Miller AFV-2 User manual

AFV-2 Auto Flux Valve
Processes
Description
OM-1101A August1993
Automatic Flux Valve
Automatic Welding
Submerged Arc (SAW) Welding
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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. To locate your nearest
distributor or service agency call 1-800-4-A-Miller,
or visit us at www.MillerWelds.com on the web.
Thank you and congratulations on choosing Miller. Now
you can get the job done and get it done right. We know
you don’t have time to do it any other way.
That’s why when Niels Miller first started building arc
welders in 1929, he made sure his products offered
long-lasting value and superior quality. Like you, his
customers couldn’t afford anything less. Miller products
had to be more than the best they could be. They had to
be the best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy.
With Miller you can count on years of reliable
service with proper maintenance. And if for
some reason the unit needs repair, there’s a
Troubleshooting section that will help you
figure out what the problem is. The 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.
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equipment manufacturer in
the U.S.A. to be registered to
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Milleroffers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.

Miller offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMAW-P.
For practical information on
welding, process applica-
tions, and Miller products,
visit our website at
www.millerwelds.com
Call
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TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. General Information And Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Safety Alert Symbol And Signal Words 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 – SPECIFICATIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Description 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 – INSTALLATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Installation Of Automatic Flux Valve On GA-80AC1 Using A Pressurized Flux
Delivery System 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Installation Of Automatic Flux Valve On GA-80AC1 Using A Gravity Flux Delivery System 2
3-3. Installation Of Automatic Flux Valve On GA-80AC1 Using A Remote Mount 2. . . . . . . . . . . . .
3-4. Transformer Installation In Automatic 1, 1D, And System 9 Gas Control Boxes 2. . . . . . . . . .
3-5. Transformer Installation In Automatic 2 Shunt Control 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – MAINTENANCE 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. V-Seal Replacement 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 – ELECTRICAL DIAGRAMS 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagram 5-1. Circuit Diagram 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 – PARTS LIST 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY

OM-1101 Page 1
SECTION 1 –SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1. GENERAL INFORMATION AND SAFETY
A. General
Information presented in this manual and on various la-
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed for the safe and effective use of this equipment.
B. Safety
The installation, operation, maintenance, and trouble-
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in-
stalled, operated, and maintained only by qualified per-
sons in accordance with this manual and all safety pre-
cautions listed in the Arc Welding Safety Precautions in
the welding power source Owner’s Manual.
1-2. SAFETY ALERT SYMBOL AND SIGNAL
WORDS
The following safety alert symbol and signal words are
used throughout this manual to call attention to and
identify different levels of hazard and special instruc-
tions. This safety alert symbol is used with the signal
words WARNING and CAUTION to call atten-
tion to the safety statements.
WARNING statements identify procedures or
practices which must be followed to avoid seri-
ous personal injury or loss of life.
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip-
ment.
SECTION 2 –SPECIFICATIONS
4 in.
(102 mm)
Inlet
5-1/2 in.
(140 mm)
1/2 in.
(12.7 mm)
Outlet
ST-099 439-A
2-3/4 in
(70 mm)
Figure 2-1. Dimensional Drawing
2-1. DESCRIPTION
The AFV-2 is a 24 volts dc, manual or fully automatic,
gravity or pressurized feed flux valve designed for re-
mote mounting or direct installation onto a GA-80AC1
gun.
Table 2-1. Specifications
Weight
Model Rated Volts Net Ship
AFV-2 24 vdc 3 lbs.
(1.4 kg) 7 lbs. (3.2 kg)

