Miller Electric STR 450 Owner's Manual

Stick (SMAW) Welding www.MillerWelds.com TIG (GTAW) Welding

job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will help you figure out what the problem is. The parts list will then help you to decide which exact part you may need to fix the problem. Warranty and service information for your particular model are also provided. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. Working as hard as you do − every power source from Miller is backed by the most hassle-free warranty in the business. From Miller to You

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. California Proposition 65 Warnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 − DEFINITIONS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Warning Label Definitions (For Wordless Labels) 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. WEEE Label (For Products Sold Within The EU) 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Symbols And Definitions 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 − INSTALLATION 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Important Information Regarding CE Products (Sold Within The EU) 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Serial Number And Rating Label Location 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Specifications 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Duty Cycle and Overheating 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Volt-Ampere Curves 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Selecting A Location 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. Tipping 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8. Weld Output Terminals and Selecting Cable Sizes 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9. Remote Receptacle Information 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10. Typical Connections For Stick (SMAW) Welding 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11. Typical Connections For TIG (GTAW) Welding 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12. Positioning Jumper Links 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13. Electrical Service Guide 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14. Connecting Input Power 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 − OPERATION 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Controls 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Stick Start Procedure − Scratch Start Technique 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Scratch Start TIG 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Routine Maintenance 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Help Displays 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Troubleshooting 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 − ELECTRICAL DIAGRAMS 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 − PARTS LIST 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WARRANTY

for European Community (CE marked) products. ITW Welding Products Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that the product(s) identified in this declaration conform to the essential requirements and provisions of the stated Council Directive(s) and Standard(s). Product/Apparatus Identification: Product Stock Number STR 450, 230/400VAC 029016239 Council Directives: • 2006/95/EC Low Voltage • 2004/108/EC Electromagnetic Compatibility Standards: • IEC 60974­1 Arc Welding Equipment ­ Welding Power Sources: edition 3, 2005­07. • IEC 60974­10 Arc Welding Equipment ­ Electromagnetic Compatibility Requirements: edition 2.0, 2007­08. • EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding, arc welding and allied processes with the basic restrictions related to human exposure to electromagnetic fields (0Hz­300Hz) EU Signatory: December 13th, 2010 ___________________________________________________________________________________ Massimigliano Lavarini Date of Declaration ELECTRONIC ENGINEER R&D TECH. SUPPORT 956 142 837

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2010−03 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if 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 hazards are shown in the adjoining symbols or ex- plained in the text. NOTICE − Indicates statements not related to personal injury. � Indicates special instructions. This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym- bols and related instructions below for necessary actions to avoid the hazards. 1-2. Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and follow all Safety Standards. Only qualified persons should install, operate, maintain, and repair this unit. During operation, keep everybody, especially children, away. ELECTRIC SHOCK can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard. � Do not touch live electrical parts. � Wear dry, hole-free insulating gloves and body protection. � Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground. � Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling. � Use AC output ONLY if required for the welding process. � If AC output is required, use remote output control if present on unit. � Additional safety precautions are required when any of the follow- ing electrically hazardous conditions are present: in damp locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped positions such 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 semiautomatic DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! � Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). � Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes. � Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet. � When making input connections, attach proper grounding conduc- tor first − double-check connections. � Keep cords dry, free of oil and grease, and protected from hot metal and sparks. � Frequently inspect input power cord for damage or bare wiring − replace cord immediately if damaged − bare wiring can kill. � Turn off all equipment when not in use. � Do not use worn, damaged, undersized, or poorly spliced cables. � Do not drape cables over your body. � If earth grounding of the workpiece is required, ground it directly with a separate cable. � Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine. � Do not touch electrode holders connected to two welding ma- chines at the same time since double open-circuit voltage will be present. � Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual. � Wear a safety harness if working above floor level. � Keep all panels and covers securely in place. � Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical. � Insulate work clamp when not connected to workpiece to prevent contact with any metal object. � Do not connect more than one electrode or work cable to any single weld output terminal. SIGNIFICANT DC VOLTAGE exists in inverter weld- ing power sources AFTER removal of inputpower. � Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section before touching any parts. HOT PARTS can burn. � Do not touch hot parts bare handed. � Allow cooling period before working on equip- ment. � To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous.

