Miller XMS 403 (400 VOLTS) CE Owner’s Manual

OM-244 243G
Processes
Multiprocess Welding
Description
Arc Welding Power Source
R
XMS 403
(400 Volts) CE
Visit our website at
www.MillerWelds.com
2013−07
From Miller to You
Thank you and congratulations on choosing Miller. Now you can get the
job done and get it done right. We know you don’t have time to do it any
other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior quality.
Like you, his customers couldn’t afford anything less. Miller products had
to be more than the best they could be. They had to be the best you could
buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can
count on years of reliable service with proper maintenance. And if for
some reason the unit needs repair, there’s a Troubleshooting section that
will help you figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your particular model are also
provided.
Miller Electric manufactures a full line of
welders and welding related equipment. For
information on other quality Miller products, contact your local Miller
distributor to receive the latest full line catalog or individual catalog sheets.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Additional Safety Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Miscellaneous Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Information On Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. IP Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Installing Turntable for Wire Feeder on Power Source (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Dimensions And Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-11. Locking Caster Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-12. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-13. Remote 7 Receptacle Information (TIG And Stick Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-14. Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-15. Filling Coolant Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-16. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-17. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Switching On the Unit and Recalling Factory Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Welding Power Source Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Remote Receptacle (RCTY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Welding Process Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Wire Type Selection in Synergic MIG or Synergic Pulsed MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Wire Diameter Selection In Synergic MIG Or Synergic Pulsed MIG Welding . . . . . . . . . . . . . . . . . . . .
4-8. Gas Selection in Synergic MIG or Synergic Pulsed MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Trigger Mode Selection (L-TIG and Stick Processes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Welding Parameter Setup Menu (Double Pulsed-MIG/L-TIG And Stick) . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Preparing Power Source For MIG (GMAW) Welding Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-12. Selecting Manual MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-13. Selecting Synergic MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-14. Selecting Synergic Pulsed MIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-15. Preparing Unit For TIG Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-16. TIG Lift-Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-17. Preparing Unit For Stick Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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DECLARATION OF CONFORMITY
for European Community (CE marked) products.
ITW Welding Products Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that
the product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
Stock Number
XMS 403
029015483
Council Directives:
•
2006/95/EC Low Voltage
•
2004/108/EC Electromagnetic Compatibility
•
2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
•
IEC 60974­1 Arc Welding Equipment ­ Welding Power Sources: edition 3, 2005­07.
•
IEC 60974­2 Arc Welding Equipment – Liquid Cooling Systems: edition 2.0, 2007­11.
•
IEC 60974­10 Arc Welding Equipment ­ Electromagnetic Compatibility Requirements: edition 2.0, 2007­08.
•
EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding, arc
welding and allied processes with the basic restrictions related to human exposure to electromagnetic fields
(0Hz­300Hz)
EU Signatory:
January 2nd , 2013
___________________________________________________________________________________
Massimigliano Lavarini
Date of Declaration
ELECTRONIC ENGINEER R&D TECH. SUPPORT
956 172 024
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−10
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring −
replace cord immediately if damaged − bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperly
grounded equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
OM-244 243 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
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.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant
material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
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.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
OM-244 243 Page 2
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise level is
high.
CYLINDERS can explode if damaged.
Compressed 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.
D Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
BATTERY EXPLOSION can injure.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
D Do not use welder to charge batteries or jump
start vehicles unless it has a battery charging
feature designed for this purpose.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
H.F. RADIATION can cause interference.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
D
D
D
D
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
D
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D
D
D
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-244 243 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures
in order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
OM-244 243 Page 4
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
SECTION 2 − DEFINITIONS
2-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Wear dry insulating gloves. Do not touch electrode (wire) with bare hand. Do not wear wet or damaged gloves.
Safe57 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe59 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe60 2012−06
Use ventilating fan to remove fumes.
Safe61 2012−06
Keep flammables away from welding. Do not weld near flammables.
Safe62 2012−06
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe63 2012−06
OM-244 243 Page 5
Do not weld on drums or any closed containers.
?
Safe64 2012−06
Do not remove or paint over (cover) the label.
Safe20 2012−05
Disconnect input plug or power before working on machine.
Safe30 2012−05
When power is applied failed parts can explode or cause other parts to explode.
Safe26 2012−05
Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.
Safe27 2012−05
Always wear long sleeves and button your collar when servicing unit.
Safe28 2012−05
After taking proper precautions as shown, connect power to unit.
Safe29 2012−05
?
?
V
A
Consult rating label for input power requirements.
Safe34 2012−05
ÍÍ
Read Owner’s Manual and inside labels for connection points and procedures.
Safe67 2012−06
Use coolant suggested by the manufacturer.
XXXXX
Safe52 2012−05
OM-244 243 Page 6
<10°
Falling unit can cause injury. Do not move or operate unit where it could tip.
Safe53 2012−05
Become trained and read the instructions before working on the
machine or welding.
Safe65 2012−06
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe66 2012−06
V
V
>5min
3
Hazardous voltage remains on input capacitors after power is turned
off. Do not touch fully charged capacitors. Always wait 5 minutes after
power is turned off before working on unit, OR check input capacitor
voltage, and be sure it is near 0 before touching any parts.
V
Safe43 2012−05
Move jumper links as shown on inside label to match input voltage at
job site. Include extra length in grounding conductor and connect
grounding conductor first. Connect line input conductors as shown on
inside label. Double-check all connections, jumper link positions, and
input voltage before applying power.
1
Safe49 2012−05
Plugged filter or hoses can cause overheating to the power source
and torch.
Safe50 2012−05
100 h. Std.
Every 100 hours, check and clean filter and check condition of hoses.