OM-1101 Page 2
SECTION 3 –INSTALLATION
WARNING: ELECTRIC SHOCK can kill.
•Do not touch live electrical parts.
•Shut down unit and, and disconnect input
power employing lockout/tagging proce-
dures before installing valve or transformer.
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon-
necting device.
3-1. INSTALLATION OF AUTOMATIC FLUX
VALVE ON GA-80AC1 USING A PRESSUR-
IZED FLUX DELIVERY SYSTEM (Figure 2-1
And Figure 3-1)
1. Remove hose clamps, flux inlet adapter tube and
bushing.
Outlet
Guide
Gun/Feeder
Connector
Head
Tube Hose
Clamp
Bushing
Flux Inlet
Adapter Tube
Hose Clamp
Ring Tube
Flux Clamp
O-Ring
Flux Valve
Flux Inlet
Tube
Nozzle
Contact Tube
Adapter
Contact
Tube
Guide
ST-049 177-D
Figure 3-1. GA-80AC1 Models
2. Loosen set screw and remove ring tube flux
clamp, o-ring and flux valve.
3. Reinstall hose clamp on flux inlet tube.
4. Slide outlet of flux valve inside flux inlet tube of
gun, and tighten hose clamps.
5. Reinstall flux inlet adapter tube to inlet of flux
valve; install and tighten clamp.
6. Install flux delivery hose in bushing, install hose
clamp over bushing and flux inlet adapter tube.
7. Install bushing on delivery hose and tighten hose
clamp.
3-2. INSTALLATION OF AUTOMATIC FLUX
VALVE ON GA-80AC1 USING A GRAVITY
FLUX DELIVERY SYSTEM (Figure 2-1 And
Figure 3-1)
1. Remove hose clamps, flux inlet adapter tube and
bushing.
2. Loosen set screw and remove ring tube flux
clamp, o-ring and flux valve.
3. Reinstall hose clamp on flux inlet tube.
4. Slide outlet of flux valve (see Figure 2-1) inside
flux inlet tube of gun, and tighten hose clamps.
5. Install hose clamp on flux inlet tube.
6. Slide flux delivery hose over flux valve inlet and
tighten hose clamp.
3-3. INSTALLATION OF AUTOMATIC FLUX
VALVE ON GA-80AC1 USING A REMOTE
MOUNT
1. Select mounting bracket (not provided) no more
than 1/4 in (6.3 mm) thick with a pair of vertically
aligned 11/32 in ( 8.7 mm) diameter holes, 3 in
(76.2 mm) apart.
2. Remove strain relief clamp from flux valve body
(see Figure 4-3). Retain all hardware.
3. Replace outlet connector with extra connector
provided.
4. Mount valve to bracket using muffler clamp pro-
vided.
5. Route valve lead over clamp and reinstall strain
relief clamp.
6. Install hose clamp on flux delivery hose, and slide
flux delivery hose over flux valve inlet. Tighten
hose clamp.
7. Install hose clamp over outlet hose and slide flux
outlet hose over flux valve outlet. Tighten hose
clamp.
3-4. TRANSFORMER INSTALLATION IN AUTO-
MATIC 1, 1D, AND SYSTEM 9 GAS CONTROL
BOXES (Figure 3-2)
1. Remove wrapper from Gas Control Box.
IMPORTANT: All supplied parts may not be required for
every installation. Mounting holes are provided effective
with Serial No. JF880450.

