Professional Documents
Culture Documents
Processes
Stick (SMAW) Welding
Description
Thunderbolt 160
R
Thunderbolt 210
R
Mil_Thank 2009−09
TABLE OF CONTENTS
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
D Always verify the supply ground − check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you
disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions
grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information D When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-5. Read and tor first − double-check connections.
follow all Safety Standards. D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and D Frequently inspect input power cord and ground conductor for
repair this unit. damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
During operation, keep everybody, especially children, away. D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
ELECTRIC SHOCK can kill.
D If earth grounding of the workpiece is required, ground it directly
Touching live electrical parts can cause fatal shocks with a separate cable.
or severe burns. The electrode and work circuit is D Do not touch electrode if you are in contact with the work, ground,
electrically live whenever the output is on. The input or another electrode from a different machine.
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic D Do not touch electrode holders connected to two welding ma-
wire welding, the wire, wire reel, drive roll housing, chines at the same time since double open-circuit voltage will be
and all metal parts touching the welding wire are present.
electrically live. Incorrectly installed or improperly D Use only well-maintained equipment. Repair or replace damaged
grounded equipment is a hazard.
parts at once. Maintain unit according to manual.
D Do not touch live electrical parts. D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats D Clamp work cable with good metal-to-metal contact to workpiece
or covers big enough to prevent any physical contact with the work or worktable as near the weld as practical.
or ground. D Insulate work clamp when not connected to workpiece to prevent
D Do not use AC output in damp areas, if movement is confined, or if contact with any metal object.
there is a danger of falling. D Do not connect more than one electrode or work cable to any
D Use AC output ONLY if required for the welding process. single weld output terminal. Disconnect cable for process not in
use.
D If AC output is required, use remote output control if present on
unit. D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
D 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
SIGNIFICANT DC VOLTAGE exists in inverter weld-
as floors, gratings, or scaffolds; when in cramped positions such ing power sources AFTER removal of input power.
as sitting, kneeling, or lying; or when there is a high risk of unavoid- D Turn Off inverter, disconnect input power, and discharge input
able or accidental contact with the workpiece or ground. For these capacitors according to instructions in Maintenance Section
conditions, use the following equipment in order presented: 1) a before touching any parts.
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 HOT PARTS can burn.
is recommended. And, do not work alone!
D Do not touch hot parts bare handed.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to D Allow cooling period before working on
OSHA 29 CFR 1910.147 (see Safety Standards). equipment.
D Properly install, ground, and operate this equipment according to D To handle hot parts, use proper tools and/or wear heavy, insu-
its Owner’s Manual and national, state, and local codes. lated welding gloves and clothing to prevent burns.
OM-278445 Page 1
D Remove stick electrode from holder or cut off welding wire at
FUMES AND GASES can be hazardous. contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free
these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high
health.
shoes, and a cap.
D Keep your head out of the fumes. Do not breathe the fumes. D Remove any combustibles, such as a butane lighter or matches,
D If inside, ventilate the area and/or use local forced ventilation at the from your person before doing any welding.
arc to remove welding fumes and gases. The recommended way D After completion of work, inspect area to ensure it is free of sparks,
to determine adequate ventilation is to sample for the composition glowing embers, and flames.
and quantity of fumes and gases to which personnel are exposed. D Use only correct fuses or circuit breakers. Do not oversize or by-
D If ventilation is poor, wear an approved air-supplied respirator. pass them.
D Read and understand the Safety Data Sheets (SDSs) and the D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
manufacturer’s instructions for adhesives, coatings, cleaners, for hot work and have a fire watcher and extinguisher nearby.
consumables, coolants, degreasers, fluxes, and metals. D Read and understand the Safety Data Sheets (SDSs) and the
D Work in a confined space only if it is well ventilated, or while manufacturer’s instructions for adhesives, coatings, cleaners,
wearing an air-supplied respirator. Always have a trained watch- consumables, coolants, degreasers, fluxes, and metals.
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath- FLYING METAL or DIRT can injure eyes.
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op- D Welding, chipping, wire brushing, and grinding
erations. The heat and rays of the arc can react with vapors to form cause sparks and flying metal. As welds cool,
highly toxic and irritating gases. they can throw off slag.
D Do not weld on coated metals, such as galvanized, lead, or D Wear approved safety glasses with side
cadmium plated steel, unless the coating is removed from the weld shields even under your welding helmet.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements BUILDUP OF GAS can injure or kill.
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin. D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
Arc rays from the welding process produce intense approved air-supplied respirator.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the ELECTRIC AND MAGNETIC FIELDS (EMF)
weld. can affect Implanted Medical Devices.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and D Wearers of Pacemakers and other Implanted
sparks when welding or watching (see ANSI Z49.1 and Z87.1 Medical Devices should keep away.
listed in Safety Standards). D Implanted Medical Device wearers should consult their doctor
D Wear approved safety glasses with side shields under your and the device manufacturer before going near arc welding, spot
helmet. welding, gouging, plasma arc cutting, or induction heating
D Use protective screens or barriers to protect others from flash, operations.
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant mate- NOISE can damage hearing.
rial (leather, heavy cotton, wool). Body protection includes Noise from some processes or equipment can
oil-free clothing such as leather gloves, heavy shirt, cuffless damage hearing.
trousers, high shoes, and a cap.
D Wear approved ear protection if noise lev-
WELDING can cause fire or explosion. el is high.
OM-278445 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)
OM-278445 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du
fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent
dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres
formations congénitales et, dans certains cas, des cancers. problèmes de procréation. Se laver les mains après
(Code de santé et de sécurité de Californie, chapitre 25249.5 utilisation.
et suivants)
V
Input Power Or Shielded Metal Arc
Voltage Input Voltage Welding (SMAW)
U0
On Single Phase
Rated No-Load
Voltage (OCV)
Single-Phase Static
Off
U1
Frequency
Primary Voltage Converter-
Transformer-
Rectifier
Line Connection
U2 Load Voltage
Percent
X Duty Cycle
Hz Hertz
IP Internal Protection
Rating
I2 Rated Welding
Current
Temperature
Look Under Unit
For Label
Positive Alternating
Current
OM-278445 Page 9
. A complete Parts List is available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the bottom. 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.
A. Thunderbolt 160
Maximum
Amperage
Maximum
Input At
Input Power Rated Output Open- Overall
Rated Load
Single-Phase Welding Amperage Circuit KVA KW Dimensions Weight
Output
AC Output Range Voltage (L x W x H)
50/60 Hz,
DC (U0)
Single−Phase
(I1max)
65 A At 22.6
Volts DC, 2.48 1.76
20% Duty Cycle
43 A At 21.7
120 V Volts DC 20−65 A 91 VDC 20.7 A 1.76 1.16
60% Duty Cycle
34 A At 21.4
Volts DC 1.42 0.91 13.375 x 7.125
100% Duty Cycle x 10.5 in.
20 lb (9 kg)
160 A At 26.4 340 x 181 x
Volts DC, 7.47 4.91 268 mm
30% Duty Cycle
113 A At 24.5
240 V Volts DC 20−160 A 91 VDC 27.8 A 5.14 3.22
60% Duty Cycle
88 A At 23.5
Volts DC 3.91 2.36
100% Duty Cycle
B. Thunderbolt 210
Maximum
Maximum Amperage
Open- Input At
Input Power Rated Output Overall
Rated Load
Single-Phase Welding Amperage Circuit KVA KW Dimensions Weight
Voltage Output
AC Output Range (L x W x H)
50/60 Hz,
DC (U0)
Single−Phase
(I1max)
210 A At 28.4
Volts DC, 10.68 7.05
20% Duty Cycle
13.375 x 7.125
121 A At 24.8 x 10.5 in.
240 V Volts DC 25−210 A 85 VDC 43.4 A 5.55 3.46 20 lb (9 kg)
60% Duty Cycle 340 x 181 x
268 mm
94 A At 23.8
Volts DC 4.27 2.59
100% Duty Cycle
OM-278445 Page 10
. A complete Parts List is available at www.MillerWelds.com
B. Temperature Specifications
100
240 VAC
80
60
40
120 VAC
20
0
10 20 30 40 50 60 70 80 90 100
% DUTY CYCLE
Overheating
0 A or V
15
OR
Minutes Reduce Duty Cycle
OM-278445 Page 11
. A complete Parts List is available at www.MillerWelds.com
B. Thunderbolt 210
150
100
50
0
10 20 30 40 50 60 70 80 90 100
% DUTY CYCLE
Overheating
0 A or V
15
OR
Minutes Reduce Duty Cycle
OM-278445 Page 12
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70
60 MAXIMUM
50
VOLTS
40
MINIMUM
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100
AMPERES
70
60
MAXIMUM
50
VOLTS
40
MINIMUM
30
20
10
0
0 20 40 60 80 100 120 140 160 180
AMPERES
C. Thunderbolt 210
80
70
60
MAXIMUM
50
40
VOLTS
MINIMUM
30
20
10
0
0 50 100 150 200
AMPERES 279224-A / 279225-A
OM-278445 Page 13
. A complete Parts List is available at www.MillerWelds.com
SECTION 5 − INSTALLATION
18 in.
(460 mm)
loc_small 2015-04
Notes
OM-278445 Page 14
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Shim Installation
4 5
6
Tools Needed:
4 mm
279288-A
6
. Tighten connection hardware with
proper tools. Do not just hand tight-
5 en hardware. A loose electrical
4 connection will cause poor weld
2
performance and excessive heat-
ing of the work clamp.
1 Work Clamp
2 Work Cable From Unit
3 Screw
3
4 Flat Washer
5 Lock Washer
6 Nut
Route work cable through hole in clamp
Tools Needed: 1 handle. Secure cable with hardware as
shown.
OM-278445 Page 15
. A complete Parts List is available at www.MillerWelds.com
1 2
279982-A / 279438-A
279438-A
OM-278445 Page 16
. A complete Parts List is available at www.MillerWelds.com
Selecting Plug
2
1
3
Selecting Plug 4 Plug − NEMA Type 5−20P (Optional) Connecting Plug To Power Cord
1 Power Cord Connector From 5 Receptacle − NEMA Type 5−20R
Welding Power Source (Customer Supplied) Align arrow on plug with arrow on power
6 Plug − NEMA Type 6−50P cord connector. Push together.
Select plug for power supply receptacle
available at site. Not all plugs shown are 7 Receptacle − NEMA Type 6−50R
provided as standard with unit. (Customer Supplied) Tighten threaded collar. As threaded collar
is tightened, push plug onto adapter until
! Follow electrical service guide for
2 Plug − NEMA Type 5−15P collar is completely tight.
240 VAC in Section 5-9. Do not use
3 Receptacle − NEMA Type 5−15R plug rating to size branch circuit
(Customer Supplied) protection. Connect plug to receptacle.
OM-278445 Page 17
. A complete Parts List is available at www.MillerWelds.com
A. Thunderbolt 160
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-
tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
B. Thunderbolt 210
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-
tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
50/60 Hz 1−Phase
Input Voltage (V) 240
Rated Maximum Supply Current I1max (A) 43.4
Maximum Effective Supply Current I1eff (A) 19.4
Max Recommended Standard Fuse Rating In Amperes1
Time-Delay Fuses2 60
Normal Operating Fuses 3 80
Min Input Conductor Size In AWG (mm2) 4 10 (5.3)
Max Recommended Input Conductor Length In Feet (Meters) 82 (25)
Min Grounding Conductor Size In AWG (mm2) 4 10 (5.3)
Notes
OM-278445 Page 19
. A complete Parts List is available at www.MillerWelds.com
OM-278445 Page 20
. A complete Parts List is available at www.MillerWelds.com
SECTION 6 − OPERATION
6-1. Controls
A. Thunderbolt 160
279230 / 276286
OM-278445 Page 21
. A complete Parts List is available at www.MillerWelds.com
B. Thunderbolt 210
279230 / 276287
OM-278445 Page 22
. A complete Parts List is available at www.MillerWelds.com
Every
3
Months
Every
6 OR
Months
~ Inside Unit
7-2. Troubleshooting
Trouble Remedy
No weld output; unit completely inop- Place Power switch in the On position.
erative; Power Indicator light is off.
Be sure power cord is plugged in and that receptacle is receiving input power.
No weld output; Power Indicator light is Check and secure loose weld cable(s) into receptacle(s).
on.
No weld output; high temperature light Unit overheated causing thermal shutdown. Allow unit to cool with fan On (see Section 4-4).
is on.
Reduce duty cycle or amperage.
Fan not operating. Check for and remove anything blocking fan movement.
Have Factory Authorized Service Agent check fan motor and control circuitry.
Erratic or improper welding arc or Use proper size and type of weld cable (see your Distributor).
output.
Clean and tighten weld connections.
Check and reverse polarity; check and correct poor connections to workpiece.
OM-278445 Page 23
. A complete Parts List is available at www.MillerWelds.com
Notes
OM-278445 Page 24
SECTION 9 − ELECTRICAL DIAGRAMS
279190-A
Figure 9-1. Circuit Diagram For Thunderbolt 160 And 210 Models
OM-278445 Page 25
SECTION 10 − STICK WELDING (SMAW) GUIDELINES
10-1. Stick Welding Procedure
! Weld current starts when
electrode touches work-
piece.
! Weld current can damage
electronic parts in vehicles.
Disconnect both battery
Tools Needed: Equipment Needed: cables before welding on a
vehicle. Place work clamp
as close to the weld as
possible.
. Always wear appropriate per-
sonal protective clothing.
1 Workpiece
Make sure workpiece is clean be-
fore welding.
2 Work Clamp
Place as close to the weld as
Constant Current possible.
Welding Power Source 3 Electrode
Before striking an arc, insert an
electrode in the electrode holder. A
small diameter electrode requires
less current than a large one. Fol-
low recommendations of the elec-
trode manufacturer when setting
weld amperage (see Section
10-2).
5
4 Insulated Electrode Holder
4
5 Electrode Holder Position
2
6 Arc Length
Arc length is the distance from the
electrode to the workpiece. A short
arc with correct amperage will give
a sharp, crackling sound. Correct
arc length is related to electrode di-
ameter. Examine the weld bead to
determine if the arc length is cor-
3 rect.
Arc length for 1/16 and 3/32 in. dia-
6 meter electrodes should be about
1/16 in. (1.6 mm); arc length for 1/8
1 7 and 5/32 in. electrodes should be
about 1/8 in. (3 mm).
7 Slag
Use a chipping hammer and wire
brush to remove slag. Remove
slag and check weld bead before
making another weld pass.
OM-278445 Page 26
10-2. Electrode and Amperage Selection Chart
AMPERAGE
RANGE
PENETRATION
ELECTRODE
ELECTRODE
POSITION
DIAMETER
USAGE
DC*
AC
100
150
200
250
300
350
400
450
50
3
S-0049 / S-0050
OM-278445 Page 27
10-4. Positioning Electrode Holder
1 End View Of Work Angle
2 Side View Of Electrode
Angle
After learning to start and hold
an arc, practice running beads
1
of weld metal on flat plates using
a full electrode.
10°-30° Hold the electrode nearly per-
2
pendicular to the work, although
tilting it ahead (in the direction of
90° 90°
travel) will be helpful.
10°-30°
1 45° 2
45°
Fillet Welds
S-0060
2 3
5
1
S-0053-A
S-0052-B
OM-278445 Page 28
10-7. Conditions That Affect Weld Bead Shape
Electrode Angle
Drag
Spatter
Arc Length
Too Short Normal Too Long
Travel Speed
Slow Normal Fast
S-0061
S-0054-A
2 3
S-0063 / S-0064
OM-278445 Page 29
10-10. Welding Groove (Butt) Joints
1 Tack Welds
Prevent butt joint distortion by tack
welding the materials in position
before final weld.
Workpiece distortion occurs when
heat is applied locally to a joint.
1 One side of a metal plate will “curl”
up toward the weld. Distortion will
2 also cause the edges of a butt joint
to pull together ahead of the elec-
trode as the weld cools.
2 Square Groove Weld
3 Single V-Groove Weld
4 Double V-Groove Weld
Materials up to 3/16 in. (5 mm)
thick can often be welded without
special preparation using the
square groove weld. However,
when welding thicker materials it
may be necessary to prepare the
edges (V-groove) of butt joints to
30° ensure good welds.
1/16 in.
(1.6 mm) The single or double V-groove
weld is good for materials 3/16 −
3/4 in. (5-19 mm) thick. Generally,
the single V-groove is used on ma-
terials up to 3/4 in. (19 mm) thick
3 4 and when, regardless of thickness,
you can weld from one side only.
Create a 30 degree bevel with oxy-
acetylene or plasma cutting equip-
ment. Remove scale from material
after cutting. A grinder can also be
used to prepare bevels.
S-0062
45°
Or
2 2
Less 3
OM-278445 Page 30
10-12. Weld Test
1 Vise
2 Weld Joint
3 Hammer
Strike the weld joint in the direction shown. A good weld
bends over but does not break.
3
If the weld breaks, examine it to determine the cause.
If the weld is porous (many holes), the arc length was
3 probably too long.
2 To 3 in. If the weld contains bits of slag, the arc may have been
(51-76 mm) too long or the electrode was moved incorrectly which
2 To 3 in. allowed molten slag to be trapped in the weld. This may
(51-76 mm) happen on a V-groove joint made in several layers and
2 2 calls for additional cleaning between layers.
1/4 in.
(6.4 mm) 1 1 If the original beveled surface is visible the material was
not fully melted which is often caused by insufficient
heat or too fast a travel speed. S-0057-B
10-13. Troubleshooting
Porosity − small cavities or holes resulting from gas pockets in weld metal.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead.
Amperage too high for electrode. Decrease amperage or select larger electrode.
Arc length too long or voltage too high. Reduce arc length or voltage.
Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding
weld bead.
Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.
Improper welding technique. Place stringer bead in proper location(s) at joint during welding.
Momentarily hold arc on groove side walls when using weaving technique.
Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
welding.
OM-278445 Page 31
Lack Of Penetration − shallow fusion between weld metal and base metal.
Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.
Insufficient heat input. Increase amperage. Select larger electrode and increase amperage.
Excessive Penetration − weld metal melting through base metal and hanging underneath weld.
Burn-Through − weld metal melting completely through base metal resulting in holes where no
metal remains.
Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.
Distortion − contraction of weld metal during welding that forces base metal to move.
Excessive heat input. Use restraint (clamp) to hold base metal in position.
OM-278445 Page 32
Effective January 1, 2017
(Equipment with a serial number preface of MH or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Call Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original * Batteries
retail purchaser that new Miller equipment sold after the effective date of
1-800-4-A-MILLER this limited warranty is free of defects in material and workmanship at 6. 90 Days — Parts
* Accessory (Kits)
for your local the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, * Canvas Covers
Miller distributor. INCLUDING THE WARRANTIES OF MERCHANTABILITY AND * Induction Heating Coils and Blankets, Cables, and
FITNESS. Non-Electronic Controls
Within the warranty periods listed below, Miller will repair or replace any * M-Guns
warranted parts or components that fail due to such defects in material * MIG Guns, Subarc (SAW) Torches, and External
Your distributor also gives or workmanship. Miller must be notified in writing within thirty (30) days Cladding Heads
you ... of such defect or failure, at which time Miller will provide instructions on
the warranty claim procedures to be followed. If notification is submitted * Remote Controls and RFCS-RJ45
Service as an online warranty claim, the claim must include a detailed * Replacement Parts (No labor)
You always get the fast, description of the fault and the troubleshooting steps taken to identify * Spoolmate Spoolguns
reliable response you failed components and the cause of their failure.
Miller’s True Blue® Limited Warranty shall not apply to:
need. Most replacement Miller shall honor warranty claims on warranted equipment listed below
parts can be in your 1. Consumable components; such as contact tips,
in the event of such a failure within the warranty time periods. All
hands in 24 hours. warranty time periods start on the delivery date of the equipment to the cutting nozzles, contactors, brushes, relays, work
original end-user purchaser, and not to exceed twelve months after the station table tops and welding curtains, or parts that
Support equipment is shipped to a North American distributor or eighteen fail due to normal wear. (Exception: brushes and
Need fast answers to the months after the equipment is shipped to an International distributor. relays are covered on all engine-driven products.)
tough welding questions? 1. 5 Years Parts — 3 Years Labor 2. Items furnished by Miller, but manufactured by others,
Contact your distributor. * Original Main Power Rectifiers Only to Include SCRs, such as engines or trade accessories. These items are
The expertise of the Diodes, and Discrete Rectifier Modules covered by the manufacturer’s warranty, if any.
distributor and Miller is 2. 3 Years — Parts and Labor 3. Equipment that has been modified by any party other than
there to help you, every * Auto-Darkening Helmet Lenses (Except Classic Miller, or equipment that has been improperly installed,
step of the way. Series) (No Labor) improperly operated or misused based upon industry
* Engine Driven Welder/Generators standards, or equipment which has not had reasonable
(NOTE: Engines are Warranted Separately by the and necessary maintenance, or equipment which has
Engine Manufacturer.) been used for operation outside of the specifications for
* Inverter Power Sources (Unless Otherwise Stated) the equipment.
* Plasma Arc Cutting Power Sources MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Process Controllers USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Semi-Automatic and Automatic Wire Feeders
MAINTENANCE OF WELDING EQUIPMENT.
* Transformer/Rectifier Power Sources
In the event of a warranty claim covered by this warranty, the
3. 2 Years — Parts and Labor exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
* Auto-Darkening Helmet Lenses − Classic Series Only replacement; or, where authorized in writing by Miller in appropriate
(No Labor) cases, (3) the reasonable cost of repair or replacement at an
* Fume Extractors − Capture 5, Filtair 400 and Industrial authorized Miller service station; or (4) payment of or credit for the
Collector Series purchase price (less reasonable depreciation based upon actual
4. 1 Year — Parts and Labor Unless Specified use) upon return of the goods at customer’s risk and expense.
* AugmentedArc and LiveArc Welding Systems Miller’s option of repair or replacement will be F.O.B., Factory at
* Automatic Motion Devices Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
as determined by Miller. Therefore no compensation or
* Bernard BTB Air-Cooled MIG Guns (No Labor) reimbursement for transportation costs of any kind will be allowed.
* CoolBelt and CoolBand Blower Unit (No Labor)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Desiccant Air Dryer System PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* External Monitoring Equipment and Sensors REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Field Options DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
(NOTE: Field options are covered for the remaining CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
warranty period of the product they are installed in, WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
or for a minimum of one year — whichever is LEGAL THEORY.
greater.) ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
* RFCS Foot Controls (Except RFCS-RJ45) IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
* Fume Extractors − Filtair 130, MWX and SWX Series TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
* HF Units CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
* ICE/XT Plasma Cutting Torches (No Labor)
OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
* Induction Heating Power Sources, Coolers DEALING, INCLUDING ANY IMPLIED WARRANTY OF
(NOTE: Digital Recorders are Warranted MERCHANTABILITY OR FITNESS FOR PARTICULAR
Separately by the Manufacturer.) PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* Load Banks FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
* Motor-Driven Guns (except Spoolmate Spoolguns) MILLER.
* PAPR Blower Unit (No Labor) Some states in the U.S.A. do not allow limitations of how long an
* Positioners and Controllers implied warranty lasts, or the exclusion of incidental, indirect,
* Racks special or consequential damages, so the above limitation or
* Running Gear/Trailers exclusion may not apply to you. This warranty provides specific
* Spot Welders legal rights, and other rights may be available, but may vary from
state to state.
* Subarc Wire Drive Assemblies
* TIG Torches (No Labor) In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and
* Tregaskiss Guns (No Labor) to the extent that they may not be waived, the limitations and
* Water Cooling Systems exclusions set out above may not apply. This Limited Warranty
* Wireless Remote Foot/Hand Controls and Receivers provides specific legal rights, and other rights may be available, but
* Work Stations/Weld Tables (No Labor) may vary from province to province.
miller_warr 2017-01
Owner’s Record
Please complete and retain with your personal records.
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2017 Miller Electric Mfg. Co. 2017−01