Frequently Asked Questions - FAQs | MillerWelds

Frequently Asked Questions

Build With Blue™

I do not have an email address; can I still submit my rebate?

In order to submit a rebate form, a valid email address needs to be provided. This email address is how we are able to contact you regarding the status and processing of your rebate.

If I do not have access to a computer, how do I enter my rebate?

If you do not have access to a computer, there are a couple options available. You can ask the distributor where you purchased the products to enter the rebate for you or you can ask a family member or a friend to help.

I do not see my product listed in the drop down menu, how do I enter it?

Unfortunately, there are too many products that could qualify for an additional purchase to list them all. If you do not see your product listed simply type "other" and you should be brought to this selection to use. The rebate center will then verify this with your invoice.

What is the difference between submitting my rebate online versus the mail in option?

Both are the identical process, the only difference is when you get to the end the mail in option, you will print off your information and mail it to the address provided.

What do I need in order to submit my rebate?

There are a couple things you will need before starting the rebate process. You will need an electronic copy of your receipt, and serial number of the machine(s) purchased.

What qualifies as an electronic copy of my receipt?

There are a few ways in which you can upload your receipt. You can scan the paper copy to your computer, save it, and upload it as an attachment. You can also take a photo of your receipt, send it to yourself, save it, and upload it as an attachment. Please keep in mind, if the name you save your file as has more than 10 characters it may have a hard time uploading.

Diversion™ 165

Is there any way to add a pulser to the unit?

No, we don't offer one at this time.

Can I add a water cooler to it?

No, the unit has a hardwired torch.

Can I stick weld?

No, the TIG torch is hardwired to the machine and it will not accept a stick electrode holder.

What's the maximum material I can weld?

Aluminum 3/16 in., Steel 3/16 in.

What input can I plug into?

230V

Diversion™ 180

Is there any way to add a pulser to the unit?

No, we don't offer one at this time.

Can I add a water cooler to it?

No, the unit has a hardwired torch.

Can it stick weld?

No, the TIG torch is hardwired to the machine and it will not accept a stick electrode holder.

What's the maximum material I can weld?

Aluminum 3/16 in., Steel 3/16 in.

What controls can I use with it?

RFCS foot control

What input can I plug into?

115V or 230V

Maxstar® 150 STH

Comes with?

DC TIG/stick with high frequency and Lift-Arc™ starting, plus built-in pulsing with a selection of four fixed-pulse frequencies.

What's the maximum material I can weld?

Steel 3/16 in.

What controls can I use with it?

RCCS-6M fingertip, RFCS-6M foot control, and wireless foot control.

What input can I plug into?

115V or 230V

What TIG torch is compatible with it?

WP1712RDI25

Why can't I run 6010 rod with it?

Unit does not have the proper inductance to run a 6010 rod. It will run a 6011 just fine.

Maxstar® 150 STL

What's the maximum material I can weld?

Steel 3/16 in.

Does the Maxstar 150 STL start without the use of high frequency?

Yes

What controls can I use with it?

RCCS-6M fingertip, RFCS-6M foot control, and wireless foot control.

What input can I plug into?

115V or 230V

What TIG torch is compatible with it?

WP1712RDI25

Why can't I run 6010 rod with it?

Unit does not have the proper inductance to run a 6010 rod. It will run a 6011 just fine.

MIG Machines

Can I use the Auto-Set™ feature with aluminum wire or flux cored wires?

The Auto-Set feature can only be used with a solid steel wire and 75/25 argon/CO2 shielding gas.

Can I put the Spoolmate™ 100 on _______ machine?

The Spoolmate 100 can only be used on the Millermatic® 140's, Millermatic 180's, 211, Passport Plus and Renegade 180. It cannot be attached to any other units.

Millermatic® 140 Auto-Set™

What's the maximum material I can weld?

Aluminum 14 ga., Mild Steel 3/16 in.

What input can I plug into?

115V

What spool gun can I hook to?

Spoolmate™ 100

Millermatic® 180 Auto-Set™

What's the maximum material I can weld?

Aluminum 1/4 in., Mild Steel 5/16 in.

What input can I plug into?

230V

What plug comes on the end of the power cord?

The plug is a NEMA 6-50P

What spool gun can I hook up to?

Spoolmate™ 100

Millermatic® 211 Auto-Set™ with MVP™

Do you have other 230V plugs for the Millermatic® 211 MVP™ cord?

The NEMA 6-50P is the only 230V plug available at this time. If a different plug configuration is required the customer will have to make an adapter cord. (Note: we do offer a 300517 that adapts from a NEMA 14-50R to a NEMA 6-50P (ex. would allow for the unit to be plugged into a Miller Bobcat™.)

*Always be sure to use the 230V plug when using 230V input power and never cut the power cord off. Cutting the cord voids the warranty and will most likely damage the machine as well.

What's the maximum material I can weld?

Aluminum 3/8 in., Mild Steel 3/8 in.

What input can I plug into?

120V or 230V

What plug comes on the end of the power cord?

The plug is a NEMA 6-50P (230V plug)

What spool gun can I hook up to?

Spoolmate™ 100

Millermatic® 212 Auto-Set™

What's the maximum material I can weld?

Aluminum 3/8 in., Mild Steel 3/8 in.

What input can I plug into?

230V

What plug comes on the end of the power cord?

The plug is a NEMA 6-50P.

What spool gun can I hook up to?

Spoolmate™ 200

Millermatic® 252

What's the maximum material I can weld?

Aluminum 3/8 in., Mild Steel 1/2 in.

What input can I plug into?

230V

What plug comes on the end of the power cord?

The plug is a NEMA 6-50P (907321 only).

What spool gun can I hook up to?

Spoolmatic® 15/30A, Spoolmate™ 200

Oxy-Fuel Torch Operation

When extinguishing the flame, do I have to turn off my oxygen first?

You can shut off either gas first, but turning off the oxygen first and the fuel gas are most commonly recommended.

Why does my torch and/or tip overheat?

The two most common causes of torch and tip overheating are:

- Incorrect flame adjustments

- Insufficient gas supply to the torch

An incorrectly adjusted flame is among the most common causes of overheating. If the torch and valves do not have enough gas flowing through them, the flame will lack the velocity necessary to push and burn away from the tip. As a result, the flame recedes and starves into the tip resulting in overheating. And because flames can reach up to 6,000 Fahrenheit, that heat is easily transferable from the tip to the torch.

Using the appropriate amount of oxygen can also help prevent overheating, as oxygen has a cooling effect on the tip as it passes through the torch and tips.

Tools such as flashback arrestors or check valves, while necessary for safety, can restrict the flow of gas and oxygen to the torch and cause overheating. Standard sized flashback arrestors will work well with tips up to a certain size, but a high-flow flashback arrestor should be used with larger tips. These high-flow models feature a larger diameter that created less gas flow resistance and therefore, less opportunity for overheating.

How do I properly adjust the flame on an acetylene cutting tip?

When using acetylene, the most common fuel gas, you must first purge the system by opening the fuel valve and allowing it to run for approximately 3 seconds for every 25 feet of hose length. Close the torch fuel valve and purge the oxygen hose by using the same process. Once you have purged the system, you are ready to light the torch.

When using a combination style torch with a cutting assembly, keep the torch handle oxygen valve fully open to prevent restricted flow during the cutting process. Next, open the fuel valve slightly and ignite the gas with a friction style lighter. Continue opening the fuel gas valve until there is sufficient gas flow to prevent the tip from starving. Open the fuel valve until the soot, which is discharged from the flame, disappears or until the preheat flames just begin separating from the tip. Next, open the oxygen valve until what are known as acetylene feathers (long white flames) are reduced in length to where they just disappear in the small bright luminous cones, that is a neutral flame.

What gas pressures should I use for my tip?

Unless you are using an extremely large cutting tip or a heating tip, you can typically set your fuel gas pressure at 10 pounds per square inch (psi) and your oxygen at the required pressure for the tip being used without any problem. With welding and brazing tips, both pressures are typically set the same. A common error is to set cutting oxygen pressures too high, which can lead to turbulence in the cut, increase the amount of slag produced and decrease economy.


The best precaution against pressure related problems is to refer to the manufacturer’s cutting guide for specific information on your gas and application, or seek advice from your local welding supply distributor.

What type of fuel gas should I use?

Choosing a gas depends on a number of variables, including: applications material thickness, material coatings, and the cost or availability of the fuel gas. The best way to determine the best fuel gas for you, in terms of both economics and performance, is to test each gas over a set period of time. Compare the results to see how much work you were able to complete, how much gas you used and the overall cost for the gas at that time before making your decision. 


If you use different gases for different applications, you can typically use the same torch for each. There are some torches on the market that may require a mixer change to correspond with different gases. Miller's torches require only a tip change when changing fuel gases.

Can I use (city) natural gas for my oxy-fuel application?

Yes, however, natural gas runs through utility pipes at an extremely low pressure and often will not provide the necessary pressure for cutting. When using a torch for heavy duty applications, you may need to run a separate fuel gas manifold line so that enough gas is forced by pressure to the tip to prevent the flame from starving. An injector style torch may also be used for low-pressure city gas.

Where is the best place to locate add on flashback arrestors in my system?

Because flashbacks often occur in the hose area right behind the torch, the best and safest place to locate an add-on flashback arrestor is on the torch handles. When using larger tips with flashback arrestors mounted on the torch, it may be necessary to increase the oxygen pressures 10 to 20 percent to ensure sufficient gas flow.

What is the difference between a check valve and a flashback arrestor? Do I need both?

Flashback arrestors are typically constructed with a sintered filter to absorb the flame in the event of a flashback and typically have a reverse flow check valve integrated into them. The check valve is designed to prevent gases from flowing in the wrong direction which could produce a flashback. In the event that a flashback still occurs, the sintered filter on the flashback arrestor is designed to pull the heat energy away from the flame and extinguish it.

What size fuel gas tank do I need to run my heating tip safely?

The type of fuel gas and the consumption requirements for your specific heating tip will determine the size of tank you need. The typical rule for acetylene is that the tip requirement is one-seventh of the cylinder’s capacity per hour. For example, if your tip requires 20 cu.ft. of acetylene gas per hour, then is requires a cylinder with a minimum capacity of 140 cu. Ft ( 20X 7=140). When using alternate fuel (LP) gases you will need to know how much gas a certain LP tank size can produce at a given temperature for the tip being used. Typically LP tanks can produce greater gas volumes and LP gases are not as unstable as acetylene. Temperature has a major effect on gas flow from LP tanks, including Propane and Propylene.

What is the difference between an "R" and a "T" grade hose?

“R” grade hoses may be used with acetylene gas and it is recommended that “T” grade hoses be used with LP gases such as Propane, Propylene and Natural gas.

Plasma Machines

How is the air quality when Plasma cutting?

All Plasma cutters require a clean dry air supply. The Spectrum® 375 X-TREME™, 625 X-TREME™, 875 and 875 Auto-Line™ all have a built-in air filter but we do recommend at the very least running an inline filter Miller part number 228926. Check the inline filter after each cutting session. If there is excess moisture in the inline filter the filter in the machine will need to be checked and the customer may require the larger RTI filter Miller part number 300491. Moisture in the airline will greatly reduce the life of the cutting tips.

Air vs Bottled Gas

The Miller plasma cutters will run off of compressed air, bottled air, or bottled Nitrogen. We have not, as a company, done any testing on cutting with any other gases or gas mixtures. Nitrogen is normally recommended when cutting stainless for improving the weld ability of the cut area.

How can I get rid of dross or slag on the bottom of my cut?

Plasma cutting dross is the result of various variables, thickness of material, output amperage, cutting speed, and standoff. With hand held cutting, there is typically an output amperage, speed and standoff for any thickness that will minimize dross, but in some cases you will not be able to completely eliminate it. With plasma units with lower output amperage capacity, like the Spectrum® 375 X-TREME™, dross levels are typically noticed on materials 1/8 in. and thicker. You can minimize the dross by holding a 1/16 in. to 1/8 in. standoff and moving as fast as possible for the thickness that you are cutting. You may not be able to eliminate it completely, but in most cases, the dross can be chipped off easily. Also, larger amperage units provide more power, constricted arcs and the ability to cut faster so it can provide the opportunity to minimize dross better than lower amperage units.

What is the life of torch consumables?

Tips should normally last for about 1 hour of arc on cut time. You should get two tips out of every one electrode.

ProHeat Rolling Inductor

How do I access the program setup screen for the Rolling Inductor?

To view the system setup screen for the Rolling Inductor, simultaneously press the Parameters and Program buttons. The following settings are available:

- Deg Units Displayed (°F or °C)

- Tolerance (±5 to 99)

- Travel Detect (On or Off)

- Control Mode (Manual, Temp, Time or Remote)

- Max Output (1 Kw to 35 Kw)

- System Lock (Yes or No)

(For more information on the setup screen, please consult the Rolling Inductor Owner’s Manual)

Can I get a full 35 kW of output power with the Rolling Inductor?

No, the Rolling Inductor is limited to 300 amps which results in about 20 kW of output power. If 35 kW at 100% duty cycle is desired, a two rolling inductor arrangement is required. The external cooler heat exchanger (300993) is recommended for two Rolling Inductor arrangements. (See owner’s manual for additional information on this topic)

If I already own a ProHeat 35, will the Rolling Inductor work with my system?

Yes, all ProHeat 35 systems are capable of running the Rolling Inductor, but if the system was purchased before August 2014 (serial number prior to ME320092G) a software update is required to run the Rolling Inductor and a hardware update is required to run the Travel Detect System (301183). If an update is needed, call Miller’s service department at 920-735-4001 for more information on how to update your systems software.

Will the Rolling Inductor work with the Intellifire 250 or other induction power sources?

No. The ProHeat 35 is the only power source that works with the Rolling Inductor.

Can I use the recorder to document heating with the Rolling Inductor?

Yes. If the Rolling Inductor is used with compatible temperature measurement devices (customer supplied) you can record heating temperatures. Measurements should be taken within two inches of the Rolling Inductor.

What happens if I run the Rolling Inductor without rolling the pipe or moving the induction head?

Depending on output, material type and material thickness, if the Rolling Inductor remains stationary for too long it can overheat the work piece and cause irreversible damage to the work piece and Rolling Inductor. For this reason it is extremely important to ensure that either the work piece or Rolling Inductor is moving at all times. Using the Travel Detect System (301183) helps minimize the chance of overheating a stationary, object by constantly sending feedback to the power source and limiting output if limited or no motion is detected.

What's the difference between the mounting arm and mounting stand that Miller offers?

The mounting arm (301119) allows heating from the top side of the pipe and will provide the most amount of flexibility and configurability. The mounting stand (301258) is ideal for heating from the bottom of the pipe.

How fast can I expect my part to reach its target temperature?

There are many variables that affect the time to temperature of the part being heated; the thickness of the part, amount of surface area, travel speed and type of material being heated.

Example: A carbon steel pipe with a diameter of 12” and a wall thickness of ¾”, traveling at 34 ipm, took under 4 minutes in our lab testing to reach 400°F on the entire interior of the pipe.

How do I determine a travel speed for optimal heating?

A larger diameter part should be rolled faster because it will dissipate heat quickly between passes of the induction head. A smaller part can be rolled slower because it will dissipate less heat between passes of the induction head. Speeds below 15 ipm will take longer to heat because the power ramp rate is limited. Below 30 ipm maximum output is limited to about 1 kW per ipm of travel speed.

Do all four Rolling Inductor wheels need to be in contact with the work piece at all times?

Power coupling to the part decreases as the distance to the part increases. Maintaining constant distance between the rolling inductor and the work piece will ensure consistent heating, using the wheels is the best way to maintain a constant distance. The wheels should be the only part to contact the work piece, if any other part of the rolling inductor stays in contact with the work piece damage can occur.

Does it matter which way I roll the pipe/work piece when using the Rolling Inductor?

When using the Rolling Inductor always roll away from the power cable. (Clockwise when the cable is exiting left and counterclockwise when the cable is exiting right)

What applications are best suited for the Rolling Inductor?

While there is no set configuration for the Rolling Inductor, primary applications include preheating fabricated pipe sections, preheating tower bases and preheating longitudinal submerged arc welding passes.

Who can I contact for additional support or information about the Rolling Inductor?

For more information regarding setup, troubleshooting, or operation of the Rolling Inductor contact Miller’s service department at 920-735-4001

Spectrum® 125C

What is the cutting capacity?

Steel 1/8 in., Aluminum 1/16 in.

What is the maximum pierce capacity?

One-half of rated cut capacity.

Spectrum® 375

What is the cutting capacity?

Steel 3/8 in., Aluminum 1/4 in.

What is the maximum pierce capacity?

One-half of rated cut capacity 3/4 in.

What is the maximum sever cut?

5/8 in.

Spectrum® 375 X-TREME™

What are the airflow and compressor requirements?

4.5 cfm, 90–120 psi

What is the cutting capacity?

Steel 3/8 in., Aluminum 1/4 in.

What are the requirements for running off a generator or engine drive?

3200 watts

What input voltages do your units run off of?

Runs on 115V (15 or 20 amp) or 220V (20 amp)

What is the maximum pierce capacity?

One-half of rated cut capacity 3/4 in.

What is the maximum sever cut?

5/8 in.

Spectrum® 625 X-TREME™

What are the airflow and compressor requirements?

6 cfm, 9–120 psi

What is the cutting capacity?

Steel 5/8 in., Aluminum 3/8 in.

What are the requirements for running off a generator or engine drive?

6600 watts

What input voltages do the units run off of?

Runs on 220V (50 amp)

What is the maximum pierce capacity?

One-half of rated cut capacity 5/4 in.

What is the maximum sever cut?

7/8 in.

Spectrum® 875 / 875 Auto-Line™

What are the airflow and compressor requirements?

6.75 cfm, 90–120 psi

What is the cutting capacity?

Steel 7/8 in., Aluminum 5/8 in.

What are the requirements for running off a generator or engine drive?

9800 watts

What input voltages does this unit run off of?

Spectrum® 875 runs on 220 V (60 amp), Spectrum® 875 Auto-Line™ runs on 190–625 V single- or three-phase (amp draw depends on input voltage)

What is the maximum pierce capacity?

One-half of rated cut capacity 7/4 in.

What is the maximum sever cut?

1-1/4 in.

TIG Machines

Can I hook a wire feeder to my TIG machine and MIG weld?

Not recommended. TIG/stick units are constant current power sources and MIG units are constant voltage.

Workstations

Can I attach two 30 S-Series tables together to make a 60 S-Series table?

Yes you can, in fact you can combine any of the S-Series ArcStation models together.

What is the ArcStation™ warranty?

The ArcStation warranty is one year on parts, but you should refer to the Owner's Manual for complete details.

Since the ArcStations™ are built from steel how much do they weigh?

Weights for the ArcStations are as follows and do not include accessories:

• 30S – 123 lbs.

• 30SX – 177 lbs.

• 60S – 230 lbs.

• 60SX – 318 lbs.

• 30FX – 74 lbs.

Should I purchase an F-Series ArcStation™ or S-Series ArcStation™?

It really depends on the type of work you are doing, the storage space you have, and whether portability is important to you.

• S-Series ArcStation is a heavy-duty workbench that is designed to remain setup in a shop or garage. It comes in 2 sizes, 30 x 30 inch and 30 x 60 inch.

• F-Series ArcStation is a 30 x 30 inch portable workbench that folds for easy transport and storage.

What comes standard with an ArcStation™?

That depends on which ArcStation you buy.

All S-Series ArcStations come with: Steel table tops; Sturdy 1/8 in. thick steel frames; Pre-welded leg assemblies; Steel leveling feet; Tube caps; Cross bars with pattern top (30SX and 60SX); Duty tray (30SX and 60 SX); All necessary hardware.

All F-Series ArcStations come with: Steel, X-pattern table tops; 1-1/2 in. diameter steel tube frames; Built-in wheels and handles; Removable gun holders.

 

What type of load can the ArcStation™ hold?

S-Series ArcStations are rated for 1000 lbs. static load.

F-Series ArcStations are rated for 500 lbs. static load.

Workstation Accessories

Can I buy the gun holder, clamp bar, or tool holder separate?

No, you must buy the convenience kit to get any of the above for the S-Series. The F-Series comes with a removable gun holder.

Do I have to buy all the accessories at the same time I purchase my ArcStation?

No, you can purchase accessories at any time.

What is a work clamp lug?

The work clamp lug is a convenient feature that provides a solid work clamp connection. It is an aluminum tab that is fastened to the bottom side of a table top. Then the work clamp from your welder is attached to the tab.

What size vise can I use with the vise mount?

The ArcStation vise mount is designed to be used with most 5 in. vises and smaller.

What would I need Miller's custom X-clamp for?

If you have ever tried to clamp something in the middle of a table you know how much of a pain this can be. You either end up tacking the part to the table top or repositioning the whole weldment to gain clamping access. Miller's X-clamp eliminates the need to do either of these. Simply slide the clamp into the nearest slot and clamp your parts where you need to. 6 in. X-clamps are designed specifically for the S-Series X-pattern. 5 in. X-clamps are available for the F-Series and will also work with the S-Series X-pattern.

Will regular C-Clamps work with the X-Pattern top?

Yes and no, you can use C-clamps on the outer edge of the table, but you will not be able to use C-clamps in the X-pattern slots, for this you need the X-pattern clamps.

Will S-Series accessories work with the F-Series ArcStation?

No. Those accessories are designed specifically for the S-Series tables. Currently the only accessories available for the F-Series are the 5 in. X-Clamps.

Workstation Assembly

Do I need any special tools to put an ArcStation together?

No, the main things you will need are a standard set of hex keys (Allen) wrenches, standard open end wrenches, a mallet, a level and a friend to help you flip the ArcStation upright once assembled. Of course, power tools do speed up the job!

How long will it take me to put an ArcStation together?

On average it takes about an hour to put a 30 S-Series together and an hour and half to put a 60 S-Series together. The F-Series comes fully assembled and should take less than a minute to unfold and stand upright.

How do I assemble my ArcStation™?

When your ArcStation arrives it is straight forward regarding assembly.

S-Series: To start with, you bolt the legs and angle iron brackets to the table tops, install the steel leveling feet and install the lower shelves. After that, flip your S-Series ArcStation over, adjust the leveling feet, attach the rear cross bars, accessorize and you are ready to weld.

F-Series: The F-Series is fully assembled. To unfold the table, simply start with the tabletop face down. Remove both pins from the leg brackets and unfold the legs. Lock the legs in place. Turn the table on its side and then lift the table upright.

Workstation Miscellaneous Questions

Can I get a replacement top for my ArcStation?

Yes, replacement tops are available; refer to the Owner's Manual for part numbers.

How are ArcStations shipped?

ArcStation packaging was designed so that you could get the product home without a flatbed or fork truck. S-Series Arc Stations typically come in two to four boxes with frames in one box, each table top in its own box and if applicable, the dust tray in its own box. F-Series ArcStations come in one box. And of course, each accessory comes in its own box.

How do I get spatter off my table tops?

In our weld labs we use a 4 in. grinder to remove weld spatter.

How do I keep the top from rusting?

First, store your ArcStation indoors. Second, to keep surface rust from building up we recommend that you occasionally spray the tops with a light duty rust inhibitor.

When should I use the rubber feet for my F-Series ArcStation?

The rubber feet should be used when there is concern for the floor's appearance. (i.e. hardwood, tile) In other instances (i.e. concrete, stone, blacktop) you may remove the rubber feet for added stability.

Where can I buy an ArcStation?

ArcStations can be purchased at any authorized Miller distributor, check out our distributor locator to find one near you at MillerWelds.com/wheretobuy.