OM-1101 Page 3
2. Use supplied transformer bracket as a template
and position parallel to 1/4 NPT x 6 pipe-nipple fit-
ting near rear of unit. Mark position of mounting
holes on bottom of case.
CAUTION: METAL FILINGS AND/OR TOOL
CONTACT WITH INTERNAL COMPONENTS
can damage unit.
•Cover internal components.
•Clean unit and remove internal covering ma-
terial before resuming operation.
3. Remove transformer bracket and drill or punch
two 5/32 in (4 mm) mounting holes at marked lo-
cations.
4. Use supplied hardware to mount transformer
bracket to bottom of case.
5. Place flux valve transformer T50 with leads to-
ward gas valve side of control on bracket, and se-
cure transformer to bracket with supplied hard-
ware.
6. Use supplied integrated rectifier SR50 as a tem-
plate, and position forward of flux valve trans-
former. Mark location of mounting hole on bottom
of case.
CAUTION: METAL FILINGS AND/OR TOOL
CONTACT WITH INTERNAL COMPONENTS
can damage unit.
•Cover internal components.
•Clean unit and remove internal covering ma-
terial before resuming operation.
7. Remove rectifier and drill or punch a 5/32 in
(4mm) mounting hole at marked location.
8. Install and secure rectifier with supplied hard-
ware.
9. Remove 7/8 in (22 mm) snap-in blank from front
panel and install supplied cable clamp.
10. Route female friction connector ends of supplied
10 ft (3 m) cord through cable clamp, and attach
female friction connector of white lead to positive
(+) terminal and black lead to negative (–) termi-
nal of installed rectifier SR50.
11. Insert plug PLG50 on remaining end of 10 ft ( 3 m)
cord in flux valve connector PLG51.
12. Tighten cable clamp.
13. Locate two supplied 3-1/2 in (89 mm ) long leads
with male friction connectors at other end. Install
male friction connectors to primary (black) leads
4 and 6 of transformer T50.
14. Disconnect two leads from gas valve, and install
piggyback connectors of primary transformer
leads (black) on gas valve terminals.
15. Reinstall gas valve leads on piggyback connec-
tors.
16. Install female friction connectors from transform-
er secondary (blue) leads 100 and 101 to AC ter-
minals on rectifier SR50.
17. Reinstall wrapper.
Receptacle
RC50
Shunt
To Welding Power
Source Output
Terminal
SR50
Intergrated
Rectifier
To Weld Cable
Terminal On Wire
Drive Housing
T50 Flux Valve
Transformer
Gas In
Fitting
Weld Cable
In Opening In Panel Bracket
AUTOMATIC 1 GAS CONTROL
Gas Control
Receptacle
SR50
Intergrated
Rectifier T50 Flux Valve
Transformer
Bracket
Gas In
Fitting
Weld Cable
In Opening
AUTOMATIC 1D GAS CONTROL
In Panel
ST-080 484-B / ST-070 483-B
Figure 3-2. Gas Controls

OM-1101 Page 4
3-5. TRANSFORMER INSTALLATION IN AUTO-
MATIC 2 SHUNT CONTROL (Figure 3-3)
WARNING: ELECTRIC SHOCK can kill.
•Do not touch live electrical parts.
•Shut down unit, and disconnect input power
employing lockout/tagging procedures be-
fore installing transformer.
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon-
necting device.
IMPORTANT: All supplied parts may not be required for
every installation. Mounting holes are provided effective
with Serial No. JF880450.
1. Remove wrapper from Shunt Control.
2. Use supplied flux valve transformer T50 as a
template, and position directly behind the 115/36
volts control transformer (see Figure 3-3). Mark
location of mounting holes on bottom of case if
applicable.
CAUTION: METAL FILINGS AND/OR TOOL
CONTACT WITH INTERNAL COMPONENTS
can damage unit.
•Cover internal components.
•Clean unit and remove internal covering ma-
terial before resuming operation.
3. Remove transformer and drill or punch two 5/32
in (4 mm) mounting holes in marked positions if
applicable.
4. Install flux valve transformer with leads to rear of
case, and secure with supplied hardware.
5. Locate 3/16 in (4.7 mm ) predrilled hole located
toward front of shunt control (front of unit is end
with connecting receptacle) between the two
snap-in blanks.
6. Install rectifier SR50 and secure with supplied
hardware.
7. Locate two supplied 10 in (254 mm) long leads
with male and female friction connectors. Install
male ends of friction connectors to secondary
(blue) leads 100 and 101 of installed flux valve
transformer T50 (see Diagram 5-1).
8. Route leads to outside of mounting bracket, and
install female ends of friction connectors to AC
terminals of installed rectifier.
9. Remove snap-in blank directly below 16-pin re-
ceptacle on front panel, and install supplied cable
clamp.
10. Route female friction connector ends of supplied
10 ft (3 m) cord through cable clamp and attach
female friction connector of white lead to positive
(+) terminal and black lead to negative (–) termi-
nal of installed rectifier.
11. Insert connector cord plug PLG50 into flux valve
connector PLG51.
12. Tighten cable clamp.
13. Locate two supplied leads: one, 11 in (279 mm)
long and the other 10-1/4 in (260 mm ) long. The
10-1/4 in (260 mm) lead has a male friction con-
nector at one end and a pin connected on the op-
posite end. The 11 in (279 mm) lead has a male
friction connector at one end and no connector at
the other end.
14. Connect male friction connectors of these two
leads to female friction connectors on primary
(black) leads 4 and 6 installed transformer T50.
3-15/32 in.
12-3/32 in. 8-19/32 in.
Flux Valve
Transformer
Run leads to
outside of
mounting
bracket
ST-099 152-A
Figure 3-3. Shunt Control