� Keep your head out of the fumes. Do not breathe the fumes. � If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. � If ventilation is poor, wear an approved air-supplied respirator. � Read and understand the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, consumables, coatings, cleaners, and degreasers. � Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained watch- person nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breath- ing air is safe. � Do not weld in locations near degreasing, cleaning, or spraying op- erations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases. � Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. � Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards). � Wear approved safety glasses with side shields under your helmet. � Use protective screens or barriers to protect others from flash, glare and sparks; warn others not to watch the arc. � Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection. ARC RAYS can burn eyes and skin. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding. WELDING can cause fire or explosion. � Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers. � Do not weld where flying sparks can strike flammable material. � Protect yourself and others from flying sparks and hot metal. � Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. � Watch for fire, and keep a fire extinguisher nearby. � Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side. � Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to AWS F4.1 (see Safety Standards). � Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline). � Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock, sparks, and fire hazards. � Do not use welder to thaw frozen pipes. � Remove stick electrode from holder or cut off welding wire at contact tip when not in use. � Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. � Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. � After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. � Use only correct fuses or circuit breakers. Do not oversize or by- pass them. � Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher nearby. FLYING METAL or DIRT can injure eyes. � Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag. � Wear approved safety glasses with side shields even under your welding helmet. BUILDUP OF GAS can injure or kill. � Shut off shielding gas supply when not in use. � Always ventilate confined spaces or use approved air-supplied respirator. ELECTRIC AND MAGNETIC FIELDS (EMF) can affect ImplantedMedical Devices. � Wearers of Pacemakers and other Implanted Medical Devices should keep away. � Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. NOISE can damage hearing. Noise from some processes or equipment can damage hearing. � Wear approved ear protection if noise level is high. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. CYLINDERS can explode if damaged. � Protect compressed gas cylinders from excessive heat, mechani- cal shocks, physical damage, slag, open flames, sparks, and arcs. � Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping. � Keep cylinders away from any welding or other electrical circuits. � Never drape a welding torch over a gas cylinder. � Never allow a welding electrode to touch any cylinder. � Never weld on a pressurized cylinder − explosion will result. � Use only correct shielding gas cylinders, regulators, hoses, and fit- tings designed for the specific application; maintain them and associated parts in good condition. � Turn face away from valve outlet when opening cylinder valve. � Keep protective cap in place over valve except when cylinder is in use or connected for use. � Use the right equipment, correct procedures, and sufficient num- ber of persons to lift and move cylinders. � Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association (CGA) publication P-1 listed in Safety Standards.

1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. � Do not install or place unit on, over, or near combustible surfaces. � Do not install unit near flammables. � Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can injure. � Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. � Use equipment of adequate capacity to lift and support unit. � If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. � Keep equipment (cables and cords) away from moving vehicles when working from an aerial location. � Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manu- ally lifting heavy parts or equipment. OVERUSE can cause OVERHEATING � Allow cooling period; follow rated duty cycle. � Reduce current or reduce duty cycle before starting to weld again. � Do not block or filter airflow to unit. FLYING SPARKS can injure. � Wear a face shield to protect eyes and face. � Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection. � Sparks can cause fires — keep flammables away. STATIC (ESD) can damage PC boards. � Put on grounded wrist strap BEFORE handling boards or parts. � Use proper static-proof bags and boxes to store, move, or ship PC boards. MOVING PARTS can injure. � Keep away from moving parts. � Keep away from pinch points such as drive rolls. WELDING WIRE can injure. � Do not press gun trigger until instructed to do so. � Do not point gun toward any part of the body, other people, or any metal when threading welding wire. MOVING PARTS can injure. � Keep away from moving parts such as fans. � Keep all doors, panels, covers, and guards closed and securely in place. � Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. � Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power. READ INSTRUCTIONS. � Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section. � Use only genuine replacement parts from the manufacturer. � Perform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes. H.F. RADIATION can cause interference. � High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. � Have only qualified persons familiar with electronic equipment perform this installation. � The user is responsible for having a qualified electrician prompt- ly correct any interference problem resulting from the installa- tion. � If notified by the FCC about interference, stop using the equipment at once. � Have the installation regularly checked and maintained. � Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and shielding to minimize the possibility of interference. ARC WELDING can cause interference. � Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven equipment such as robots. � Be sure all equipment in the welding area is electromagnetically compatible. � To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the floor. � Locate welding operation 100 meters from any sensitive elec- tronic equipment. � Be sure this welding machine is installed and grounded according to this manual. � If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables, using line filters, or shielding the work area.

1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. For Gasoline Engines: Engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproduc- tive harm. For Diesel Engines: Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. 1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Glob- al Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). National Electrical Code, NFPA Standard 70, from National Fire Protec- tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org and www. sparky.org). Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 4221 Walney Road, 5th Floor, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, from American National Standards Institute, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web- site: www.ansi.org). Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org. OSHA, Occupational Safety and Health Standards for General Indus- try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and Part 1926, Subpart J, from U.S. Government Printing Office, Super- intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov). U.S. Consumer Product Safety Commission (CPSC), 4330 East West Highway, Bethesda, MD 20814 (phone: 301-504-7923, website: www.cpsc.gov). Applications Manual for the Revised NIOSH Lifting Equation, The Na- tional Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH). 1-6. EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). Welding current creates an EMF field around the welding circuit and welding equipment. EMF fields may inter- fere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, access restrictions for passers−by or individual risk assess- ment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 1. Keep cables close together by twisting or taping them, or using a cable cover. 2. Do not place your body between welding cables. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep head and trunk as far away from the equipment in the welding circuit as possible. 5. Connect work clamp to workpiece as close to the weld as possible. 6. Do not work next to, sit or lean on the welding power source. 7. Do not weld whilst carrying the welding power source or wire feeder. About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recom- mended.

SECTION 2 − DEFINITIONS 2-1. Warning Label Definitions (For Wordless Labels) Warning! Watch Out! There are possible hazards as shown by the symbols. 1 Electric shock from welding electrode or wiring can kill. 1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves. 1.2 Protect yourself from electric shock by insulating yourself from work and ground. 1.3 Disconnect input plug or power before working on machine. 2 Breathing welding fumes can be hazardous to your health. 2.1 Keep your head out of the fumes. 2.2 Use forced ventilation or local exhaust to remove the fumes. 2.3 Use ventilating fan to remove fumes. 3 Welding sparks can cause explosion or fire. 3.1 Keep flammables away from welding. Do not weld near flammables. 3.2 Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it. 3.3 Do not weld on drums or any closed containers. 4 Arc rays can burn eyes and injure skin. 4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use welding helmet with correct shade of filter. Wear complete body protection. 5 Become trained and read the instructions before working on the machine or welding. 6 Do not remove or paint over (cover) the label.

Warning! Watch Out! There are possible hazards as shown by the symbols. Electric shock from wiring can kill. Disconnect input plug or power before working on machine. Read the Owner’s Manual before working on this machine. 1 Consult rating label for input power requirements, and check power available at the job site − they must match. 2 Read Owner’s Manual and inside labels for connection points and procedures. 3 Move jumper links as shown on inside label to match voltage at job site. 4 Having a loop of extra length, connect grounding conductor first. 5 Connect line input conductors as shown on inside label − double-check all connections, jumper link positions, and input voltage before applying power. 1/96 2-2. WEEE Label (For Products Sold Within The EU) Do not discard product (where ap- plicable) with general waste. Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collec- tion facility. Contact your local recycling office or your local distributor for further information.

2-3. Symbols And Definitions A Amperes Negative Weld Output Terminal Positive Weld Output Terminal Protective Earth (Ground) Output Supplementary Protector Off On V Volts Shielded Metal Arc Welding (SMAW) Input Remote Constant Current (CC) X Duty Cycle I1 Rated Supply Current I2 Rated Welding Current U0 Rated No-Load Voltage (Average) U1 Rated Supply Voltage U2 Load voltage Line Connection Scratch Start TIG Adjust X Duty Cycle Three Phase Transformer Rectifier Fuse IP Internal Protection Rating S1 KVA Current Increase Scale Current Increase/ Decrease

SECTION 3 − INSTALLATION 3-1. Important Information Regarding CE Products (Sold Within The EU) ! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding. This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person. Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure information. � The EMF assessment on this equipment was conducted at 0.5 meter. � At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values. 3-2. 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. 3-3. Specifications Model Rated Welding Output Ampere Range DC Max Open-Circuit Voltage DC IP Rating Amperes Input at Rated Load Output, 50/60 Hz, Three-Phase KVA/KW Weight Dimensions (mm) L x W x H 230 V 400 V 450 450 A @ 38 Volts DC, 35% Duty Cycle 25−450 A 80 V IP23S 72 A 42 A 29/26 Net: 163 kg (359 lb) Ship: 179 (395 lb) 1120 x 620 x 730 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.

3-4. Duty Cycle and Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding. NOTICE − Exceeding duty cycle can damage unit and void warranty. 3.5 Minutes Welding 6.5 Minutes Resting Overheating 0 15 A or V OR Reduce Duty Cycle Minutes 35% Duty Cycle At 450 A 200 250 300 400 450 350 500 150 Weld Amperes 0 10 20 30 40 50 60 70 80 90 100 % Duty Cycle 6 Minutes Welding 4 Minutes Resting 60%Duty Cycle At 350 A 100% Duty Cycle At 270 A Continuous Welding

3-5. Volt-Ampere Curves The volt-ampere curves show the normal minimum and maximum voltage and amperage output capa- bilities of the unit. DC Volts DC Amperes 0 10 20 30 40 50 60 70 80 90 0 40 80 120 160 200 240 280 320 360 400 440 480 3-6. Selecting A Location 1 Lifting Eye 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 Locate unit near correct input pow- er supply. ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. 3 18 in. (460 mm) 18 in. (460 mm) OR 1 2 Movement Location And Airflow

3-7. Tipping ! Do not move or operate unit where it could tip. 956142737_5−5_B 3-8. Weld Output Terminals and Selecting Cable Sizes NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cable size. ! Turn off power be- fore connecting to weld output termi- nals. ! Do not use worn, damaged, under- sized, or poorly spliced cables. Weld Output Terminals Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 30 m (100 ft) or Less 45 m (150 ft) 60 m (200 ft) 70 m (250 ft) 90 m (300 ft) 105 m (350 ft) 120 m (400 ft) Welding Amperes 10 − 60% Duty Cycle mm2 (AWG) 60 − 100% Duty Cycle mm2 (AWG) 10 − 100% Duty Cycle mm2 (AWG) Negative Terminal Positive Terminal 956142737_5−5_B 100 20 (4) 20 (4) 20 (4) 30 (3) 35 (2) 50 (1) 60 (1/0) 60 (1/0) 150 30 (3) 30 (3) 35 (2) 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 95 (3/0) 200 30 (3) 35 (2) 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 120 (4/0) 250 35 (2) 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2 ea. 2/0) 2x70 (2 ea. 2/0) 300 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2 ea. 2/0) 2x95 (2 ea. 3/0) 2x95 (2 ea. 3/0) 350 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2 ea. 2/0) 2x95 (2 ea. 3/0) 2x95 (2 ea. 3/0) 2x120 (2 ea. 4/0) 400 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2 ea. 2/0) 2x95 (2 ea. 3/0) 2x120 (2 ea. 4/0) 2x120 (2 ea. 4/0) 500 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2 ea. 2/0) 2x95 (2 ea. 3/0) 2x120 (2 ea. 4/0) 3x95 (3 ea. 3/0) 3x95 (3 ea. 3/0) 600 95 (3/0) 120 (4/0) 2x70 (2 ea. 2/0) 2x95 (2 ea. 3/0) 2x120 (2 ea. 4/0) 3x95 (3 ea. 3/0) 3x120 (3 ea. 4/0) 3x120 (3 ea. 4/0) * This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable. **Weld cable size is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere. ***For distances longer than those shown in this guide, call a factory applications representative. Milan Ref. S-0007-G 2009−08

3-9. Remote Receptacle Information � This unit automatically uses the remote control if connected to the remote receptacle. A B C D E REMOTE Socket* Socket Information REMOTE CONTROL A Contact closure to B completes 24 volts AC con- tactor control circuit. B Contact closure to A completes 24 volts AC con- tactor control circuit. C Output to remote control; +10 volts DC. D Remote control circuit common. E 0 to +10 volts DC input command signal from re- mote control. * The remaining sockets are not used. Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.

3-10. Typical Connections For Stick (SMAW) Welding 956142737_1-5_C / Ref. 803 310 3-11. Typical Connections For TIG (GTAW) Welding � Remote output is always On in TIG mode. See Section 4-3 for scratch start TIG information. Hot Start function (for Stick weld- ing) is disabled in TIG mode. � This unit automatically uses the remote control if connected to the remote receptacle (see Section 3-9). 1 Remote Hand Control 2 Remote Foot Control 1 2

3-12. Positioning Jumper Links ! Disconnect and lockout/tag- out input power before installing or moving jumper links. Check input voltage available at site. 1 Jumper Links Access Remove side panel. 2 Jumper Link Label Check label − only one is on unit. 3 Input Voltage Jumper Links Move jumper links to match input voltage. Close and secure side panel. Ref. S9215056 3-13. Electrical Service Guide Failure to follow these fuse and circuit breaker recommendations could create an electric shock or fire hazard. These recommendations are for a dedicated branch circuit that applies to the rated output and duty cycle of the welding power source. 3-Phase Input Voltage (V) 230 400 Input Amperes (A) At Rated Output 73 42 Max Recommended Standard Fuse Rating In Amperes 1 Time-Delay Fuses 2 90 50 Normal Operating Fuses3 110 60 Min Input Conductor Size In mm2 (AWG) 4 10 (8) 6 (10) Max Recommended Input Conductor Length In Meters (Feet) 33 (107) 67 (219) Min Grounding Conductor Size In mm2 (AWG) 4 10 (8) 6 (10) ** Power cord supplied with the unit is sized for 230V operation. Larger power cord may be required for cable lengths greater than 3 meters. Consult national and local regulations. Reference: 2008 National Electrical Code (NEC) (including article 630) 1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse. 2 “Time-Delay” fuses are UL class “RK5” . See UL 248. 3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and above). 4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table 310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.

3-14. Connecting Input Power ! Installation must meet all Na- tional and Local Codes − have only qualified persons make this installation. ! Disconnect and lockout/tag- out input power before con- necting input conductors from unit. ! Always connect green or green/yellow conductor to supply grounding terminal first, and never to a line ter- minal. ! Make input power connec- tions to the welding power source first. ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. See rating label on unit and check input voltage available at site. 1 Disconnect Device (switch shown in OFF position) 2 Disconnect Device (Supply) Grounding Terminal Connect green or green/yellow grounding conductor to disconnect device grounding terminal first. 3 Disconnect Device Line Terminals Connect input conductors L1 (U), L2 (V) And L3 (W) to disconnect device line terminals. 4 Overcurrent Protection Select type and size of overcurrent protection using Section 3-13 (fused disconnect switch shown). Close and secure door on line dis- connect device. Remove lockout/ tagout device, and place switch in the On position. 2 L1 (U) L2 (V) L3 (W) GND/PE Connect First GND/PE 1 3 4

SECTION 4 − OPERATION 4-1. Controls 1 Negative (−) Weld Terminal 2 Power On-Off Switch 3 Stick (SMAW) Welding Indicator Light 4 Process Selection Switch � Remote output is always On in TIG mode. Hot Start function (for Stick welding) is disabled in TIG mode. 5 TIG (GTAW) Welding Indicator Light 6 Power On Pilot Light 7 Welding Current Indicator 8 High Temperature Indicator 9 Weld Current Control 10 Remote Control Receptacle (See Section 3-9) 11 Positive (+) Weld Terminal 1 3 4 5 6 7 8 9 10 11 2

4-2. Stick Start Procedure − Scratch Start Technique With Stick selected, start arc as follows: 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it. 1 2 3 4-3. Scratch Start TIG Ref. WM Marketing This starting method is not accept- able for critical applications since small tungsten particles may be- come embedded in the workpiece and contaminate the weld. Turn gas on. Quickly drag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out electrode was lifted to high. If electrode sticks to workpiece, use a quick twist to free it.

SECTION 5 − MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance ! Disconnect power before maintaining. � = Check � = Change � = Clean � = Replace * To be done by Factory Authorized Service Agent Every 3 Months � Damaged Or Unreadable Labels � Cracked Weld cables �� Weld Connections Every 6 Months OR � Inside Unit 5-2. Help Displays 1 AL1 Display 2 AL2 Display 3 AL3 Display � Power On pilot light flashes when any of these help displays are shown. Displays indicate a malfunction in the primary power circuit (loss of input power phase). If any of these displays are shown, check input power con- nections. If trouble continues, contact a Factory Authorized Service Agent. 1 2 3 AL1 AL2 AL3 5-3. Troubleshooting Trouble Remedy No weld output; fan does not run. Be sure Power switch is On (see Section 4-1). Be sure line disconnect switch is in On position. Check and replace line fuses if open. Reset breakers if necessary. Fan does not run; weld output okay. Be sure nothing is blocking movement of fan. If fan does not run freely, replace fan motor. Erratic or improper weld output. Clean and tighten all weld cable connections. Check for proper size and type of cable (see Section 3-8). Check for proper input and output connections (see Sections 3-8 and/or 3-14). Replace electrode.

Trouble Remedy Erratic arc with excessive spatter. Use dry, properly stored electrodes. Shorten arc length. Reduce amperage setting. Electrode freezing to work. Increase amperage setting. Increase arc length. Use dry, properly stored electrodes. Low weld output with no control. Check position of Amperage Control (see Section 4-1). Limited output and low open-circuit voltage. Check incoming power for correct voltage. Replace line fuse if open (see Section 3-14). Check for proper input and output connections (see Sections 3-8 and/or 3-14). Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.

SECTION 7 − PARTS LIST � Hardware is common and not available unless listed. 956142737_2-5_C 15 12 13 4 9 8 12 10 11 12 7 5 6 5 16 1 2 3 18 17 4 5 6 5 7 8 9 10 11 12 13 14 12 Figure 7-1. Case And Running Gear Part No. Description Item No. Figure 7-1. Case And Running Gear Quantity Dia. Mkgs. 1 +156122085 Panel, RH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 +156121042 Upper panel 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 156011019 Eyebolt 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 156005129 Washer, Hooking (Support For Handle) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 556009031 Washer, Brass .26 x 35 x 3 mm 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 056054057 Wheel d.300 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 156023156 Cup, Retaining Wheel 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 156009127 Washer, Round hooking (For Handle) 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 056020071 Knob (for hose) 25 mm dia. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 156002047 Handle 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 156018114 Nut, Locking 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 156009128 Washer, flat 10x30 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 156012132 Handle, Fixing Pin 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 +156122086 Panel, LH 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 156110001 Foot 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 156012133 Axle, Wheels 25x605 mm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 000176254 Label, General Precautionary 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 000207291 Label, Warning Electric Shock Input 1 And 3Phase CE 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.

956142737_3-5_C � Hardware is common and not available unless listed. 9 8 7 30 29 1 28 31 27 26 25 24 23 22 21 20 19 18 17 16 15 12 14 13 12 11-Figure 7-3 10 2 3 1 4 5 6 Figure 7-2. Main Assembly Part No. Description Item No. Figure 7-2. Main Assembly Quantity Dia. Mkgs. 1 656089037 Clamp, Cable D.16−23 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 556070017 Link, Primary Terminal 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 756069030 Board, Primary Voltage Terminal 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 156005130 Support, Voltage Change Board 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 L1 057098017 Choke, 80x62x240 Al 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 T1 058021143 Transformer 230/400V, 60x100 Al 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 TP1 056159026 Thermostat 100c 10 A 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SR1 056050155 Rectifier 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 HD1 057028116 Probe Kit 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 056020069 Knob, Pointer, D.40 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 058040016 Control Panel (Effective w/MA295465D) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 058040013 Control Panel (Prior to MA295465D) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 056076152 Socket, Dinse 50 Sq Mm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Part No. Description Item No. Figure 7-2. Main Assembly (continued) Quantity Dia. Mkgs. 13 356029223 Nameplate, Lower, STR 450/450 C 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 056076267 Connector kit, 14 Pin Female+cover 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 058075014 Front Panel + Pcb Box 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 R1, R2 056059281 Resistor, 500 Ohm D16 L90 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 156006069 Base 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 FM1 057035009 Fan, 230 V, 110W 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 116117077 Conveyor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 156118073 Panel, Rear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 057014212 Cable, Primary Input 4 X10 Mt.4,5 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 956142610 Nameplate, Rear, 48V 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 056076212 Outlet, 32 A 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 656081027 Rubber boot 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 000175282 Cover Receptacle Duplex 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 RCPT1 000604176 Receptacle, 115VAC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 CB1 056067263 Breaker, Circuit 32 A 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 CB2 056067264 Breaker, Circuit 10 A 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 656089026 Clamp, Cable, D30 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 S1 056067210 Switch, 32 A 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 956142611 Nameplate, Rear, 115VAC 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. � Hardware is common and not available unless listed. 956142737_4-5_C 6 5 1 2 3 4 Figure 7-3. Front Panel Part No. Description Item No. Figure 7-3. Front Panel Quantity Dia. Mkgs. 1 000207075 Knob, pointer 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 756029012 Nameplate, upper, front 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 116145012 Plate, pcb support (Eff. with MA295465D) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 116145010 Plate, pcb support (Prior to MA295465D) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 R3 056059282 Potentiometer 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PC2 057084132 PCB, digital meter board 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 PC1 057084133 PCB, main board 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor.

Pros weld and cut safely. Read the safety rules at the beginning of this manual.

Pros weld and cut safely. Read the safety rules at the beginning of this manual.

(Equipment with a serial number preface of MB or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the terms and conditions below, ITW Welding Products Italy warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date the equipment was delivered to the original retail purchaser or one year after the equipment is shipped to a European distributor or eighteen months after the equipment is shipped to an International distributor. 1. 5 Years Parts — 3 Years Labor * Original main power rectifiers only to include SCRs, diodes, and discrete rectifier modules 2. 3 Years — Parts and Labor * Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) * HF Units * Inverter Power Sources (Unless Otherwise Stated) * Process Controllers * Semi-Automatic and Automatic Wire Feeders * Transformer/Rectifier Power Sources 3. 2 Years — Parts * Auto-Darkening Helmet Lenses (No Labor) * Migmatic 171 4. 1 Year — Parts and Labor Unless Specified * Automatic Motion Devices * Field Options (NOTE: Field options are covered under True Blue® for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.) * Induction Heating Power Sources, Coolers, and Electronic Controls/Recorders * Motor Driven Guns (w/exception of Spoolmate Spoolguns) * Positioners and Controllers * Powered Air Purifying Respirator (PAPR) Blower Unit (No Labor) * Racks * Running Gear and Trailers * Subarc Wire Drive Assemblies * Water Coolant Systems (Hydramate 1 and 2) * Water Coolant Systems (USA Models, Non-Integrated) * Work Stations/Weld Tables (No Labor) 5. 6 Months — Parts * Batteries 6. 90 Days — Parts * Accessory (Kits) * Canvas Covers * Induction Heating Coils and Blankets * MIG Guns * Remote Controls * Replacement Parts (No Labor) * Spoolmate Spoolguns Miller’s True Blue® Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, switches, slip rings, relays or parts that fail due to normal wear. 2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any. 3. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment. MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at ITW Welding Products Group Europe or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER.

© 2011 Miller Electric Mfg. Co. 2011−01 ITW Welding Products Italy S.r.l. Via Privata Iseo, 6/E 20098 San Giuliano Milanese, Italy Phone: 39 (0) 2982901 Fax: 39 (0) 298290-203 email: miller@itw−welding.it Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address Country Zip/Postal Code Please complete and retain with your personal records. Owner’s Record Always provide Model Name and Serial/Style Number. Contact a DISTRIBUTOR or SERVICE AGENCY near you. Welding Supplies and Consumables Options and Accessories Service and Repair Replacement Parts Owner’s Manuals Contact the Delivering Carrier to: For Service 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. Contact your Distributor for: