Unitor UWF-SC12RC User manual

UWF-SC12RC
OM-215 092 210 177A
August 2005
Processes
Description
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Wire Feeder

TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Warning Label Definitions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Manufacturer’s Rating Label For CE Products 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Symbols And Definitions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Specifications 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. 14-Pin Plug Information 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Equipment Connection Diagram 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Gun Recommendation Table 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Consumable Parts and Spares for the T-400 MP Torch 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Installing And Aligning Wire Guide And Drive Rolls 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Connecting Welding Gun 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Connecting Shielding Gas 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Connecting Weld Cable 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Installing And Threading Welding Wire 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Setting Digital Meter Board PC4 DIP Switches 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE & TROUBLESHOOTING 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Overload Protection And Thermostat Protection 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Troubleshooting 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAMS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7− PARTS LIST 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY

dec_wire_6/05
Declaration of Conformity for
European Community (CE) Products
This information is provided for units with CE certification (see rating label on unit).
NOTE
Manufacturer:European Contact:
Miller Electric Mg. Co. Mr. Danilo Fedolfi,
1635 W. Spencer St. Managing Director
Appleton, WI 54914 USA ITW Welding Products Italy S.r.l.
Phone: [phone] Via Privata Iseo 6/E
20098 San Giuliano
Milanese, Italy
Phone: [phone]
Fax: [phone]
European Contact Signature:
Declares that the product: UWF-SC12RC
conforms to the following Directives and Standards:
Directives
Low Voltage Directive: 73/23/EEC
Electromagnetic Compatibility (EMC) Directive: 89/336/EEC
Machinery Directives: 98/37/EEC, 91/368/EEC, 92/31/EEC, 133/04, 93/68/EEC
Standards
Arc Welding Equipment − Part 5: Wire Feeders. IEC 60974-5 Ed. 1
Arc Welding Equipment − Part 10: Electromagnetic Compatibility (EMC) Requirements. IEC 60974-10 August 2002
Arc Welding Equipment − Part 1: Welding Power Sources. IEC 60974-1 Ed. 2.1
Degrees Of Protection Provided By Enclosure (IP Code) IEC 60529 Ed. 2.1
Insulation Coordination For Equipment Within Low-Voltage Systems −
Part 1: Principles, Requirements and Tests: IEC 60664-1 Ed. 1.1
The product technical file is maintained by the responsible Business Unit(s) located at the manufacturing facility.

OM-215 092 Page 1
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som _3/05
YWarning: Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
MeansWarning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
YMarks a special safety message.
.Means “Note”; not safety related.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consultsymbols and related instructions below for necessary actions
to avoid the hazards.
1-2. Arc Welding Hazards
YThe 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.
YOnly qualified persons should install, operate, maintain, and
repair this unit.
YDuring operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touchinglive electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electricallylive 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
groundedequipment is a hazard.
DDo not touch live electrical parts.
DWear dry, hole-free insulating gloves and body protection.
DInsulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
DDo not use AC output in damp areas, if movement is confined, or if
thereis a danger of falling.
DUse AC output ONLY if required for the welding process.
DIf AC output is required, use remote output control if present on
unit.
DAdditionalsafety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locationsor 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-
ableor accidental contact with the workpiece or ground. For these
conditions,use the following equipment in order presented: 1) a
semiautomaticDC 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!
DDisconnect 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).
DProperly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
DAlways verify the supply ground − check and be sure that input
powercord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
groundedreceptacle outlet.
DWhenmaking input connections, attach proper grounding conduc-
tor first − double-check connections.
DFrequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
DTurn off all equipment when not in use.
DDo not use worn, damaged, undersized, or poorly spliced cables.
DDo not drape cables over your body.
DIf earth grounding of the workpiece is required, ground it directly
with a separate cable.
DDo not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
DDo not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
DUse only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
DWear a safety harness if working above floor level.
DKeep all panels and covers securely in place.
DClamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
DInsulate work clamp when not connected to workpiece to prevent
contact with any metal object.
DDo not connect more than one electrode or work cable to any
singleweld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter-type
welding power sources after removal of input
power.
DTurn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
beforetouching any parts.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
DKeep your head out of the fumes. Do not breathe the fumes.
DIf inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
DIf ventilation is poor, wear an approved air-supplied respirator.
DRead and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings,cleaners, and degreasers.
DWork in a confined space only if it is well ventilated, or while
wearingan 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.
DDo 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.
DDo not weld on coated metals, such as galvanized, lead, or
cadmiumplated steel, unless the coating is removed from the weld
area,the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.

OM-215 092 Page 2
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.
ARC RAYS can burn eyes and skin.
DWear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes when welding or watching
(see ANSI Z49.1 and Z87.1 listed in Safety Standards).
DWear approved safety glasses with side shields under your
helmet.
DUse protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
DWear protective clothing made from durable, flame-resistant mate-
rial (leather, heavy cotton, or wool) and foot protection.
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.
DRemove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
DDo not weld where flying sparks can strike flammable material.
DProtect yourself and others from flying sparks and hot metal.
DBe alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
DWatch for fire, and keep a fire extinguisher nearby.
DBe aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
DDo not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
DConnect 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.
DDo not use welder to thaw frozen pipes.
DRemove stick electrode from holder or cut off welding wire at
contact tip when not in use.
DWear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
DRemove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
DFollowrequirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL can injure eyes.
DWelding,chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
DWear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
DShut off shielding gas supply when not in use.
DAlways ventilate confined spaces or use
approvedair-supplied respirator.
HOT PARTS can cause severe burns.
DDo not touch hot parts bare handed.
DAllow cooling period before working on gun or
torch.
DTo handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothingto prevent burns.
MAGNETIC FIELDS can affect pacemakers.
DPacemaker wearers keep away.
DWearers should consult their doctor before
going near arc welding, gouging, or spot
weldingoperations.
NOISE can damage hearing.
Noise from some processes or equipment can
damagehearing.
DWear 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.
DProtect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
DInstall cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
DKeepcylinders away from any welding or other electrical circuits.
DNever drape a welding torch over a gas cylinder.
DNever allow a welding electrode to touch any cylinder.
DNever weld on a pressurized cylinder − explosion will result.
DUse only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
associatedparts in good condition.
DTurn face away from valve outlet when opening cylinder valve.
DKeepprotective cap in place over valve except when cylinder is in
use or connected for use.
DUse the right equipment, correct procedures, and sufficientnum-
ber of persons to lift and move cylinders.
DRead and follow instructions on compressed gas cylinders,
associatedequipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.

OM-215 092 Page 3
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
DDo not install or place unit on, over, or near
combustiblesurfaces.
DDo not install unit near flammables.
DDo not overload building wiring − be sure power supply system is
properlysized, rated, and protected to handle this unit.
FALLING UNIT can cause injury.
DUse lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
DUse equipment of adequate capacity to lift and
supportunit.
DIf using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
OVERUSE can cause OVERHEATING
DAllow cooling period; follow rated duty cycle.
DReduce current or reduce duty cycle before
startingto weld again.
DDo not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
DPut on grounded wrist strap BEFORE handling
boards or parts.
DUse proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can cause injury.
DKeep away from moving parts.
DKeep away from pinch points such as drive
rolls.
WELDING WIRE can cause injury.
DDo not press gun trigger until instructed to do
so.
DDo not point gun toward any part of the body,
other people, or any metal when threading
weldingwire.
MOVING PARTS can cause injury.
DKeep away from moving parts such as fans.
DKeep all doors, panels, covers, and guards
closed and securely in place.
DHave only qualified persons remove doors,
panels,covers, or guards for maintenance as
necessary.
DReinstall doors, panels, covers, or guards
when maintenance is finished and before re-
connectinginput power.
READ INSTRUCTIONS.
DRead Owner’s Manual before using or servic-
ing unit.
DUse only genuine Miller/Hobart replacement
parts.
H.F. RADIATION can cause interference.
DHigh-frequency(H.F.) can interfere with radio
navigation, safety services, computers, and
communicationsequipment.
DHave only qualified persons familiar with
electronicequipment perform this installation.
DThe user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
DIf notified by the FCC about interference, stop using the
equipmentat once.
DHave the installation regularly checked and maintained.
DKeephigh-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimizethe possibility of interference.
ARC WELDING can cause interference.
DElectromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
DBe sure all equipment in the welding area is
electromagneticallycompatible.
DTo reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
DLocate welding operation 100 meters from any sensitive elec-
tronic equipment.
DBe sure this welding machine is installed and grounded
accordingto this manual.
DIf 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
YWelding 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.)
YBattery 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
reproductiveharm. Wash hands after handling.
For Gasoline Engines:
YEngine exhaust contains chemicals known to the State of
Californiato cause cancer, birth defects, or other reproductive
harm.
For Diesel Engines:
YDieselengine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.

OM-215 092 Page 4
1-5. Principal Safety Standards
SafetyinWelding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: [phone], website:
www.global.ihs.com).
Recommended Safe Practices for the Preparation for Weldingand Cut-
ting of Containers and Piping, American Welding Society Standard
AWS F4.1 from Global Engineering Documents (phone:
1-877-413-5184,website: www.global.ihs.com).
NationalElectrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, P.O. Box 9101, 1 Battery March Park, Quincy, MA
02269−9101(phone: 617−770−3000, website: www.nfpa.org).
SafeHandling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 1735 Jefferson Davis Highway,
Suite 1004, Arlington, VA 22202−4102 (phone: 703−412−0900, web-
site: www.cganet.com).
Code for Safety in Welding and Cutting, CSA Standard W117.2, from
Canadian Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3 (phone:
800−463−6727or in Toronto 416−747−4044, website: www.csa−in-
ternational.org).
Practice For Occupational And Educational Eye And Face Protection,
ANSI Standard Z87.1, from American National Standards Institute, 11
West 42nd Street, New York, NY 10036−8002 (phone: 212−642−4900,
website:www.ansi.org).
Standardfor Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
P.O. Box 9101, 1 Battery March Park, Quincy, MA 02269−9101 (phone:
617−770−3000,website: www.nfpa.org).
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 (there
are 10 Regional Offices−−phone for Region 5, Chicago, is
312−353−2220,website: www.osha.gov).
1-6. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Weldingcurrent, as it flows through welding cables, will cause electro-
magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power-
frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined.Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
weldingor cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from opera-
tor as practical.
5. Connect work clamp to workpiece as close to the weld as possi-
ble.
About Pacemakers:
Pacemaker wearers consult your doctor before welding or going near
weldingoperations. If cleared by your doctor, then following the above
procedures is recommended.

OM-215 092 Page 5
SECTION 2 − DEFINITIONS
2-1. Warning Label Definitions
1 1.1 1.2 1.3
3 3.1 3.2 3.3
4 4.1 +
22.1 2.2
+
+
56
+
2.3
S-178 936
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
Drive rolls can injure fingers
Welding wire and drive parts are at
weldingvoltage during operation −
keep hands and metal objects
clear.
1 Electric shock 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. Don’t weld near
flammables.
3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby and have a watch
person 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.

OM-215 092 Page 6
2-2. Manufacturer’s Rating Label For CE Products
For label location
see Section 4-1.
S/N:
24
10.0 Hz50/60
IP 23
V100 A500 X 100 %
MILLER ELECTRIC MFG. CO., APPLETON, WI USA
V
U1
=A
I1=1
U2
=I2=
2-3. Symbols And Definitions
Some symbols are found only on CE products.
NOTE
Output Input AAmperes VVolts
X
Duty Cycle Wire Feed Percent
IP
Degree Of Protec-
tion
Input Cold Jog (Inch) To-
wards Workpiece Purge By Gas Fast
Constant Current Circuit Breaker Constant Voltage Slow
Trigger Hold Off Trigger Hold On I2Rated Welding
Current Increase
Read Instructions U1Primary Voltage U2Conventional Load
Voltage Hz Hertz
I1Primary Current
SECTION 3 − INSTALLATION
3-1. Specifications
Type of
Input
Power
Welding
Power
Source
Type
Wire Feed
Speed
Range
Wire
Diameter
Range
Input
Welding
Circuit
Rating
IP
Rating
Max. Wire
Spool
Capacity
Overall
Dimensions Weight
24 Volts AC
Single Phase
10 Amperes
50/60 Hz
Constant
Voltage (CV)
DC With
14-Pin And
Contactor
Control
50 to 700 ipm
(1.3 To 17.8
mpm) .023 To 5/64 in
(0.6 To 2 mm)
100 Volts,
500
Amperes,
100%
Duty Cycle
23 30 lb (13.6
kg),
12 in (304
mm)
Length: 20 in
(508 mm)
Width: 8 in
(203 mm)
Height: 15-1/2 in
(394 mm)
25.5 lb
(11.6 kg)

OM-215 092 Page 7
3-2. 14-Pin Plug Information
Pin* Pin Information
A24 volts ac with respect to socket G.
AJ K
BContact closure to A completes 24 volts ac contactor control circuit.
AJ
B
K
I
L
GCircuit common for 24 volts AC circuit.
C
L
NH
D
M
G
C+10 volts dc input from power source to wire feeder with respect to socket D.
D
M
GE
FDRemote control circuit common.
E
F
E0 to +10 volts dc output signal from wire feeder to power source with respect to socket D.
HVoltage feedback; 0 to +10 volts dc, 1 volt per 10 arc volts.
FCurrent feedback; 0 to +10 volts dc, 1 volt per 100 amperes.
*The remaining pins are not used.
3-3. Equipment Connection Diagram
804 207-A
1 ConstantVoltage (CV)
Welding Power Source
Supplying 24 VAC To Feeder
Use optional PSA-2 adapter for
power sources having only 115
VAC supply.
2 Negative (−) Weld Cable
3 Positive (+) Weld Cable
4 Workpiece
5 Interconnecting Cord
(Customer Supplied)
6 14-Pin Plug And Cord
7 Wire Feeder
8 Gun
9 Gun Trigger Receptacle
10 Gas Hose
11 Gas Cylinder
.Shielding gas pressure not to
exceed 90 psi (620 kPa).
1
2
3
45
6
7
8
9
10
11

OM-215 092 Page 8
3-4. Gun Recommendation Table
Process Gun
GMAW − Hard or Cored Wires T-400 MP
FCAW − Self-Shielding Wires T-400 MP + torch neck for self-sheilding wire
3-5. Consumable Parts and Spares for the T-400 MP Torch
The torch has adjustable neck and
is delivered complete with tools for
neck adjustment and contact tip
change. It is delivered with 3 m
cable,complete with liner and con-
tact tips for 0.8–1.2 mm wire. The
teflonliner allows for all wire types
including aluminium.
2
B
A
9 8 7 5
3
1
4
610
A
B
Pos. Description Qty. Unit Product no.
1Wire torch for T-400 MP for gas shielded wire with 3 m cable and con-
nector with 1.2 mm contact tip and steel liner (1.2 − 1.4 mm). pcs 193-607451
2Torch neck 160 mm for self-shileded wire. To be mounted on wire
torch T-400 MP handle. pcs 193-607452
3Torch neck 300 mm for self-shileded wire. To be mounted on wire
torch T-400 MP handle. pcs 193-607453
4Tip insulation cup for self-shileded neck. pcs 193-607454
5Gas nozzle for torch. pcs 193-613765
6Contact tips −
0.8 mm
1.0-1.2 mm
1.2-1.4 mm
1.6-2.0 mm
10
10
10
10
set
set
set
set
193-594622
193-594630
193-607455
193-607456
7Nozzle insulator. 5 set 193-613766
8Gas diffuser for T-400. 5 set 193-613763
9Neck insualtor for T-400. 5 set 193-613764
10 Torch liner, Teflon for 0.8-1.2 mm wire 4.5 m long.
Torch liner, Steel for 0.8-1.2 mm wire (blue) 3.0 m long.
Torch liner, Steel for 3 m for 1.4-2.0 mm wire (red) 3.0 m long
pcs
pcs
pcs
193-594606
193-594614
193-607457

OM-215 092 Page 9
3-6. Installing And Aligning Wire Guide And Drive Rolls
804 210-A
Installing Wire Guide And Drive
Rolls:
1 Drive Roll Nut
2 Drive Roll Carrier
Turn nut one click until lobes of nut
line up with lobes of drive roll carrier.
3 Drive Roll
Slidedrive roll onto drive roll carrier.
Turn nut one click.
Repeatprocedure for top drive roll.
4 Inlet Wire Guide Screw
5 Inlet Wire Guide
Loosen securing screw. Install inlet
guide so inlet guide screw is
centeredingroove in guide, or so tip
is as close to drive rolls as possible
withouttouching. Tighten screw.
Aligning Wire Guide And Drive
Rolls:
View is from top of drive rolls look-
ing down with pressure assembly
open.
6 Drive Roll Securing Nut
7 Drive Roll
8 Wire Guide
9 Welding Wire
10 Drive Gear
Turn screw in or out until drive roll
groovelines up with wire guide.
Close pressure roll assembly.
Only bottom drive roll alignment is
adjustable. Turn adjustment screw
in or out until groove in drive roll
lines up with wire guide as shown.
Cleaning Drive Rolls:
Remove drive rolls, and clean
grooves using a wire brush.
Tools Needed:
3/16 in
Aligning Wire Guide And Drive Rolls
Correct Incorrect
8
7
6
10
3/8 in
2
34
5
Installing Wire Guide
And Drive Rolls
9
1

OM-215 092 Page 10
3-7. Connecting Welding Gun
804 209-A
1 Gun Securing Knob
2 Gun Block
3 Gun Outlet Wire Guide
Loosen knob, insert gun end into
block. Position outlet wire guide as
close as possible to drive rolls with-
out touching. Tighten knob.
4 Gun Trigger Plug
5 Gun Trigger Receptacle
Internal Side View
5
4
3
1
2
3-8. Connecting Shielding Gas
804 208-A
1 Gas Hose With 5/8-18
Right-hand Thread Fittings
(Customer Supplied)
2 Shielding Gas Cylinder
.Shielding gas pressure not to
exceed 90 psi (620 kPa).
3 Valve
4 Flowmeter
5 14-Pin Plug
Close valve on cylinder when fin-
ished welding.
Tools Needed:
5/8 in 1
Rear View
2
34
5

OM-215 092 Page 11
3-9. Connecting Weld Cable
804 211-A
1 User-SuppledWeld Cable
Follow wire manufacturer’s recom-
mendations for weld cable polarity.
2 User-Suppled Male Connector
3 User-Suppled Female
Connector
Push female connector over male
connector, and turn 1/4 turn clock-
wise.
2
1
3
From Wire Feeder
3-10. Installing And Threading Welding Wire
804 212-A
Installing Wire And Adjusting
Hub Tension:
1 Retaining Nut
2 Hub Tension Adjustment
Screw
Remove retaining ring, and install
spool so hub pin fits spool hole. Re-
installretaining nut.
Adjust tension nut so only a slight
force is needed to turn spool.
Threading Welding Wire:
3 Pressure Assembly
Adjustment Knob
Lay gun cable out straight.
Open pressure assembly, hold wire
tightly, and cut off end. Push wire
throughguides into gun.
Close and tighten pressure assem-
bly. Press Jog switch until wire
comes out gun.
Feedwire against wooden surface,
and tighten knob so wire does not
slip.
Cut off wire, and close door.
Tools Needed:
9/16 in
Pull and hold wire; cut off end.
Hold wire tightly to keep it
from unraveling.
6 in
(150 mm)
12
3
WOOD
Tighten
Clockwise

OM-215 092 Page 12
SECTION 4 − OPERATION
4-1. Controls
804 213-A
InternalControl Panel
Internal Side View
1 Power Control Switch
2 Trigger Hold Switch (Optional)
Depress the upper part of the switch
(turns trigger hold On) to weld without
holding gun trigger throughout the
weld cycle.
To start weld, press and release gun
trigger. To end weld, press and re-
lease gun trigger.
Depress the lower part of the trigger
hold switch to turn trigger hold Off.
3 Purge Switch
Press switch to momentarily energize
gas solenoid and purge air from gun,
and to adjust shielding gas regulator.
4 Meter Display (Optional)
5 Volts, Wire Feed Speed Or
Amps Select Switch (Optional)
.Meter is factory set to display
voltage and wirefeed speed. To
displayvoltage and amps refer to
Section 4-2 for DIP switch set-
tings.
6 VoltageControl
7 Wire Speed Control
Use control to adjust wire speed with-
in range selected by switch.
8 Jog Switch
Use Jog position to momentarily feed
welding wire at speed set on Wire
Speed control without energizing
weldingcircuit or shielding gas valve.
Close and latch door.
67
OFF
ON
31
4
5
2
POWERPURGE
VOLTAGE WIRE SPEED
JOG
8
Front Panel

OM-215 092 Page 13
4-2. Setting Digital Meter Board PC4 DIP Switches
803 141/ Ref. 803 124
1 FrontMeter Panel
2 S1 DIP Switch
3 S2 DIP Switch
If the DIP switches are set to a Meter
Hold (ON) position, the meter value
will hold 5 seconds after gun is trig-
gered.The meter value will continue
to hold for 8 seconds after trigger is
released or until gun is re-triggered.
.When using power sources
without 14 pin voltage/current
feedback − optional remote
voltage/current kit 195194 is
required.
Indicatesthis DIP switch setting has
no effect on this function.
14 Pin
Voltage
Feedback
1
3Meter DIP switches are
factory set to display wirefeed
speed and voltage using 14 pin
feedback. Meter hold feature is
factory set to off position.
2
Wire Feed Speed Display
S1
S2
Meters Per MinuteInches Per Minute
Meter Hold
S1
(OFF)
S2
Amps Display
14 Pin
Current
Feedback
S2
S1
(ON)
14 Pin
Voltage
Feedback
Voltage/Current
Sense Kit
(195194)
S2S2S2
S1
Voltage/Current
Sense Kit
(195194)
Voltage/Current
Sense Kit
(195194)

OM-215 092 Page 14
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
YDisconnectpower
before maintaining. .Maintain more often
during severe conditions.
3 Months
Replace
DamagedOr
Unreadable
Labels
Replace Damaged
Gas Hose
Repair Or Replace
Cracked Cables
And Cords
6 Months
Clean
Drive
Rolls
Blow Out Or
Vacuum Inside
5-2. Overload Protection And Thermostat Protection
804 213-A
YTurn Off wire feeder and
welding power source. Stop
engine on welding
generator.
1 Circuit Breaker CB1
CB1 protects wire feeder from over-
load. Correct problem and reset
CB1.
Close and latch door.
Thermostat Protection
Unit has internal thermostat protec-
tion and will not feed wire if over-
heatingoccurs (see Section 5-3).
CB1
1
Internal Side View

OM-215 092 Page 15
5-3. Troubleshooting
Trouble Remedy
Wiredoes not feed, unit completely inop
-
erative.
Turn Power switch On.
erative. Check 14−pin plug PLG2 connections.
Check input power.
Wire does not feed. Check circuit breaker CB1. (see Section 5-2).
Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s
Manual.
Have Factory Authorized Service Agent check drive motor and control board PC1.
Wire feeds erratically. Readjust hub tension and drive roll pressure (see Section 3-10).
Use correct size drive roll (see Parts Listing).
Clean or replace dirty or worn drive roll (see Section 3-6).
Remove weld spatter around nozzle opening.
Replace contact tip or liner. See gun Owner’s Manual.
Have Factory Authorized Service Agent check drive motor and control board PC1.
Wire feeds when Jog switch is pressed
but not when gun trigger is pressed. Check gun trigger connection at wire feeder. Check gun trigger leads and trigger switch. See gun Owner’s Manual.
Wire feeds as soon as power is applied. Check gun trigger. See gun Owner’s Manual.
Wire does not feed until trigger is
pressed but continues to feed after trig-
ger is released.
Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
Gas valve rattles loudly and wire feeds
slowly or erratically. Check for short between gun trigger leads and weld cable. Repair or replace gun trigger leads.
Gas does not flow; wire feeds. Check gas valve.

OM-215 092 Page 16
Notes