OM-1101 Page 5
15. Route leads to the outside of mounting bracket
and install pin end of 10-1/4 in (260 mm) lead to
receptacle No. 3 of 16-pin receptacle on shunt
control. Push pin into receptacle until it locks into
place.
16. Use supplied tab connector to splice remaining
end of 11 in (279 mm) long lead to lead 4 from
16-pin receptacle on shunt control (see
Figure 3-4).
17. Use supplied cable ties to tie leads into wiring har-
ness.
WARNING: ELECTRIC SHOCK can kill.
•Do not touch live electrical parts.
•Shut unit down and disconnect input power by
employing lockout/tagging procedures be-
fore preforming this installation.
•Use connector only with insulated wire.
•Do not strip insulation.
•Use only recommended tool: 9 in (229 mm)
lineman’s pliers.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
Step 1 Step 2 Step 3 Step 4
Inspection
Port Tap Wire
Run
Wire 9 inch (229 mm)
Lineman’s
Pliers
Step 1 Place unstripped run wire inside
run channel.
Step 2 Close side cover until latched. In-
sert unstripped tap wire complete-
ly and check position in inspection
port.
Step 3 Make connection with pliers by
driving “U”contact down flush
with top of connector.
Step 4 Close hinged top cover until
latched. ST-106 486
Figure 3-4. Lead Installation In Tab Connector
SECTION 4 –MAINTENANCE
4-1. V-SEAL REPLACEMENT
WARNING: ELECTRIC SHOCK can kill.
•Do not touch live electrical parts.
•Shut down unit, and disconnect input power
employing lockout/tagging procedures be-
fore inspecting or installing.
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon-
necting device.
IMPORTANT: Retain all hardware removed during this
procedure for reinstallation unless specifically in-
structed otherwise.
1. Disconnect flux valve from connector cord and
remove flux valve from bracket or gun.
2. Remove strain relief clamp from valve body.
3. Remove inlet and outlet connectors from valve
body.
4. Remove 1/4-20 nuts from extension studs.
5. Remove handle and handle bushing from 3-5/16
in (84 mm) extension stud.
6. Separate valve body from rotary solenoid and re-
move o-ring.
7. Remove pin and v-seal from end of valve shaft.
8. Remove two 6-32 x 1/4 machine flange screws
from flux stop, and remove stop support and flux
stop from valve shaft.
9. Press valve shaft assembly from valve body.
10. Remove valve coupler pin, valve coupler, and
bushing.
11. Remove v-seals from valve shaft.
12. Install new v-seals with flanged end out.

OM-1101 Page 6
S-0840
Flanged
End
Figure 4-1. Flanged End of V-Seal
13. Reinstall bushing, valve coupler, and valve cou-
pler pin (see Figure 4-2).
V-Seal
Valve
Coupler
V-Seal
Off Set Pin
End Of Valve
Shaft Valve
Coupler
Pin
Bushing
Ref. ST-099 239-B
Handle
Pin
Figure 4-2. Valve Coupler Installation
IMPORTANT: Incorrectly installed valve shaft will not
operate properly. Ensure that valve coupler and valve
coupler pin are installed to offset pin end of valve shaft
as shown in Figure 4-2.
14. Press valve shaft assembly into valve body.
15. Reinstall flux stop and stop support to valve shaft
with two 6-32 x 1/4 machine flange screws re-
moved in Step 8.
16. Reinstall v-seal with flanged end in onto handle
end of valve shaft.
17. Reinstall handle pin in end of valve shaft assem-
bly.
18. Seat o-ring on rotary solenoid, reinstall valve
body to rotary solenoid, and secure with 1/4-20
nuts. Spring pin side of valve body aligns with
3-5/16 (84 mm) extension stud.
19. Reinstall handle bushing and handle on 3-5/16
(84 mm) extension stud. Curved groove in handle
fits over handle stop pin.
20. Reinstall inlet (large diameter opening) tube.
IMPORTANT: Inlet and outlet tubes are same size in re-
mote mount installation. Disregard Steps 20 and 21 in
remote mount applications.
21. Reinstall outlet (small diameter opening) tube.
22. Reinstall strain relief clamp on valve body.
23. Reconnect flux valve to bracket or gun.
24. Reconnect male terminal connector to cord con-
nector.
1/4-20
Nuts (Two)
Pin
Follower
Handle
Bushing
Inlet
Stop
Support
Flux
Stop
Valve
Shaft
Valve
Coupler
O-Ring
3-5/16 in. (84 mm)
Extension Stud
Rotary
Solenoid
2-11/16 in.
(68.3 mm)
Extension
Stud
Valve
Coupler
Pin
Bushing
Male
Terminal
Connector
V-Seal
Valve
Body
V-Seal
Outlet
Brass
Bushing Strain Relief
Clamp
V-Seal
Handle
Pin
Handle
Ref. ST-099 239-B
Stop
Pin
Figure 4-3. Valve Disassembly

OM-1101 Page 7
SECTION 5 –ELECTRICAL DIAGRAMS
Circuit Diagram No. SA-098 349-A
Diagram 5-1. Circuit Diagram

OM-1101 Page 8
SECTION 6 –PARTS LIST
123 4 5
6
78
910 11
12
13
14
7
15
16
17
18
19
20
21
22
24
25
Ref. ST-099 239-B
Figure 6-1. AFV-2 Auto Flux Valve
23
26
27
.Hardwareis common and
not available unless listed.

OM-1101 Page 9
Description Quantity
Part
No.
Figure 6-1. AFV-2 Auto Flux Valve
Item
No. Dia. Mkgs.
1 099 057 BUSHING, brass 9/32 ID x .340 OD x 3/4 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 059 926 PIN, spring 3/32 x 1 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 099 035 SEAL, V ring .160 ID 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 099 034 CLAMP, 1/8dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 099 212 CONNECTOR, outlet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 099 584 SHAFT, valve w/components (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 099 035 . SEAL, V ring .160 ID 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 099 209 . SHAFT, valve 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 099 215 . BUSHING, brass .749 OD x 1/4 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 010 837 . PIN, spring 3/32 x 5/8 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 099 214 . COUPLER, valve 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 099 224 SOLENOID, rotary (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 PLG51 048 280 . HOUSING PLUG & PINS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
058 971 . . TERMINAL, male 20-14ga 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14 081 958 . TUBING, 3/16dia (order by ft) 1ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 107 355 . SOLENOID, rotary 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16 099 216 . EXTENSION, stud mtg 2-11/16 inches 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17 099 217 . EXTENSION, stud mtg 2-5/16 inches 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
059 926 PIN, spring 3/32 x 1 inch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 107 624 O-RING, 2-1/4 ID x 0.070 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 099 218 STOP, flux 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 099 213 SUPPORT, strip 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 099 210 CONNECTOR, inlet 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 099 585 BODY, valve w/components (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 099 208 BODY, valve 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 010 837 PIN, spring 3/32 x 5/8 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 099 215 BUSHING, brass .749 OD x 1/4 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 099 457 PIN, follower 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27 099 456 HANDLE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLG50 048 281 RECEPTACLE w/SOCKETS, (consisting of) 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
058 972 . TERMINAL, female 20-14ga 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
604 525 CABLE, No. 18 2/c (order by ft) 11ft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115 104 CONNECTOR, clamp cable 1/2 inch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SR50 035 704 RECTIFIER, integ 40A 800V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T50 098 844 TRANSFORMER, control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
098 845 BRACKET, mtg transformer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
034 392 CLAMP, muffler 2-1/2 inch dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
010 859 CLAMP, hose 9/16 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 072 SCREW, truss hd 6-32 x 5/8 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
072 785 SCREW, hexwhd slt stl slffmg 6-32 x 3/8 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
602 199 WASHER, lock external tooth No. 6 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
601 859 NUT, hex 6-32 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
605 510 CABLE TIE, 0-3/4 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
106 456 CONNECTOR, tab 22-18 wire 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.

Notes

Warranty Questions?
Call
1-800-4-A-MILLER
for your local
Miller distributor.
miller_warr 7/00
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Effective January 1, 2000
(Equipment with a serial number preface of “LA”or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY –Subject to the terms and conditions
below, Miller Electric Mfg. Co., Appleton, Wisconsin, 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 that
the equipment was delivered to the original retail purchaser, or
one year after the equipment is sent to a North American
distributor or eighteen months after the equipment is sent to an
Internationaldistributor.
1. 5 Years Parts –3 Years Labor
* Original main power rectifiers
* Inverters (input and output rectifiers only)
2. 3 Years —Parts and Labor
* Transformer/Rectifier Power Sources
* Plasma Arc Cutting Power Sources
* Semi-Automatic and Automatic Wire Feeders
* Inverter Power Supplies
* Intellitig
* Engine Driven Welding Generators
(NOTE: Engines are warranted separately by
the engine manufacturer.)
3. 1 Year —Parts and Labor
* DS-2 Wire Feeder
* Motor Driven Guns (w/exception of Spoolmate
185 & Spoolmate 250)
* Process Controllers
* Positioners and Controllers
* Automatic Motion Devices
* RFCS Foot Controls
* Induction Heating Power Sources
* Water Coolant Systems
* HF Units
* Grids
* Maxstar 140
* Spot Welders
* Load Banks
* Miller Cyclomatic Equipment
* Running Gear/Trailers
* Plasma Cutting Torches (except APT & SAF
Models)
* Field Options
(NOTE: Field options are covered under True
Bluefor the remaining warranty period of the
product they are installed in, or for a minimum of
one year —whichever is greater.)
4. 6 Months —Batteries
5. 90 Days —Parts
* MIG Guns/TIG Torches
* Induction Heating Coils and Blankets
* APT, ZIPCUT & PLAZCUT Model Plasma Cutting
Torches
* Remote Controls
* Accessory Kits
* Replacement Parts (No labor)
* Spoolmate 185 & Spoolmate 250
* Canvas Covers
Miller’s True BlueLimited Warranty shall not apply to:
1. Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, slip rings,
relays or parts that fail due to normal wear.
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
depreciationbased upon actual use) upon return of the goods
at customer’s risk and expense. Miller’s option of repair or
replacementwill be F.O.B., Factory at Appleton, Wisconsin, or
F.O.B. at a Miller authorized service facility as determined by
Miller. Therefore no compensation or reimbursement for
transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES.IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR
ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE
OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL
EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND
DISCLAIMEDBY MILLER.
Some states in the U.S.A. do not allow limitations of how long
an implied warranty lasts, or the exclusion of incidental,
indirect, special or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty
provides specific legal rights, and other rights may be
available,but may vary from state to state.
In Canada, legislation in some provinces provides for certain
additionalwarranties or remedies other than as stated herein,
and to the extent that they may not be waived, the limitations
and exclusions set out above may not apply. This Limited
Warranty provides specific legal rights, and other rights may
be available, but may vary from province to province.

PRINTED IN USA 2000 Miller Electric Mfg. Co. 6/00
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
International Headquarters–USA
USA Phone: [phone] Auto-Attended
USA & Canada FAX: [phone]
International FAX: [phone]
European Headquarters –
United Kingdom
Phone: [phone]
FAX: [phone]
www.MillerWelds.com
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
City
State Zip
Please complete and retain with your personal records.
Always provide Model Name and Serial/Style Number.
Call 1-800-4-A-Miller or see our website at www.MillerWelds.com
to locate a DISTRIBUTOR or SERVICE AGENCY near you.
Welding Supplies and Consumables
Options and Accessories
Personal Safety Equipment
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information
and Parts)
Circuit Diagrams
Welding Process Handbooks
Contact the Delivering Carrier for:
For assistance in filing or settling claims,
contact your distributor and/or equipment
manufacturer’s Transportation Department.
For Service
Owner’s Record
File a claim for loss or damage during
shipment.
Contact your Distributor for: