flowmeter
5 Shielding Gas Fitting
Close valve on cylinder when fin-
ished welding.
5

1
Ref. 281841-A / 256620-A

OM-279248 Page 18
5-9. Rotating Drive Assembly
1 Drive Assembly
2 Wire Drive Assembly Angle
Rotate the drive assembly to re-
duce bends in the MIG gun cable.
Wire can be setup to feed off either
the top or bottom of wire spool. Se-
lect the option that results in the
straightest possible path into drive
1 assembly.
3 Drive Assembly Rotation
Knob
3 To rotate the drive assembly,
loosen drive assembly rotation
knob, rotate drive assembly to de-
sired position and tighten knob to
secure.

2 Good 2

Wire Feeds Off Bottom Of Spool Wire Feeds Off Top Of Spool

Bad

Ref. 281838-A / 281947-A

OM-279248 Page 19
5-10. Installing Welding Gun
1 Power Clamp Knob
2 Gun Locking Tab
3 Gun Locking Tab Rotated 180
Degrees
4 Power Pin Groove
5 Gun Connection End
Installing gun with Accu-Mate
connection
Loosen power clamp knob to allow
power pin of gun to clear the gun
locking tab.
Push power pin into power clamp
5 as far as possible to align the
groove in the power pin of the gun
with the gun locking tab.
Secure gun by tightening power
clamp knob.
Installing gun without Accu-
Mate connection
When using a gun without the
4 groove in the power pin, loosen
power clamp knob and rotate gun
locking tab 180 degrees. This pre-
vents the locking tab from extend-
ing into the power pin gun connec-
Installing gun with Installing gun without tion.
Accu-Mate connection Accu-Mate connection Push power pin into power clamp
1 as far as possible.
1 3
2 Secure gun by tightening power
clamp knob.
6 Gun Control Cable
Insert plug into Gun Control
receptacle, and tighten threaded
collar.

Ref. 281840-A

OM-279248 Page 20
5-11. Installing Wire Guides And Drive Rolls

6 7

6 4

1 4

8
5

Ref. 281467-C

Installing Wire Guides Insert inlet wire guide into wire entry as taining nut one click to secure in place. Re-
shown. Push into place to secure. Repeat peat procedure for remaining drive rolls.
1 Inlet Wire Guide
procedure for intermediate guide.
2 Intermediate Wire Guide To remove drive rolls reverse procedure.
To remove wire guides, push on wire guide
3 Upper Drive Roll Carrier securing button and remove guide. Aligning Wire Guide And Drive Rolls
4 Drive Roll Pressure Adjustment Installing Drive Rolls Self-aligning drive rolls do not require any
Knob manual adjustment.
6 Drive Roll Carrier
5 Wire Guide Securing Button Cleaning Drive Rolls
7 Drive Roll Retaining Nut
Open upper drive roll carriers by grasping Remove drive rolls, and clean grooves
drive roll pressure adjustment knob and 8 Drive Roll
using a wire brush.
pull out and down. Carrier will spring open. With upper drive roll carriers open, slide
Repeat for other carrier. drive roll onto carrier. Rotate drive roll re- Close drive assembly cover.

OM-279248 Page 21
5-12. Installing And Threading Welding Wire

Tools Needed:

15/16 in.

. Hold wire tightly to keep it from unraveling.

6 in.
(150 mm)
Pull and hold wire; cut off end.

Select wire spool hub mounting position

(see Section 5-9). Install wire spool. Adjust
tension nut so wire is taut when wire feed
stops.

Back Of Gun

Pressure Drive Rolls

Indicator
Scale
Pressure
Adjust

End Of Liner

No Wire Slip Wire Slips

NONCONDUCTIVE NONCONDUCTIVE
SURFACE SURFACE

. For best wire feeding performance, be . For soft wire or small diameter stainless . To adjust drive roll pressure, hold nozzle
sure that the outlet cable has the proper steel wire, reduce drive roll pressure on about 2 in. (51 mm) from nonconductive
size liner for the welding wire size being the rear roll to half that of the front rolls. surface and press gun trigger to feed wire
used. Also, when the gun is installed, the against surface. Tighten knob so wire
liner extending from the back of the gun does not slip. Do not overtighten. If
should be as close to the drive rolls as contact tip is completely blocked, wire
possible, without touching. should slip at the feeder (see pressure
adjustment above).Cut wire off. Close
Install gun. Lay gun cable out straight. Cut off cover.
end of wire. Push wire through guides up to
drive rolls; continue to hold wire. Press Jog
button to feed wire out gun.
Ref. 156929-A / 281838-A / 242517-A

OM-279248 Page 22
Notes

OM-279248 Page 23
 SECTION 6 − OPERATION
6-1. Wire Feeder User Interface

2 4 5 6 7 8
27
1 3

10

28

11
9

12

13 14 15 16 17

26

18 19 20 21

22

23

24

25

Ref. 279273-D

OM-279248 Page 24
6-2. Description Of Front Panel Controls (See Section 6-1)

1 Memory 1-2 Buttons 9 Left Adjust Control - Voltage/Arc 19 Trigger Select Button
Length Use to enable and disable trigger select
Allows two memory selections to recall
pre-selected welding process, wire type, Use control to adjust voltage or arc length function. When active, tap gun trigger to se-
wire size, gas and weld parameters. as determined by indicator below Left Dis- lect between Memory 1 or 2. Indicator is lit
play. when active
2 Left Display 20 Preflow Button
10 Right Adjust Control - Wire Speed /
Indicates weld voltage or arc length as de- Preflow / Postflow Time Use to enable and disable gas preflow func-
termined by indicator below display. Also, tion. Indicator is lit when active.
displays welding gas preflow and postflow Use control to adjust wire speed when indi-
cator is lit below Right Display. Use control 21 Postflow Button
indication when corresponding button is
pressed. to adjust welding gas preflow or postflow Use to enable and disable gas postflow
time after pressing preflow or postflow but- function. Indicator is lit when active.
3 Right Display tons. 22 Trigger Hold Indicator
Indicates weld amperage or wire feed 11 Arc Control Indicates trigger hold function enabled
speed as determined by indicator below when lit.
Use control to adjust arc characteristics.
display. Also, displays welding gas preflow
Rotate to review and adjust desired setting. 23 Trigger Select Indicator
and postflow time when corresponding but-
ton is pressed. 12 Wire And Gas Selection Display Indicates trigger select function enabled
when lit.
4 Voltage Indicator Indicates selected weld process, wire type,
24 Preflow Indicator
wire size and gas type.
Indicates weld voltage value shown on Left Indicates preflow function enabled when lit.
Display. 13 MIG/Pulse Button
25 Postflow Indicator
5 Arc Length Indicator Used to select desired welding process. Indicates postflow function enabled when
14 Wire Button lit.
Indicates arc length value shown on Left
Display. 26 Jog/Purge Switch
Use to select desired welding wire type.
6 Amps Indicator Pressing the top portion of switch enables
15 Wire Size Button wire feeder to feed wire without energizing
Indicates weld amperage value shown on Use to select desired welding wire size. weld output or gas valve.
Right Display. Pressing bottom portion of switch enables
16 Gas Button
7 EZ-Set Indicator gas valve to purge gas lines.
Use to select desired welding gas type. 27 EZ-Set Voltage Range Indicator
Indicates weld voltage or arc length have
been automatically determined for the se- 17 Done Button Indicates weld voltage has been adjusted
lected process, wire type, size, gas type higher (∧), lower (∨) or at recommended (∗)
Use to switch the selected welding
and material size. voltage for wire feed speed when using MIG
process, wire type, size and gas type.
(EZ-Set) welding arc.
8 Wire Speed Indicator 18 Trigger Hold Button 28 Arc Control Indicators
Indicates wire speed value shown on Right Use to enable and disable trigger hold func- Visually indicates selected arc control set-
Display. tion. Indicator is lit when active. ting.

OM-279248 Page 25
 6-3. Power Switch
1 Power Switch
(Located on rear of feeder)

281841-A

6-4. Jog/Purge
1 Jog/Purge Switch
Pressing the top portion of switch
enables wire feeder to feed wire
without energizing weld output or
gas valve.
Pressing bottom portion of switch
enables gas valve to purge gas
lines.
2 Wire Speed Control
Wire speed can be adjusted with
the Wire Speed control when the
unit is jogging wire. The unit dis-
plays wire speed while the unit is
being jogged.
3 Gun Trigger Receptacle
The wire feeder can also be jogged
by using the gun trigger. However,
the weld output is energized for 3
seconds. If the welding arc does
not initiate in 3 seconds after the
gun trigger is activated the unit will
perform a jog operation for a maxi-
mum of one minute. If the gun trig-
ger is still activated after one
minute, the jog operation is termi-
nated to prevent complete despool-
2 ing of the wire, as in the case of a
damaged gun.

. The unit displays HELP HELD

to inform operator to release
3 gun trigger or Jog switch.

281841-A

OM-279248 Page 26
6-5. Arc Control

1 Arc Control Knob

2 Arc Control Indicators
Arc control allows the arc characteristics, fluid versus stiff, to be changed for specific applications and wires. The star setting is good for most
applications. Use fluid settings (0 −25) to soften the arc, increase puddle fluidity and flatten the weld bead appearance. Use stiff settings (0−25)
to stiffen the arc, reduce puddle fluidity and crown the weld bead appearance.
To adjust or review the arc control setting, begin by turning Arc Control knob. The type (fluid or stiff) and value (0−25) will be displayed in the
Left and Right display for three seconds. Turn knob to desired arc control setting. Indicators around arc control knob will light to give visual indica-
tion of arc control setting.

6-6. Memory 1-2

1 Memory 1-2 Buttons

2 Memory 1-2 LEDs
Memory 1-2 allows the operator to quickly select between welding setups.
To save welding setups to a memory, press and release desired memory button. Indicator will be lit. Choose welding parameters using Section
6-12. The welding setup is now saved to this memory. Repeat process for other memory button. Operator can now recall either setup by pressing
corresponding memory button.

. Each memory has independent preset voltage or arc length, wire speed, arc control, preflow, postflow and trigger hold settings. These set-
tings are preserved when unit is turned off.

6-7. Trigger Hold

2
1

1 Trigger Hold Button

2 Trigger Hold LED
Trigger Hold function allows the operator to weld without continuously pressing the welding gun trigger. The operator presses the welding gun
trigger for five seconds and an arc is established. The weld enable signal latches on and the operator can release the welding gun trigger. The
welding operation will continue. To stop the welding operation, press and release the welding gun trigger.
To enable Trigger Hold function, press and release button. Indicator will light. To disable press and release button. Indicator will not be lit.

OM-279248 Page 27
6-8. Trigger Select

2
1

1 Trigger Select Button

2 Trigger Select LED
Trigger Select function allows the operator to switch between saved welding setups using the welding gun trigger. The operator momentarily
presses and releases the welding gun trigger to switch between Memory 1 or Memory 2.
To enable Trigger Select function, press and release button. Indicator will light. To disable, press and release button. Indicator will not be lit.

6-9. Preflow

2
1

1 Preflow Button
2 Preflow LED
Preflow function allows a timed amount of shielding gas to flow after welding gun trigger is press and before welding arc will be enabled. The
preflow time can be adjusted from 0.1 to 30 seconds.
To enable preflow function, press and release button. Indicator will light. Immediately after enabling, the preflow time will be displayed in the Right
Display. Turn Right Adjust Control (knob below Right Display) to adjust desired preflow time. To disable press and release button. Indicator will
not be lit.

6-10. Postflow

2
1

1 Postflow Button
2 Postflow LED
Postflow function allows a timed amount of shielding gas to flow after the welding operation has ended. The postflow time can be adjusted from
0.1 to 30 seconds.
To enable postflow function, press and release button. Indicator will light. Immediately after enabling, the postflow time will be displayed in the
Right Display. Turn Right Adjust Control to adjust desired postflow time. To disable press and release button. Indicator will not be lit.

OM-279248 Page 28
6-11. Operational Terms
The following is a list of terms and their definitions as they apply to this wire feeder:

General Terms:
Arc Length Is the physical distance between the wire electrode and the molten weld puddle. It is a term used to
represent adjustments in the Pulsed MIG welding process. The default setting for arc length is 0.0
and good for most applications. The operator can change the setting for specific applications.

The arc length setting will be displayed in the Left Display when a Pulsed MiG welding process is
selected. To adjust setting, turn Left Adjust Control knob. Use settings of 0 to −10.0 to decrease arc
length. Use settings of 0 to 10.0 to increase arc length.

EZ-Set A synergic operation which automatically determines weld parameters by using the wirefeed speed
knob to select the thickness of the material being welded. Once the material thickness is selected, the
welding parameters are set to a suggested starting point for welding.

. All settings are approximate. Welds should be tested to comply to your specifications.
Accu-Pulse Is a Pulsed MIG welding process utilizing constant current ramps with constant voltage control of
peaks and background. Adaptive response is controlled by peak and background current levels.

Notes

OM-279248 Page 29
6-12. Selecting Welding Arc, Wire Type, Size And Gas

MIG
STEEL
.035”
75% AR 25% CO2

Wire and Gas Selection Display

The Wire and Gas Selection Display indicates the current welding arc, wire
type, wire size and shielding gas.

. To change parameters, follow the steps below:

SELECT WELDING ARC:

MIG

Selecting Welding Arc

To select welding arc, press and release MIG/PULSE button. Indicator will
light. The selected welding arc will be displayed. Press MIG/PULSE button
again to change welding arc selection.

SELECT WIRE TYPE:

STEEL

Selecting Wire Type

To select wire type, press and release Wire button. Indicator will light. MIG/
PULSE indicator will turn off. The selected wire type will be displayed.
Press Wire button again to change wire type.
Ref. 279273-D

OM-279248 Page 30
6-12. Selecting Welding Arc, Wire Type, Size And Gas (Continued)

SELECT WIRE SIZE:

.035”

Selecting Wire Size

To select wire size, press and release Wire Size button. Indicator will light.
Wire Type indicator will turn off. The selected wire size will be displayed.
Press Wire Size button again to change wire size.

SELECT SHIELD GAS:

75% AR 25% CO2

Selecting Shielding Gas

To select shielding gas, press and release Gas button. Indicator will light.
Wire Size indicator will turn off. The selected gas type will be displayed.
Press Gas button again to change gas type.

MIG
STEEL
.035”
75% AR 25% CO2

Saving Selected Parameters

To save selected parameters, press and release the Done button. The Gas
indicator will turn off. The selected welding arc, wire type, wire size and gas
type will be saved. This step must be performed to save any changes.

. Selection process will time out if begun and no buttons are pressed within
20 seconds. Any changes made during this time will not be saved.
Ref. 279273-D

OM-279248 Page 31
6-13. MIG - Wire and Gas Selection Table
WIRE TYPES SHIELD GAS TYPES
CO2 (CARBON DIOXIDE)
.030 (0.8)
AR CO2 (ARGON / CARBON DIOXIDE)

.035 (0.9) CO2 (CARBON DIOXIDE)

.045 (1.2) AR CO2 (ARGON / CARBON DIOXIDE)
Steel
.052 (1.4) AR O2 (ARGON / OXYGEN)

AR CO2 (ARGON / CARBON DIOXIDE)

.062 (1.6)*
AR O2 (ARGON / OXYGEN)
.045 (1.2)
.052 (1.4)
Metal Core ARGN CO2 (ARGON / CARBON DIOXIDE)
.062 (1.6)
.078 (2.0)*
.045 (1.2)
.052 (1.4) CO2 (CARBON DIOXIDE)
Flux Core
.062 (1.6) AR CO2 (ARGON / CARBON DIOXIDE)
.078 (2.0)*
AR CO2 (ARGON / CARBON DIOXIDE)
.035 (0.9)
AR HE CO2 (ARGON / HEL CARBON DIOXIDE)
Stainless Steel .045 (1.2)
AR O2 (ARGON / OXYGEN)
.062 (1.6)*
HE AR CO2 (HELIUM / ARGON / CARBON DIOXIDE)

* Available With Deltaweld 500 only.

6-14. Accu-Pulse - Wire and Gas Selection Table

WIRE TYPES SHIELD GAS TYPES
.035 (0.9)
.045 (1.2) AR CO2 (ARGON / CARBON DIOXIDE)
Steel
.052 (1.4)* AR O2 (ARGON / OXYGEN)
.062 (1.6)*
.045 (1.2)
Metal Core .052 (1.4) AR CO2 (ARGON / CARBON DIOXIDE)
.062 (1.6)*
AR CO2 CARBON DIOXIDE)
.035 (0.9)
AR HE CO2 (ARGON / HEL CARBON DIOXIDE)
Stainless Steel .045 (1.2)
AR O2 (ARGON / OXYGEN)
.062 (1.6)*
HE AR CO2 (HELIUM / ARGON / CARBON DIOXIDE)

* Available With Deltaweld 500 only.

OM-279248 Page 32
6-15. Accu-Power

The Accu-Power feature displays the instantaneous output power while welding, which can then be used with the equation below to compute
the heat input for a particular weld operation.
At end of the weld the total average power in kilojoules per second and total arc time in seconds are displayed for up to 30 seconds on the
Wire and Gas selection display.

To calculate the weld heat input, multiply the instantaneous power by the arc time and divide by the weld bead length.

Power(kJńs)xArcTime(s)
HeatInput[kJńin(kJńmm)] +
WeldBeadLength[in(mm)]

To convert from kilojoules to joules, multiply this result by 1000.

Enabling Accu-Power
Accu−Power is always displayed when using Accu-Pulse. To enable in other welding arc modes, connect voltage sense lead from weld volt-
age sense receptacle on rear of wire feeder to work piece. See section 5-7 for more information.

. Use the weld voltage sense connection for better accuracy when using this feature.

Wire and Gas Selection Display

ACCU-PULSE 4.82 kJ/s Power

STEEL
.035” 5s Arc Time
95% AR 5% CO2

Ref 279273-D

OM-279248 Page 33
 SECTION 7 − MAINTENANCE & TROUBLESHOOTING
7-1. Routine Maintenance

! Disconnect power . Maintain more often

before maintaining. during severe conditions.

n = Check Z = Change ~ = Clean l = Replace Reference

* To be done by Factory Authorized Service Agent

l Unreadable Labels ~ Weld Terminals nl Weld Cables nl Gun Cables

Every
3
Months

nl Cords nl Cracked Parts ~ Weld Connections n Tighten Weld Cable

Connections

l Damaged Gas Hose

Every
6 OR
Months

~ Drive Rolls ~ Inside Unit

OM-279248 Page 34
7-2. Cleaning Debris From Shielding Gas Filter Fitting
! Disconnect power before
maintaining.
1 Shielding Gas Filter Fitting
Remove fitting from gas valve on
back panel of feeder.
Blow compressed air through the
threaded male end of fitting to dis-
lodge debris from internal mesh
screen.

. Replace fitting if blowing com-

pressed air through fitting does
not clear obstructions.
Reinstall fitting into gas valve.
Tighten fitting to 150 in. lbs (17 N⋅m).

Rear View of Feeder

Tools Needed:

3/4 in.
283551-A

OM-279248 Page 35
7-3. Diagnostics Table For Fault Codes

Unit Display Toggles Message Description

HELP SET HELP 10XX Indicates an issue with the weld program library, or the wire feeder attempted to
use an invalid memory. Select a different memory (PRO feeder only). If the prob-
lem persists, contact a Factory Authorized Service Agent.

HELP COMM HELP 11XX Indicates a communication failure between two of the circuit boards within the
system. Cycle power. Inspect and replace the ArcConnect cable between the
power source and wire feeder. If the problem persists, contact a Factory Autho-
rized Service Agent.

HELP FEED HELP 14XX Indicates input power to the wire feeder is outside specifications, or the motor
experienced an overcurrent. Verify the power source is operating within it’s rated
supply voltages. Check the drive rolls, spool tension, gun liner, wire guides and
contact tip for anything that could cause excessive drag on the wire feeding.

HELP DUTY HELP 2501 or Indicates the wire feeder motor(s) are operating at too high of a current over a
HELP 2502 period of time. Check the drive rolls, spool tension, gun liner, wire guides and
contact tip for anything that could cause excessive drag on the wire feeding.

. HELP 2500 indicates a power source over-duty cycle, consult power source
Owner’s manual.

HELP HELD HELP 26XX Indicates a button or trigger is held for too long or is stuck. Verify no buttons are
held down on the wire feeder or gun. Unplug the gun trigger. If the problem goes
away, there is an issue with the gun trigger. If the problem persists, contact a
Factory Authorized Service Agent.

HELP XXXX HELP XXXX For other codes not listed, consult power source Owner’s manual.

. The last two digits in the right display (shown with XX in the table) will indicate a specific fault a Factory Authorized Service Agent can use to
troubleshoot the wire feeder.

Notes

OM-279248 Page 36
7-4. Troubleshooting

! Disconnect power before troubleshooting

Trouble Remedy

Wire feeds, shielding gas flows, but Check and secure weld cable connections (see Section 5-2).
electrode wire is not energized.

Electrode wire feeding stops or feeds Check welding gun trigger connection. See gun Owner’s Manual.
erratically during welding.
Check welding gun trigger. See gun Owner’s Manual.

Readjust hub tension and drive roll pressure (see Section 5-12).

Change to correct size drive roll.

Clean or replace dirty or worn drive roll.

Incorrect size or worn wire guides.

Replace contact tip or liner. See welding gun Owner’s Manual.

Remove weld spatter or foreign matter from around nozzle opening.

Wire feeder power is on, displays light Check welding gun trigger connection at wire feeder.
up, but unit is inoperative.
Check welding gun trigger leads and trigger switch. See welding gun Owner’s Manual.

Unit completely inoperative- no display. Turn Power switch On (see Section 6-3).

Check ArcConnect cable connection at wire feeder and power source.

Check supplementary protector at power source. See power source Owner’s Manual.

Wire feeds when Jog switch is pressed Check welding gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun
but not when gun trigger is pressed. Owner’s Manual.

Wire does not feed until trigger is Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
pressed but continues to feed after trig-
ger is released. Wire feeds as soon as
power is applied.

Gas does not flow; wire feeds. Check gas supply.

Check gas flowmeter.

Check gas hose for damage or loose connections.

Check for blockage in gas filter (see Section 7-2).

Check for blockage in welding gun.

Erratic or improper weld output. Use proper size and type of weld cable.

Clean and tighten all weld connections.

Check for correct polarity or welding circuit.

Poor weld cable layout. See (Section 5-4) for recommended cable arrangement.

If using weld voltage sense lead, verify cable and connections. Repair or replace as needed.

. Do not leave unused lead connected to the weld voltage sense terminal.

OM-279248 Page 37
 SECTION 8 − ELECTRICAL DIAGRAM

Figure 8-1. Circuit Diagram

OM-279248 Page 38
 279241-B

OM-279248 Page 39
 SECTION 9 − PARTS LIST

. Hardware is common and

11 not available unless listed.

12
9
8

13 10
14
15
16

17
7
16
15
6 14
18

5
19
3
26
4
30
27
Fig.9−3

28
24

25

20

29 2

21

Fig.9−2

22

23

283383-A

Figure 9-1. Main Assembly

OM-279248 Page 40
 Item Part
No. No. Description Quantity

Figure 9-1. Main Assembly

... 1 . . . . . . . . . . . . . Figure 9-2 . . Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

... 2 . . . . . . . . . . . . . . . 275806 . . Label, Warning Hot Surfaces And Moving Parts . . . . . . . . . . . . . . . . . . . . 1
... 3 . . . . . . . . . . . . . . +279265 . . Wrapper Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 . . . . . . . . . . . . . . . 269889 . . Label, Caution Pinch Point (EN/FR/SP) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 5 . . . . . . . . . . . . . . . 279355 . . Insulator, Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 6 . . . . . . . . . . . . . . . 279267 . . Door, Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 . . . . . . . . . . . . . . . 089899 . . Latch, Slide Flush Style Series 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 . . . . . . . . . . . . . . . 282105 . . Hinge, Door Friction Adjustable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 9 . . . . . . . . . . . . . . . 274964 . . Label, Warning General Precautionary (EN/FR/SP) . . . . . . . . . . . . . . . . . 1
... 10 . . . . . . . . . . . . . . . 141753 . . Hub+Spindle Assembly (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 . . . . . . . . . . . . . . . 058427 . . . . Ring, Retaining Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 12 . . . . . . . . . . . . . . . 180571 . . . . Shaft Assy, Support Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 . . . . . . . . . . . . . . . 010233 . . . . Spring, Cprsn .970 Od X .120 Wire X 1.250Pld . . . . . . . . . . . . . . . . . . . 1
... 14 . . . . . . . . . . . . . . . 057971 . . . . Washer, Flat Stl Keyed 1.500Dia X .125Thk . . . . . . . . . . . . . . . . . . . . . 2
... 15 . . . . . . . . . . . . . . . 010191 . . . . Washer, Fbr .656 Id X 1.500 Od X .125Thk . . . . . . . . . . . . . . . . . . . . . . 2
... 16 . . . . . . . . . . . . . . . 058628 . . . . Washer, Brake Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 17 . . . . . . . . . . . . . . . 058428 . . . . Hub, Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 . . . . . . . . . . . . . . . 248974 . . . . Tubing, Stl .875 Od X12Ga Wall X .562 . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 . . . . . . . . . . . . . . . 135205 . . . . Nut, Stl Slflkg Hex Reg .625-11 W/Nylon Insert . . . . . . . . . . . . . . . . . . . 1
... 20 . . . . . . . . . . . . . . . 279240 . . Support, Spool Tilted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 21 . . . . . . . . . . . . . . . 281994 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 22 . . . . . . . . . . . . . . . 134306 . . Foot, Rubber 1.250 Dia X 1.375 High No 10 Screw . . . . . . . . . . . . . . . . . 4
... 23 . . . . . . . . . . . . . . . 281535 . . Bracket, Stiffener Rear Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 24 . . . . . . . . . . . . . . . 124778 . . Knob, T 2.000 Bar W/.312−18 Stud 1.000 Lg . . . . . . . . . . . . . . . . . . . . . . 1
... 25 . . . . . . . . . . . . . . . 279842 . . Extension, Knob Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 26 . . . . . . . . . . . . . . . 279238 . . Clamp, Motor Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 27 . . . . . . . . . . . . . . . 279239 . . Insulator, Motor Barrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 28 . . . . . . . . . . . . . . . 279237 . . Clamp, Motor Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 29 . . . . . . . . . . . . . . . 200814 . . Hose Assy, SAE .187 Id X .410 Od X 17.000 W/Clamps . . . . . . . . . . . . 1
... 30 . . . . . . . . . . . . . Figure 9-3 . . Wire Drive Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Notes

OM-279248 Page 41
 . Hardware is common and
not available unless listed.
3 4 5
1 2

20

6
21 7
8

11 10
13 12 9

14

19
18 15

16

17 283384-A

Figure 9-2. Control Box

Item Dia. Part

No. Mkgs. No. Description Quantity

Figure 9-2. Control Box

. . . 1 . . . . PC1 . . . . . 279350 . . Circuit Card Assy, Motor Control W/Program . . . . . . . . . . . . . . . . . . . . . . 1

. . . 2 . . . . . . . . . . . . . . . 239737 . . Receptacle, Banana Jack Blk 10−32 Binding Post . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . . . . . 134201 . . Stand−Off Support, PC Card .312/.375W/Post&Lock .43 . . . . . . . . . . . . 5
. . . 4 . . . . . . . . . . . . . . . . 281158 . . Bushing, Snap−In Nyl .938 Id X 1.187 Mtg Hole Blk . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . S1 . . . . . . . 111997 . . Switch, Rocker Spst 10A 250VAC On-Off Visi Red Rock . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . . 211989 . . Fitting, W/Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 220805 . . Nut, 750−14 Nps 1.48Hex .41H Nyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 .......................... Label, Rear Panel (Order By Model And Serial Number) . . . . . . . . . . . . . 1
. . . 9 . . . . GS1 . . . . . 226819 . . Valve, 12VDC 1Way .750−14 Thd 2MM Orf 100PSI . . . . . . . . . . . . . . . . 1
. . . 10 . . . . RC1,
. . . . . . . . PLG17, 18 . . . 280119 . . Receptacle, W/Leads & Plug 19Pin Ethernet (Feeder) . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . . . . . +279264 . . Enclosure, Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . . . . . . . . . . . . . . . . . Label, Lower (Order By Model And Serial Number) . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . . 279169 . . Bezel, Feeder (For Door) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . PC2 . . . . . 275747 . . Circuit Card Assy, Intellx Pro UI W/Program . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . PC3 . . . . . 279269 . . Membrane, Switch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . . . . . . 279272 . . Panel, Front W/Stand-Offs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . PLG3, S2 . . . 280005 . . Switch Assy, Jog/Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 279189 . . Door, Control Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . 245663 . . Knob, Encoder 1.250 Dia X .250 Id Push On W/Spring . . . . . . . . . . . . . . 3
. . . 20 . . . . . . . . . . . . . . . 279742 . . Panel, Side Drive Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . RC2, PLG9 . . 280004 . . Plugs, W/Leads (Trigger Receptacle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

OM-279248 Page 42
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-2. Control Box (Continued)

. . . . . . . . PLG2, 19 . . . 280003 .. Plugs, W/Leads (UI Board To Motor Board) (Not Shown) . . . . . . . . . . . . 1
. . . . . . . . . . PLG4 . . . . . 280006 .. Plug W/Leads (Gas Valve) (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . PLG16 . . . . 280007 .. Plug W/Leads (Power Switch) (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG1 . . . . . 280008 .. Plug W/Leads (Volt Sense) (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . 1

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Notes

OM-279248 Page 43
 . Hardware is common and
not available unless listed. 26

24 25
23 27
See Table 9-1 For 22
Drive Roll & Wire Guide Kits 28

1
19
20
15
16
21
2
17

14
3

13
12
11

18

5
10
6
9 7
8 282450-B

Figure 9-3. Drive Assembly, Wire

Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-3. Drive Assembly, Wire (Figure 9-1 Item 30)

... 1 . . . . M1 . . . . . . 279222 .. Motor, Gear 24VDC 146RPM 29:1 Ratio Continuous W/Tach . . . . . . . . . 1
... 2 ............... 279256 .. Ftg, Hose Brs Barbed W/Volt Sense Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 3 ............... 279252 .. Insulator, Motor Drive (4 Roll) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 4 ............... 281870 .. Screw, 010−32x .94 Flathd−Soc Stl Pld (Customized) . . . . . . . . . . . . . . . . 2
... 5 ............... 281784 .. Spring, Cprsn .180 Od X .018 Wire X .531 Pld . . . . . . . . . . . . . . . . . . . . . . 1
... 6 ............... 279259 .. Clamp, Power Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 7 ............... 237188 .. Lock, Pin Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 8 ............... 124778 .. Knob, T 2.000 Bar W/.312−18 Stud 1.000 Lg . . . . . . . . . . . . . . . . . . . . . . . 1
... 9 ............... 172077 .. Carrier, Drive Roll Keyed 24 Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 10 ............... 605308 .. Ring, Rtng Ext .500 Shaft X .035 Thk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 11 ............... 166072 .. Spacer, Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 12 ............... 279262 .. Button, Lock Guide Intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 13 ............... 279263 .. Spring, Cprsn .312 Od X .250 Id Rate 5.2 Lbs/In . . . . . . . . . . . . . . . . . . . . 2
... 14 ............... 279261 .. Button, Lock Guide Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 15 ............... 221030 .. Guide, Wire Inlet Anti−Wear One Pc (.023 TO 5/64) . . . . . . . . . . . . . . . . . 1
... 16 ............... 056209 .. Guide, Wire Intermediate 1/16−5/64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 17 ............... 234073 .. Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 18 ............... 279167 .. Housing, Wire Drive 4 Roll (Push Button) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 19 ............... 279255 .. Pin, Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 20 ............... 279257 .. Spring, Torsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 21 ............... 279179 .. Lever, Mtg Pressure Gear Front (Single Drive) . . . . . . . . . . . . . . . . . . . . . . 1
... 22 ............... 172075 .. Carrier, Drive Roll W/Cmpnts 24 Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
... 23 ............... 252238 .. Stand−Off, Drive Roll Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

OM-279248 Page 44
 Item Dia. Part
No. Mkgs. No. Description Quantity

Figure 9-3. Drive Assembly, Wire (Continued)

... 24 ............... 279181 .. Lever, Mtg Pressure Gear Rear (Single Drive) . . . . . . . . . . . . . . . . . . . . . . 1
... 25 ............... 151828 .. Pin, Cotter Hair .042 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
... 26 ............... 252217 .. Knob Assy, Tension Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
... 27 ............... 281348 .. Screw, 312−18x .50 Flathd−Phl Stl Pld W/Lkg Patch . . . . . . . . . . . . . . . . . 2
... 28 ............... 092865 .. Key, Stl .1215/.1230 X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Notes

OM-279248 Page 45
 Table 9-1. Drive Roll & Wire Guide Kits (4 Drive Roll)

. Base selection of drive rolls upon the following recommended usages:

1. V-Grooved rolls for hard wire.
2. U-Grooved rolls for soft and soft shelled cored wires.
3. U-Cogged rolls for extremely soft shelled wires (usually hard surfacing types).
4. V-Knurled rolls for hard shelled cored wires.
5. Drive roll types may be mixed to suit particular requirements (example:
V-Knurled roll in combination with U-Grooved).

Wire Diameter Drive Roll Wire Guide

Kit No.
Fraction Decimal Metric Part No. Type Inlet Intermediate
.023/.025 in. .023/.025 in. 0.6 mm 087132 087130 V-Grooved 056192 056206
.030 in. .030 in. 0.8 mm 046780 053695 V-Grooved 056192 056206
.035 in. .035 in. 0.9 mm 046781 053700 V-Grooved 056192 056206
.040 in. .040 in. 1.0 mm 191917 053696 V-Grooved 056192 056206
.045 in. .045 in. 1.2 mm 046782 053697 V-Grooved 056193 056207
.052 in. .052 in. 1.3 mm 046783 053698 V-Grooved 056193 056207
1/16 in. .062 in. 1.6 mm 046784 053699 V-Grooved 056195 056209
.035 in. .035 in. 0.9 mm 044750 072000 U-Grooved 056192 056206
.045 in. .045 in. 1.2 mm 046785 053701 U-Grooved 056193 056207
.052 in. .052 in. 1.3 mm 046786 053702 U-Grooved 056193 056207
1/16 in. .062 in. 1.6 mm 046787 053706 U-Grooved 056195 056209
5/64 in. .079 in. 2.0 mm 046788 053704 U-Grooved 056195 056209

.035 in. .035 in. 0.9 mm 046792 132958 V-Knurled 056192 056206
.045 in. .045 in. 1.2 mm 046793 132957 V-Knurled 056193 056207
.052 in. .052 in. 1.3 mm 046794 132956 V-Knurled 056193 056207
1/16 in. .062 in. 1.6 mm 046795 132955 V-Knurled 056195 056209
5/64 in. .079 in. 2.0 mm 046796 132960 V-Knurled 056195 056209
.045 in. .045 in. 1.2 mm 083319 083489 U-Cogged 056193 056207
1/16 in. .062 in. 1.6 mm 046800 053708 U-Cogged 056195 056209
5/64 in. .079 in. 2.0 mm 046801 053710 U-Cogged 056195 056209
Ref. S-0025-D

OM-279248 Page 46
 Effective January 1, 2020
(Equipment with a serial number preface of NA 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 * Supplied Air Respirator (SAR) Boxes and Panels
Warranty Questions? below, Miller Electric Mfg. LLC, Appleton, Wisconsin, warrants to * TIG Torches (No Labor)
authorized distributors that new Miller equipment sold after the * Tregaskiss Guns (No Labor)
Call effective date of this limited warranty is free of defects in material * Water Cooling Systems
and workmanship at the time it is shipped by Miller. THIS * Wireless Remote Foot/Hand Controls and Receivers
1-800-4-A-MILLER WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Work Stations/Weld Tables (No Labor)
for your local WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
5. 6 Months — Parts
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Miller distributor. * Batteries
Within the warranty periods listed below, Miller will repair or replace 6. 90 Days — Parts
any warranted parts or components that fail due to such defects in * Accessories (Kits)
material or workmanship. Miller must be notified in writing within
* ArcReach Heater Quick Wrap and Air Cooled Cables
Your distributor also gives thirty (30) days of such defect or failure, at which time Miller will
* Canvas Covers
you ... provide instructions on the warranty claim procedures to be
followed. Notifications submitted as online warranty claims must * Induction Heating Coils and Blankets, Cables, and
Service provide detailed descriptions of the fault and troubleshooting steps Non-Electronic Controls
taken to diagnose failed parts. Warranty claims that lack the * MDX Series MIG Guns
You always get the fast,
required information as defined in the Miller Service Operation * M-Guns
reliable response you
Guide (SOG) may be denied by Miller. * MIG Guns, Subarc (SAW) Torches, and External
need. Most replacement Cladding Heads
parts can be in your Miller shall honor warranty claims on warranted equipment listed * Remote Controls and RFCS-RJ45
hands in 24 hours. below in the event of a defect within the warranty coverage time * Replacement Parts (No labor)
periods listed below. Warranty time periods start on the delivery
Support * Spoolmate Spoolguns
date of the equipment to the end-user purchaser, or 12 months
Need fast answers to the after the equipment is shipped to a North American distributor, or Miller’s True Blue® Limited Warranty shall not apply to:
tough welding questions? 18 months after the equipment is shipped to an international 1. Consumable components; such as contact tips,
Contact your distributor. distributor, whichever occurs first. cutting nozzles, contactors, brushes, relays, work
The expertise of the 1. 5 Years Parts — 3 Years Labor station table tops and welding curtains, or parts that
distributor and Miller is * Original Main Power Rectifiers Only to Include SCRs, fail due to normal wear. (Exception: brushes and
there to help you, every Diodes, and Discrete Rectifier Modules relays are covered on all engine-driven products.)
step of the way. 2. 3 Years — Parts and Labor Unless Specified 2. Items furnished by Miller, but manufactured by others,
* Auto-Darkening Helmet Lenses (No Labor) (See such as engines or trade accessories. These items are
Classic Series Exception Below) covered by the manufacturer’s warranty, if any.
* Engine Driven Welder/Generators 3. Equipment that has been modified by any party other than
(NOTE: Engines are Warranted Separately by the Miller, or equipment that has been improperly installed,
Engine Manufacturer.) improperly operated or misused based upon industry
* Insight Welding Intelligence Products (Except External standards, or equipment which has not had reasonable
Sensors) and necessary maintenance, or equipment which has
* Inverter Power Sources been used for operation outside of the specifications for
* Plasma Arc Cutting Power Sources the equipment.
* Process Controllers 4. Defects caused by accident, unauthorized repair, or
* Semi-Automatic and Automatic Wire Feeders improper testing.
* Transformer/Rectifier Power Sources MILLER PRODUCTS ARE INTENDED FOR COMMERCIAL
3. 2 Years — Parts and Labor AND INDUSTRIAL USERS TRAINED AND EXPERIENCED IN
THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
* Auto-Darkening Helmet Lenses − Classic Series Only
(No Labor) The exclusive remedies for warranty claims are, at Miller’s
* Auto-Darkening Weld Masks (No Labor) option, either: (1) repair; or (2) replacement; or, if approved in
* Fume Extractors − Capture 5, Filtair 400 and Industrial writing by Miller, (3) the pre-approved cost of repair or
Collector Series replacement at an authorized Miller service station; or (4)
4. 1 Year — Parts and Labor Unless Specified payment of or credit for the purchase price (less reasonable
* ArcReach Heater depreciation based upon use). Products may not be returned
without Miller’s written approval. Return shipment shall be at
* AugmentedArc and LiveArc Welding Systems
customer’s risk and expense.
* Automatic Motion Devices
* Bernard BTB Air-Cooled MIG Guns (No Labor) The above remedies are F.O.B. Appleton, WI, or Miller’s
authorized service facility. Transportation and freight are the
* CoolBelt (No Labor)
customer’s responsibility. TO THE EXTENT PERMITTED BY
* Desiccant Air Dryer System
LAW, THE REMEDIES HEREIN ARE THE SOLE AND
* Field Options EXCLUSIVE REMEDIES REGARDLESS OF THE LEGAL
(NOTE: Field options are covered for the remaining THEORY. IN NO EVENT SHALL MILLER BE LIABLE FOR
warranty period of the product they are installed in, DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
or for a minimum of one year — whichever is CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
greater.) PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY
* RFCS Foot Controls (Except RFCS-RJ45) WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED
* Fume Extractors − Filtair 130, MWX and SWX Series, WARRANTY, GUARANTY, OR REPRESENTATION,
ZoneFlow Extraction Arms and Motor Control Box INCLUDING ANY IMPLIED WARRANTY OF
* HF Units MERCHANTABILITY OR FITNESS FOR PARTICULAR
* ICE/XT Plasma Cutting Torches (No Labor) PURPOSE, ARE EXCLUDED AND DISCLAIMED BY
* Induction Heating Power Sources, Coolers MILLER.
(NOTE: Digital Recorders are Warranted Some US states do not allow limiting the duration of an implied
Separately by the Manufacturer.) warranty or the exclusion of certain damages, so the above
* Load Banks limitations may not apply to you. This warranty provides
* Motor-Driven Guns (except Spoolmate Spoolguns) specific legal rights, and other rights may be available
* PAPR Blower Unit (No Labor) depending on your state. In Canada, some provinces provide
* Positioners and Controllers additional warranties or remedies, and to the extent the law
* Racks (For Housing Multiple Power Sources) prohibits their waiver, the limitations set out above may not
* Running Gear/Trailers apply. This Limited Warranty provides specific legal rights, and
* Subarc Wire Drive Assemblies other rights may be available, but may vary by province.
mil dom warr 2020-01
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

Register your product at www.millerwelds.com/support/

product−registration

For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

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Options and Accessories
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USA Phone: 920-735-4505 Auto-Attended
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For International Locations Visit
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Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2020 Miller Electric Mfg. LLC 2020−01