Safe51 2012−05
2-2. Miscellaneous Symbols And Definitions
A
U1
V
Hz
Voltage
Alternating
Current (AC)
Remote
On
Off
Protective Earth
(Ground)
Line connection
Three Phase
Direct Current
(DC)
Increase
Constant Voltage
Constant Current
Lift-Arc Operation
(GTAW)
Gas Tungsten Arc
Welding
Three Phase Static
Frequency ConverterTransformerRectifier
Gas Metal Arc
Welding (GMAW)
Shielded Metal Arc
Welding (SMAW)
Recycle or dispose
of used coolant in
an environmentally
safe way
Maximum Effective
Supply Current
Wire Feed Speed
Amperage
Primary Voltage
I1max
Rated Maximum
Supply Current
I1eff
Hertz
OM-244 243 Page 7
U2
U0
Conventional
Load Voltage
Rated No Load
Voltage (Average)
I2
IP
Rated Welding
Current
X
Duty Cycle
%
Percent
Degree Of
Protection
Purge
Wire ’Jog’
Set-Up
MIG Synergic
MIG Pulsed
Synergic Welding
MIG Double
Pulsed Synergic
Welding
Circuit Breaker
2T Trigger Mode
Memory Store
4T Trigger Mode
Material Thickness
Mini-Logic
Trigger Mode
Arc Length
(Trim)
Read Instructions
OM-244 243 Page 8
SECTION 3 − INSTALLATION
3-1. Important Information Regarding CE Products (Sold Within The EU)
!
This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S
S
The EMF assessment on this equipment was conducted at 0.5 meter.
At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.
ce-emf 1 2010-10
3-2. Information On Electromagnetic Compatibility (EMC)
!
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low
voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
!
This equipment does not comply with IEC 61000−3−12. If it is connected to a public low voltage system, it is the responsibility of
the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment can be connected.
ce-emc 2 2011-09
3-3. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back panel. Use rating label to determine input power requirements and/or
rated output. For future reference, write serial number in space provided on back cover of this manual.
3-4. IP Rating
IP Rating
Operating Temperature Range
IP23S
−10 to 40 °C (14 to 104 °F)
This equipment is designed for outdoor use. It may be stored, but is
not intended to be used outside during precipitation unless sheltered.
3-5. Specifications
Rated Welding
Output
300 A @
32 Volts DC,
60% Duty Cycle
Voltage Range
10 − 35 V
Amperage
Range
5 − 400 A
Maximum
Open-Circuit
Voltage DC
90
Amperes Input
at Rated Load
Output 50/60 Hz
400 V
KVA
KW
17.0
(0,15*)
12.4
(0,09*)
11.5
(0,04*)
*While idling
OM-244 243 Page 9
3-6. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, output stops, a
Help message is displayed, and
cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
60% Duty Cycle
6 Minutes Welding
4 Minutes Resting
Overheating
A
0
15
Minutes
OR
Reduce Duty Cycle
Ref. SA-178 651
3-7. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amperage output capabilities of unit.
Curves of other settings fall between curves shown.
A. CC Mode
B. CV Mode
ARC CONTROL
va_curve1 4/95 − SA-178 652 / SA-178 653
OM-244 243 Page 10
3-8. Installing Turntable for Wire Feeder on Power Source (Optional)
!
Turn off welding power
source and disconnect input power before proceeding.
Remove wire spool.
1
2
1
Turntable
Screw
Remove the 4 screws and the plastic cap on the power source upper
cover and keep them for future use.
2
Insert the turntable in the upper hole
and secure with 4 screws. Be sure
screws are tight.
If desired, install the wire feeder on
the turntable using the hole in the
bottom of the feeder.
Ref. 956142645-5-A
3-9. Dimensions And Weight
Dimensions
1010 mm
(39.7 in.)
Weight
90 kg (198 lb)
860 mm
(33.8 in.)
490 mm
(19.3 in.)
Ref. 956142645-3-B
OM-244 243 Page 11
3-10. Selecting a Location
Location
!
Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
1
Handle
Do not use handle to lift unit.
2
Line Disconnect Device
Locate unit near correct input
power supply.
2
500 mm
(19.7 in.)
500 mm
(19.7 in.)
1
Movement
!
Do not move or operate unit
where it could tip.
500 mm
(19.7 in.)
500 mm
(19.7 in.)
Ref. 956142645-3-B
3-11. Locking Caster Operation
1
2
3
Caster With Brake Off
Brake
Caster With Brake On
To lock caster, push brake down.
To release (unlock) caster, push
brake up and back.
Lock casters to prevent unwanted
movement of power source.
3
1
2
Ref. 956142645_6-A
OM-244 243 Page 12
3-12. Weld Output Terminals And Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
!
Turn off power before connecting to
weld output terminals.
!
Do not use worn,
damaged,
undersized, or poorly
spliced cables.
30 m (100 ft) or Less
Positive
receptacle
MIG
* This
70 m
(250 ft)
90 m
(300 ft)
105 m
(350 ft)
120 m
(400 ft)
60 − 100%
Duty
Cycle
mm2 (AWG)
mm2 (AWG)
100
20 (4)
20 (4)
20 (4)
30 (3)
35 (2)
50 (1)
60 (1/0)
60 (1/0)
150
30 (3)
30 (3)
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
95 (3/0)
200
30 (3)
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
120 (4/0)
250
35 (2)
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
(2x2/0)
2x70
(2x2/0)
300
50 (1)
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
(2x2/0)
2x95
(2x3/0)
2x95
(2x3/0)
350
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
(2x2/0)
2x95
(2x3/0)
2x95
(2x3/0)
2x120
(2x4/0)
400
60 (1/0)
70 (2/0)
95 (3/0)
120 (4/0)
2x70
(2x2/0)
2x95
(2x3/0)
2x120
(2x4/0)
2x120
(2x4/0)
500
70 (2/0)
95 (3/0)
120 (4/0)
2x70
(2x2/0)
2x95
(2x3/0)
2x120
(2x4/0)
3x95
(3x3/0)
3x95
(3x3/0)
600
95 (3/0)
120 (4/0)
2x70
(2x2/0)
2x95
(2x3/0)
2x120
(2x4/0)
3x95
(3x3/0)
3x120
(3x4/0)
3x120
(3x4/0)
10 − 100% Duty Cycle
mm2 (AWG)
Gas
Negative receptacle
MIG/TIG/Stick
60 m
(200 ft)
10 − 60%
Duty
Cycle
Welding
Amperes
Positive
receptacle
TIG/Stick
45 m
(150 ft)
chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
***For distances longer than those shown in this guide, call a factory applications representative.
Milan Ref. S-0007-J 2011−07
OM-244 243 Page 13
3-13. Remote 7 Receptacle Information (TIG And Stick Only)
Socket
7-Pin Remote Receptacle
Socket Information
1
+10 volts DC supply voltage to remote
2
GND Remote control circuit common
3
IREF 0 to 10 current control signal
4
Not used.
5
UP 0V/10V digital signal
6
Not used.
7
TYPE 0V/10V digital signal
. This remote receptacle cannot be used with a standard Miller remote control. A customer supplied remote control is required to use the remote
receptacle.
Some signals can be enabled when TIG or Stick welding. Contact Factory Authorized Service Agent for confirmation.
3-14. Circuit Breakers
Circuit breakers with numbers 7
and 10 are placed on the rear panel
of the welder as shown.
1
1
2
Circuit Breaker 7
Protects the auxiliary 115 volt AC
output from overload. The 115 volt
AC output powers the water cooling
unit inside the power source.
2
Circuit Breaker 10
Protects the auxiliary 24 volt AC
output from overload. The 24 volt
AC output powers the wire feeder
inside the power source.
Ref. 956142645-4-A
OM-244 243 Page 14
3-15. Filling Coolant Tank
. Operating cooler when coolant
is low can damage cooler and
torch components. Always
have proper amount of coolant
in tank and use coolant recommended by the manufacturer.
1
2
Coolant Tank Cap
Coolant Level Indicator
. Remove shielding gas cylinder
1
from rear of unit to fill coolant
tank.
2
Unscrew cap from tank.
Use table to select proper coolant,
and fill tank until coolant appears in
upper half of indicator.
Check coolant level after attaching
torch coolant hoses and running
cooler. Be sure coolant appears in
upper half of indicator. Add coolant
if necessary.
Rear View
GTAW Or Where
HF* Is Used
GMAW Or Where
HF* Is Not Used
Where Coolant Contacts
Aluminum Parts
MILLER Low Conductivity
Coolant No. 043 810**;
Distilled Or Deionized Water
OK Above 32° F (0° C)
MILLER Low Conductivity
Coolant No. 043 810**; Or
MILLER Aluminum Protecting
Coolant No. 043 809**;
Distilled Or Deionized Water
OK Above 32° F (0° C)
MILLER Aluminum
Protecting Coolant
No. 043 809**
Application
Coolant
*HF: High Frequency Current
**MILLER coolants protect to -37° F (-38°C) and resist algae growth.
NOTICE − Use of any coolant other than those listed in the table voids the warranty on any parts
that come in contact with the coolant (pump, radiator, etc.).
Ref. 956142645-4-A
3-16. Electrical Service Guide
. Actual input voltage should not exceed ± 10% of indicated required input voltage. If actual input voltage is outside of this range, output may not
be available.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommendations 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 Three Phase
Input Voltage (V)
400
Input Amperes (A) At Rated Output
17
Max Recommended Standard Fuse Rating In Amperes
1
Time-Delay Fuses 2
Normal Operating Fuses
3
20
25
Min Input Conductor Size In mm2, 4
2.5
Max Recommended Input Conductor Length In Meters
41
mm2, 4
Min Grounding Conductor Size In
2.5
Reference: 2011 National Electrical Code (NEC) (including article 630)
1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5” . See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable
requirements.
OM-244 243 Page 15
3-17. Connecting Input Power
3
= GND/PE Earth Ground
4
7
2
L1
3
L2
5
L3
6
1
Tools Needed:
5/16 in.
Input2 2012−05 / Ref. 803 766-C / 956142645-3-B
956142645-3-A
OM-244 243 Page 16
3-17. Connecting Input Power (Continued)
!
Installation must meet all National
and Local Codes − have only qualified
persons make this installation.
See rating label on unit and check input voltage available at site.
!
Disconnect and lockout/tagout input
power before connecting input
conductors from unit. Follow established procedures regarding the installation and removal of lockout/
tagout devices.
1
Input Power Cord
Connect input conductors L1, L2, and L3 to
disconnect device line terminals.
2
Disconnect Device (switch shown in
the OFF position)
7
3
Green Or Green/Yellow Grounding
Conductor
Select type and size of over-current protection using Section 3-16 (fused disconnect
switch shown).
!
Always
connect
green
or
green/yellow conductor to supply
grounding terminal first, and never to
a line terminal.
For Three-Phase Operation
4
Disconnect Device Grounding Terminal
5
Input Conductors L1, L2, L3
6
Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Over-Current Protection
Close and secure door on disconnect device.
Follow established lockout/tagout procedures to put unit in service.
Input2 2012−05
Notes
Work like a Pro!
Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.
OM-244 243 Page 17
SECTION 4 − OPERATION
4-1. Front Panel Controls
8
10
11
12
13
14
15
9
18
19
20
17
16
4
1
5
3
2
7
6
Ref. 956142645-5-A
1
ON/OFF Switch (I/O)
Use switch to turn unit On/Off.
. The
power source cooling fan is
thermally controlled running only as required (Fan On Demand).
. Water cooling unit operation can be set
to function as required (auto) (Cooling
On Demand) “ON or OFF”.
2
Positive Power Connection for TIG
and Stick Welding.
. Do not use for MIG welding.
3
4
5
6
Negative Power Connection for all
welding processes.
Remote Control Receptacle for TIG
and Stick welding
Gas Connector (TIG Process)
Red Quick Connect Fitting
Coolant return from torch.
7
Blue Quick Connect Fitting
OM-244 243 Page 18
Coolant output to torch.
15 P2 (Setup Push Button)
8 Handle
9 Control Panel
10 D1 (Display 1)
Allows selecting setup or advanced programming menus.
Displays values and parameters for selected welding process. During welding it
displays actual arc voltage.
Allows selecting welding process.
11 D2 (Display 2)
Displays values and parameters for selected welding process. During welding it
shows measured welding current.
12 E1 (Encoder Control 1)
Use control to change values and parameters that appear on display D1.
13 E2 (Encoder Control 2)
Use control to change values and parameters that appear on display D2.
14 P1 (Memory Push Button)
Permits storage of welding parameters into
4 locations (TIG and Stick only).
16 P3 (Process Push Button)
17 P4 (Material Push Button)
Allows selecting material type for synergic
MIG and synergic pulsed MIG processes.
18 P5 (Wire Diameter Push Button)
Selects desired welding wire diameter for
synergic MIG and synergic pulsed MIG
processes.
19 P6 (Gas Selection Push Button)
Selects desired welding gas type for synergic MIG and synergic pulsed MIG processes.
20 P7 (Trigger Selection Push Button)
Selects desired trigger mode in TIG welding and enables weld output for Stick welding (Default = OFF).
4-2. Switching On the Unit and Recalling Factory Parameters
. Write down any parameters that
need to be restored before performing this procedure.
1
Power Switch
Use power switch to turn unit On.
When XMS 403 appears on D1 and
D2, press P3 and P8 simultaneously.
When MEMO CLEAR appears on
D1 and D2, release P3 and P7.
Wait until DONE appears on D1, and
turn unit Off.
The next time unit is turned On, all
parameters will return factory default
settings.
1
P3
P7
Ref. 956142645-5-A
OM-244 243 Page 19
4-3. Welding Power Source Setup Menu
P1 - Welding Parameter Setup Button.
P2 - Power Source Setup Button.
Press and hold P1 and P2.
XMS 403 appears on D1 and D2 followed by UNIT - IPM.
Wire feed speed is displayed as
(IPM) inches per minute.
Rotating knob P2 scrolls through
the following options:
UNIT MPM - Wire feed speed is
displayed in Meters Per Minute.
UNIT CUR - Power source will display welding current.
P1
P2
UNIT THCK - Power source welding parameters will be chosen according to the gauge (thickness) of
material to be welded.
Rotating knob P1 scrolls through
the following options:
W-UN AUTO - Rotate P2 to select
water cooling unit mode. AUTO
(Default) ON (Continuous) or OFF
(Water cooling not required)
RCTY 1 - Selects function mode for
remote receptacle (TIG).
Rotating P2 selects the following:
RCTY 2 - Selects function mode for
remote receptacle (For future applications)
RCTY 3 - Selects function mode for
remote receptacle (For future applications)
RCTY 4 - Selects function mode for
remote receptacle (For future applications)
LANG ENG - Selects language
ENG = English (Default)
Rotating P2 selects the following:
LANG FRA - Selects language
FRA = French
LANG ITA - Selects language ITA
= Italian
LANG GER - Selects language
GER = German
LANG SPA - Selects language
SPA = Spanish
Ref. 956142645-5-A
OM-244 243 Page 20
4-4. Remote Receptacle (RCTY)
1
7 Pin Remote Receptacle
1
4-5. Welding Process Selection
L1
L2
L3
L4
P3
Ref. 956142645-5-A
L1 LED
L2 LED
L3 LED
L4 LED
P3 Push Button
Press P3 until desired process LED illuminates.
Values and parameters that appear on D1
and D2 are either factory default settings or
last settings entered for the selected process.
L1 selection is Manual MIG welding.
D1 value is welding voltage, default is
18.5V (range is 10 V to 50 V).
D2 value is wire feed speed, default is 5.0
m/min (range is 1 m/min to 20 m/min). See
Section 4-11.
L2 Synergic MIG welding (non-pulsed).
D1 value is welding voltage, default is 16.5
V (range is −10 V to 50 V).
D2 value is the unit of measure as determined in the setup menu. (IPM, MPM, Current and Thickness)
. When L2 LED is stable the welding arc
is in a Short Circuit or Spray Arc transfer. If L2 is flashing this indicates that
the welding parameters are outside of
the specific setting required for either
arc transfer to exist. This process is
known as Globular Arc transfer. This
process produces considerable undesirable welding spatter. It may be desirable to switch to a Pulsed-MIG Arc
transfer to reduce/eliminate welding
spatter.
L3 Synergic Pulsed MIG welding.
D1 value is welding voltage, default is 20
V (range is −10 V to 50 V).
D2 value is the unit of measure as determined in the setup menu. (IPM, MPM, Current and Thickness)
L4 Lift-TIG process (see Section 4-16) or
Stick process (see Section 4-17).
If selected process is TIG:
D1 displays TIG, and D2 value is welding
current, default is 220 A (range is 10 A to
400 A).
If selected process is Stick:
D1 displays Stick welding. Output is not enabled until button P7 is set to Output enabled mode. Display D1 displays open circuit voltage (OCV) at approximately 85
VDC. Display D2 displays welding current,
default is 220 A (range is 10 A to 400 A).
OM-244 243 Page 21
4-6. Wire Type Selection in Synergic MIG or Synergic Pulsed MIG Welding
L5
L6
L7
Ref. 956142645-5-A
L8
P4
L5 LED
is no program for the process, material,
wire diameter, and shielding gas combination.
L6 LED
L7 LED
L8 LED
L5 selection is for carbon steel.
P4 Push Button
Press P4 until desired material LED illuminates. D1 and D2 will show material name
only momentarily, and then return to the
main display.
. D1 and D2 will show NO PROG or a
selection will not be allowed when there
L6 selection is for stainless steel.
L7 selection is for aluminum.
L8 selection is for other wire types not provided by standard selection.
Pressing P2 push button after a selection is
made to allow choosing other wire types
within the main selection.
SG2/3 allows selecting SG2 or SG3.
CrNi allows selecting 308L, 309L, or 316L.
Al allows selecting AlMg (AlMg5) or AlSi
(AlSi5).
Special permits selection of cored wire or
special wire types. (Abbreviations for the
different wire types appear in displays D1
and D2).
. Wire type selection is retained in the
welding process memory until a new
selection is made.
4-7. Wire Diameter Selection In Synergic MIG Or Synergic Pulsed MIG Welding
L9
L10
L11
L12
P5
Ref. 956142645-5-A
L9 LED
L10 LED
L11 LED
L12 LED
P5 Push Button
Press P5 until desired wire diameter LED
illuminates.
OM-244 243 Page 22
. D1 and D2 will show NO PROG or a
selection will not be allowed when
there is no program for the process,
material, wire diameter, and shielding
gas combination.
L9 selection is for 0.8 mm diameter wire.
L10 selection is for 1.0 mm diameter wire.
L11 selection is for 1.2 mm diameter wire.
L12 selection is for other wire diameters not
provided by standard selection.
Pressing P2 push button after the special
selection is made to allow choosing other
wire diameters not available by standard
selection.
4-8. Gas Selection in Synergic MIG or Synergic Pulsed MIG Welding
L13
Ref. 956142645-5-A
Gas
P6
L13 LED
P6 Push Button
Press P6 until gas LED illuminates. D1 and
D2 will show gas name momentarily. Rotate
E2 encoder to select desired gas type. After
a brief moment the the displays will return to
the main parameters.
. Displays D1 and D2 will display NO
PROG or alternate selection will not be
possible when either process, material,
wire diameter, and shielding gas combination is not permitted.
4-9. Trigger Mode Selection (L-TIG and Stick Processes)
L14
L15
L16
L17
P7
. Always check and set a trigger mode.
If trigger mode is undefined for a welding process, select the desired mode.
L14 LED
L15 LED
L16LED
L17 LED
Ref. 956142645-5-A
al welding current. If welding output is disabled welding (L17 OFF, D1 displays
STICK and D2 displays set current).
Press P7 to select the desired trigger mode:
L14 ON selects 2T trigger mode.
When trigger is pressed, welding starts.
When trigger is released, welding stops.
When trigger is pressed, welding starts with
initial level of welding current (Level 1).
When trigger is released, welding current
increases to the set current level (Level 2).
When trigger is pressed a second time,
weld current decreases to the set current
level (Level 3) arc extinguishes.
Trigger mode can be set for TIG only.
When trigger is pressed, welding starts at
initial current level (IN).
During level 2 mode if the torch trigger is
pressed and held, welding current decreases to the set final-current level (FI-A).
Releasing trigger extinguishes welding arc.
In TIG welding, pressing P7 will change the
trigger mode, but D1 and D2 will not change
values.
When trigger is released, welding current
increases to the set current level.
. L16 trigger mode is useful for thin mate-
In Stick welding, pressing P7 will enable
welding (L17 ON, D1 shows open circuit
voltage (OCV) or weld voltage.
When trigger is pressed and held, welding
current decreases to the set final current
(FI-A) is achieved. Releasing trigger extinguishes welding arc.
D2 displays pre-set welding current or actu-
L16 ON selects 3 levels trigger function.
L17 ON: Weld output power is enabled
welding terminals are electrically live. Stick/
TIG process requires LED L17 to be enabled. LED L17 will illuminate when welding
output power is enabling MIG mode.
P7 Push Button
L15 ON selects 4T trigger mode.
rials and for a crater fill sequence.
OM-244 243 Page 23
4-10. Welding Parameter Setup Menu (Double Pulsed-MIG/L-TIG And Stick)
Press P2 to enter SET UP menu.
SET UP will appear on D1 and D2 momentarily changing to the selected process parameter values.
Setup permits the viewing and changing of default parameters for each process mode.
Double Pulsed-MIG (DP) Mode
D1 displays DP.
D2 displays ON/OFF.
E1 changes the mode of D2.
L-TIG/STICK Mode
D1 displays the welding parameter.
P2
D2 displays the parameter value.
E1 changes the welding parameter.
E2 changes the parameter value.
. Incorrect settings in any process
can result in a program with undesirable weld characteristics. Setup
should only be used by operators
familiar with various welding processes and parameters.
Ref. 956142645-5-A
4-11. Preparing Power Source For MIG (GMAW) Welding Process
Ref. 956142645-5-A
To select MIG welding process, proceed as
follows:
. Follow safety precautions according to
Section 1.
Prepare unit according to Section 3.
Use the correct interconnecting cable to
connect power source unit to the wire feeder (see Wire Feeder manual).
Use a cable with a correct adapter, connect
gun to the MIG gun connector on wire feeder (see Wire Feeder manual).
OM-244 243 Page 24
Connect work clamp cable to the WORK
connector.
If using a water-cooled gun, connect input
coolant hose to blue quick connect fitting
and return coolant hose to red quick connect fitting.
. Check
coolant level after attaching
torch coolant hoses and running cooler. Be sure coolant appears in upper
half of indicator. Add coolant if necessary (see Section 3-15).
Setting Cooler Status (see Section 4-3)
. To
prevent damage to water-cooled
torch and components, be sure that
coolant is turned on.
If a remote control is desired, connect it to
the Remote Control receptacle on the wire
feeder (see Wire Feeder manual).
Turn unit On.
Allow time for unit to complete its start up
cycle.
Set MIG welding process using P3 push
button.
4-12. Selecting Manual MIG Welding
D1
D2
P3
Ref. 956142645-5-A
Set Manual MIG welding process using P3
push button.
In Manual MIG mode, the operator may
need to adjust main welding parameters for
specific arc characteristics. Wire feed
speed and arc voltage will appear on D1
and D2.
During Setting :
D1 value is default voltage setting of 18.5 V
(range is 10.0 V to 50.0 V).
D2 value is default wire feed speed setting
of 5.0 m/min (range is 1.0 m/min to 20.0
m/min).
During MIG Welding:
D1 value is Measured Welding Voltage in
Volts.
D2 value is Measured Welding Amperage
in Amperes.
See Wire Feeder manual for remaining
manual MIG settings.
OM-244 243 Page 25
4-13. Selecting Synergic MIG Welding
E1
P3
P4
D1
P5
D2
P6
E2
P7
Ref. 956142645-5-A
Set Synergic MIG welding process using
P3 push button.
In Synergic MIG mode, the operator may
need to adjust welding data (wire type, wire
diameter, and gas type) and only one weld
parameter. Generally, wire feed speed is
adjusted and the synergic process automatically sets appropriate weld voltage.
Synergic welding also sets many secondary welding parameters automatically for
improved weld quality.
D1 value is default voltage setting (range is
OM-244 243 Page 26
defined by wire type, wire diameter and gas
type selection).
D2 value is the default current setting
(range is defined by wire type, wire diameter and gas type selection).
During Synergic MIG Welding:
D1 value is Measured Welding Voltage in
Volts.
D2 value is Measured Welding Amperage
in Amperes.
See Wire Feeder manual for all remaining
Synergic MIG settings.
Select wire type using P4 push button.
Select wire diameter using P5 push button.
Select gas using P6 push button.
Select trigger mode using P7 push button.
See Wire Feeder manual for remaining
Synergic MIG settings.
Setting Cooler Status (see Section 4-3 )
. To
prevent damage to water-cooled
torch and components, be sure that
coolant is turned on.
4-14. Selecting Synergic Pulsed MIG Welding
E1
P3
P4
D1
P5
D2
P6
E2
P7
Ref. 956142645-5-A
Set Synergic Pulsed MIG welding process
using P3 push button.
Synergic Pulsed MIG welding is a high quality welding process that produces very
little spatter. This process works well on thin
metals such as stainless steel and aluminum.
During Synergic MIG Welding:
D1 value is Measured Welding Voltage in
Volts.
D2 Value is Measured Welding Amperage
in Amperes.
Select wire type using P4 push button.
Select wire diameter using P5 push button.
In Synergic Pulsed MIG mode, the operator
may need to adjust welding data (wire type,
wire diameter, and gas type) and only one
weld parameter. Generally, wire feed speed
is adjusted and the synergic process automatically sets appropriate weld voltage.
Synergic welding also sets many secondary welding parameters automatically for
improved weld quality.
During Setting:
D1 value is the default voltage setting
(range is defined by wire type, wire diameter and gas type selection).
D2 value is the default current setting
(range is defined by wire type, wire diameter and gas type selection).
. Incorrect settings in Synergic Double
Pulsed Welding process can result in a
program with undesirable weld characteristics. Setup should only be used by
operators familiar with various welding
processes and parameters. In certain
applications standard Pulsed MIG
welding may be preferred.
Select gas using P6 push button.
Press P2 to enter setup menu.
Select trigger mode using P7 push button.
D1 displays DP.
See wire feeder manual for all the remaining
Synergic MIG settings.
D2 default setting is OFF.
Setting Cooler Status (see Section 4-3)
Use E2 to change D2 value to ON. This setting will enable or disable Double Pulsed
MIG Synergic welding.
Setting Synergic Double Pulsed MIG
Welding
Some metals weld better using the Synergic Double Pulsed Welding process due to
the unique pulsing of the welding arc. Heat
generated in the workpiece is generally
lower and the arc characteristics produce a
better weld bead appearance especially on
aluminum. The Synergic Double Pulsed
MIG process allows control all parameters
to produce high quality welds on aluminum.
. On power source, only Double pulse
enabling and disabling is possible. All
the remaining Double Pulse settings
are made on the wire feeder (see Wire
Feeder manual). From the wire feeder
it is possible to recall Synergic MIG,
Synergic Pulsed MIG and Synergic
Double Pulsed MIG programs (see
Wire Feeder manuals).
OM-244 243 Page 27
4-15. Preparing Unit For TIG Welding
E1
D1
D2
E2
P2
P3
P7
Ref. 956142645-5-A
To prepare unit for TIG welding, proceed as
follows:
. If D1 does not display TIG proceed as
Follow safety precautions according to
Section 1.
Press P2 setup button. D1 will display STK.
Rotating E2 encoder changes process to
TIG mode.
Use E1 to change D1 to SLUP.
Purge air from torch gas hose using Torch
Trigger (Manual Purge).
Setting Slope-Down Time
Prepare unit according Section 3.
Connect torch to the WORK connector 3
and the gas pipe to the gas connector 5.
Using a cable with a proper adapter, connect work clamp cable to the MIG gun connector.
If using a water-cooled torch, connect input
coolant hose to blue quick connect fitting
and return coolant hose to red quick connect fitting.
. Check
coolant level after attaching
torch coolant hoses and running cooler. Be sure coolant appears in upper
half of indicator. Add coolant if necessary (see Section 3-15).
Turn unit On.
Allow time for unit to complete its start up
cycle.
Set TIG welding process using P3 push
button.
OM-244 243 Page 28
follows:
Select trigger mode using P7 push button
(see Section 4-9).
Setting Slope-Up Time
Press P2 to enter SET UP menu.
D2 default setting is 0.1 second (range is
0.0 seconds to 10.0 A).
Press P2 to enter SET UP menu.
Use E1 to change D1 to SLDW.
Setting Initial And Final Current
D2 value is default setting of 0.1 second
(range is 0.0 seconds to 10.0 A).
Use E1 to change D1 to IN−A (Initial Current).
Setting Postflow
D2 value is default setting of 20 A (range is
5 A to 400 A).
Use E2 to change D2 value.
This parameter allows starting the welding
process at a lower initial amperage setting.
Use E1 to change D1 to FI−A (Final Current).
D2 value is default setting of 20 A (range is
5 A to 400 A).
Use E2 to change D2 value.
This parameter allows finishing the welding
process at a lower final amperage setting.
Press P2 to enter SET UP menu.
Use E1 to change D1 to POSG.
D2 value is default setting of 5.0 second
(range is 0.0 seconds to 50.0 seconds).
Use E2 to change D2 value.
Setting Cooler Status (see Section 4-3)
. To prevent
damage to water-cooled
torch and components, be sure that
coolant is turned on.
Purge air from torch gas hose using Torch
Trigger (Manual Purge).
Select trigger mode using P7 push button.
4-16. TIG Lift-Arc Welding
Lift-Arc Start
When process selector LED 4 is illuminated in TIG mode Lift-Arc TIG
is enabled.
1
“Touch”
2
1−2
Seconds
1
TIG Electrode
2
Workpiece
Touch tungsten electrode to workpiece at weld start point, enable output and shielding gas with torch trigger, foot control, or hand control.
Hold electrode to workpiece for
1-2 seconds, and slowly lift electrode. Arc is formed when electrode
is lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
electrode and workpiece. The
solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece without overheating, sticking, or getting
contaminated.
Application:
Do NOT Strike Like A Match!
Lift-Arc is used for the DCEN or AC
GTAW process when HF Start
method is not permitted, or to replace the scratch method.
Ref. S-156 279
4-17. Preparing Unit For Stick Welding
To select Stick welding process, proceed
as follows:
Follow safety precautions according to
Section 1.
Prepare unit according to Section 3.
Connect electrode holder to the Positive
power connector 2.
Connect work clamp cable to the negative
connector 3.
If a remote control is desired, connect it to
the Remote Control receptacle 4.
Turn unit On.
Allow time for unit to complete its start up
cycle.
Set Stick welding process using P3 push
button.
. If D1 does not display STK proceed as
follows:
Press P2 setup button. D1 will display TIG.
Rotating E2 encoder changes process to
STK mode.
HOT START Setting
To change HOT START setting, proceed
as follows:
Press P2 to enter SET UP menu.
Use E1 to change D1 to HOT.
D2 value is default setting of 20% (range is
0% to 100%).
Use E2 to change D2 value.
This parameter increases output amperage at the start of a weld to eliminate electrode sticking.
ARC FORCE Setting
To change ARC FORCE setting, proceed
as follows:
Press P2 to enter SET UP menu.
Use E1 to change D1 to ARC.
D2 value is default setting of 0% (range is
0% to 100%).
Use E2 to change D2 value.
When setting is increased, short-circuit
amperage at low arc voltage increases.
STUCK Setting
To change STUCK ON/OFF setting, proceed as follows:
Press P2 to enter SET UP menu.
Use E1 to change D1 to STUK.
D2 default setting is OFF
Use E2 to change D2 to ON.
This parameter prevents the wire from
sticking at the start of the weld
. STICK welding can be enabled (L20
ON) or disabled (L20 OFF) using P7
push button, and this status is retained
in the STICK welding process
memory.
OM-244 243 Page 29
SECTION 5 − MAINTENANCE & TROUBLESHOOTING
5-1. Routine Maintenance
!
. Maintain more often
Disconnect power
before maintaining.
during severe conditions.
3 Months
Repair Or
Replace
Cracked
Cables
Replace
Damaged Or
Unreadable
Labels
Replace Cracked
Torch Body
Repair Or Replace
Cracked Cables
And Cords
Clean
And
Tighten Weld
Connections
6 Months
Blow Out Inside
Replace
Cracked
Hoses
Change
Coolant (If
Using Water)
Blow Out Heat
Exchanger Fins
12 Months
Change Coolant (If
Using MILLER Coolant)
OM-244 243 Page 30
5-2. Help Displays
. All directions are in reference to the front
of the unit. All circuitry referred to is
located inside the unit.
Help 0
Help 4
Help 8
Indicates a malfunction in the thermal protection circuitry on right side of unit. Contact a
Factory Authorized Service Agent.
Help 5
Indicates shorted thermistor RT2 on left side
of unit. Contact a Factory Authorized Service
Agent.
Help 1
Indicates overheating on right side of unit.
Unit will shutdown and fan will run until internal temperature drops within operational
range.
Help 6
Indicates a malfunction in the primary power
circuit. Contact a Factory Authorized Service
Agent.
Help 2
Indicates a malfunction in the thermal protection circuitry on left side of unit. Contact a
Factory Authorized Service Agent.
Help 3
Indicates overheating on left side of unit. Unit
will shutdown and fan will run until internal
temperature drops within operational range.
Indicates input voltage is too low and unit has
automatically shut down. Operation will continue when voltage is within an acceptable
lower range limit (15% below acceptable input voltage). Contact an electrician to check
input line voltage.
Help 7
Indicates input voltage is too high and unit
has automatically shut down. Operation will
continue when voltage is within an acceptable upper range limit (15% above acceptable input voltage). Contact an electrician to
check input line voltage. HELP 7 may also indicate a bus voltage imbalance.
Indicates a malfunction in the secondary
power circuit of the unit. Contact a Factory
Authorized Service Agent.
Help 9
Indicates a shorted thermistor RT1 on right
side of unit. Contact a Factory Authorized
Service Agent.
Help 15
Indicates a malfunctioning cooling unit. Unit
will shut down immediately. Turn off primary
power. Check and repair cooling unit components as necessary. Unit will operate when
power to unit is turned off and back on.
Help 50
Indicates an overload at the power module.
Reduce weld parameter settings and/or duty
cycle. If error continues, contact a Factory
Authorized Service Agent.
5-3. Troubleshooting
Trouble
Remedy
No weld output: unit completely inopera- Place line disconnect switch in On position (see Section 3-17).
tive.
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-17).
Check for proper input power connections (see Section 3-17).
No weld output; meter display On.
Verify welding parameter settings.
Verify Help messages and correction procedures as necessary.
Check, repair, or replace remote control.
Unit overheated. Allow fan to run and unit cool (see Section 3-6).
Erratic or improper weld output.
Use proper size and type of weld cable (see Section 3-12).
Clean and tighten all weld connections.
Coolant system not working (HELP 15
is displayed).
Check and secure coolant hose connectors.
Reset circuit breaker CB7 (see Section 3-14).
Motor overheated. Allow motor to cool and restart operation.
Have Factory Authorized Service Agent check cooling unit.
Reduced or no coolant flow from cooling unit (HELP 15 can be displayed).
Add coolant.
Check for blockage at hoses.
Control panel not functioning properly.
Software problems.
Switch unit off and back on again to verify LEDs and display status.
Reinstall factory parameters (see Section 4-2).
Contact a Factory Authorized Service Agent.
OM-244 243 Page 31
SECTION 6 − ELECTRICAL DIAGRAM
Figure 6-1. Circuit Diagram For XMS 403
OM-244 243 Page 32
956142623-C
OM-244 243 Page 33
SECTION 7 − PARTS LIST
8
. Hardware is common and
9
7
12
17
18
16
15
1
2
14
3
4
13
12
11
5
6
19
10
23
22
21
20
not available unless listed.
956142645-1-B
Figure 7-1. Unit Outer Assembly
OM-244 243 Page 34
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-1. Unit Outer Assembly
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
. . . . . . . . . . . . . . . . . +V17031284
. . . . . . . . . . . . . . . . . . . 156012136
. . . . . . . . . . . . . . . . . . . . . . 207235
. . . . . . . . . . . . . . . . . +156005098
. . . . . . . . . . . . . . . . . . . 956142616
. . . . . . . . . . . . . . . . . . . 956142617
. . . . . . . . . . . . . . . . . . . 956142621
. . . . . . . . . . . . . . . . . . . 156087017
. . . . . . . . . . . . . . . . . . . 156009067
. . . . . . . . . . . . . . . . . . . 056054075
. . . . . . . . . . . . . . . . . . . 156012119
. . . . . . . . . . . . . . . . . . . . . . 207233
. . . . . . . . . . . . . . . . . +V16122287
. . . . . . . . . . . . . . . . . . V56142305
. . . . . . . . . . . . . . . . . . . 056054092
. . . . . . . . . . . . . . . . . . V56142303
. . . . . . . . . . . . . . . . . . . . . . 207291
. . . . . . . . . . . . . . . . . +V16122288
. . . . . . . . . . . . . . . . . . . 156018115
. . . . . . . . . . . . . . . . . . . 057052044
. . . . . . . . . . . . . . . . . . . 057052045
. . . . . . . . . . . . . . . . . . . 057052043
. . . . . . . . . . . . . . . . . . . 058066057
...
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...
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...
...
...
...
...
...
...
...
...
...
...
Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Warning, Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder Rack, Upper Support . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Rear, Gas, 14 Pin & Fuse Terminals . . . . . . . . . . . .
Nameplate, Rear, Water & Dinse . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pin, Split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel, Rear, 250 o.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axle, Rear Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Side Panel, R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Front, Dinse Negativ . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel/Caster Wheel w/Brake, Front . . . . . . . . . . . . . . . . . . . . . . .
Nameplate, Front, Dinse Positiv . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Primary Power Connections . . . . . . . . . . . . . . . . . . . . . . . .
Side Panel, L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nut 5/8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting, Hose Brs Barbed M 1/4Tbg x 5/8−18 SAE . . . . . . . . . . .
Fitting, Quick Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adapter 5/8 UNC−3/8 BSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas, Connection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
4
2
1
2
1
1
2
1
1
1
1
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-244 243 Page 35
2
3
1
4
5
OM-244 243 Page 36
18
6
19
20
12
13
8
7
21
9
22
Figure 7-2. Unit Main Assembly
36
32
6
35
10
34
25
26
24
27
23
11
33
32
31
30
29
28
39
38
37
15
14
41
40
48
46
47
16
17
50
42
51
49
52
60
43
44
53
54
45
33
32
31
59
58
55
61
48
56
57
62
63
64
65
. Hardware is common and
not available unless listed.
956142645-2-B
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-2. Unit Main Assembly
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8
9
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11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
. . . . . . . . . . . . . . . . . . . 316005010
. . . . . . . . . . . . . . . . . . . . . . 201531
. . . . . . . . . . . . . . . . . . . . . . 199840
. . . . . . PC6 . . . . . . . . . . . 229967
. . . . . . HD1 . . . . . . . . . . . 182918
. . . . . . RT2 . . . . . . . . . . . 173632
. . . . . . PC1 . . . . . . . . . . . 229959
. . . . . . . T1 . . . . . . . . . . . . 179616
. . . . . . . L1 . . . . . . . . . . . . 173563
. . . . . . . Z1 . . . . . . . . . . . . 173570
. . . . . . . T2 . . . . . . . . . . . . 195829
. . . . . PM1,2 . . . . . . . . . . 233043
. . . . . . SR1 . . . . . . . . . . . 179629
. . . . . . C1 . . . . . . . . . . . 188446
. . . . . . C3,4 . . . . . . . . . . . 192935
. . . . . . . . . . . . . . . . . . V16117300
. . . . . . . . . . . . . . . . . . V16117360
. . . . . . . . . . . . . . . . . . . 156002045
. . . . . . . . . . . . . . . . . . . . . . 213051
. . . . . . . . . . . . . . . . . . . . . . 193919
. . . . . . . . . . . . . . . . . . . 156118056
. . . . . . . S1 . . . . . . . . . . . 176226
. . . . . . PC2 . . . . . . . . . . . 212210
. . . . . . PC3 . . . . . . . . 057084139
. . . . . . . . . . . . . . . . . . . 116118180
. . . . . . . . . . . . . . . . . . . 057028110
. . . . . . . . . . . . . . . . . . . 656026097
. . . . . . . . . . . . . . . . . . . 656026099
. . . . . . . . . . . . . . . . . . . 656026102
. . . . . . . . . . . . . . . . . . . . . . 188192
. . . . . . . . . . . . . . . . . . . . . . 208967
. . . . . . . . . . . . . . . . . . . 556049402
. . . . . . . . . . . . . . . . . . . 556049401
. . . . . . FM . . . . . . . V56126046
. . . . . . . . . . . . . . . . . . V56005296
. . . . . . . . . . . . . . . . . . V16039294
. . . . . . . . . . . . . . . . . . . 056082099
. . . . . . . . . . . . . . . . . . . 656026100
. . . . . . . . . . . . . . . . . . . 116117082
. . . . . . . . . . . . . . . . . . . 156005141
. . . . . . . . . . . . . . . . . . . 056061070
. . . . . . . . . . . . . . . . . . . 656026111
. . . . . . . . . . . . . . . . . . V56031377
. . . . . . . . . . . . . . . . . . . 556049411
. . . . . . . . . . . . . . . . . . V16006289
. . . . . . . . . . . . . . . . . . . . . . 176106
. . . . . . . . . . . . . . . . . . . 116122306
. . . . . . . . . . . . . . . . . . . 656026098
. . . . . . . . . . . . . . . . . . . 027042002
. . . . . . . . . . . . . . . . . . . . . . 166564
. . . . . . . . . . . . . . . . . . V57011071
. . . . . . . . . . . . . . . . . . . 656026092
. . . . . WCP . . . . . . . 057010059
. . . . . . . . . . . . . . . . . . V56118293
. . . . . . CB2 . . . . . . . . . . . 083423
. . . . . . CB1 . . . . . . . . . . . 161078
. . . . . . . . . . . . . . . . . . V56091091
. . . . . . GSV . . . . . . . . . . . 228036
. . . . . . . . . . . . . . . . . . . 156076085
. . . . . WCF . . . . . . . . . . 213072
. . . . . . . . . . . . . . . . . . . 656026101
. . . . . . . . . . . . . . . . . +V16118292
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LEM, Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit Diode, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . .
Thermistor, NTC 30K ohms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transformer, HF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transformer, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit, Transistor IGBT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit Diode, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, Polyp Film .5Uf 900VDC . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor, Elctlt 2700Uf 450VDC . . . . . . . . . . . . . . . . . . . . . . . . . .
Wind Tunnel Extension, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wind Tunnel Extension, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plastic, Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Knob, Pointer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Panel, Membrane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switch, Power ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Interconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Card, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control 14 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, 5x8,5x940 Black Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, 6x11x470 Blu Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, 6x11x270 Red Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle, Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle, Dinse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Connection, Quick Connect . . . . . . . . . . . . . . . . . . . . . . . . .
Water Connection, Quick Connect . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support, Module, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Box Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, 6x11x780 Blu Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plenum, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support, Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow-Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, 6x11x160 Red Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support Switch, Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Header, 3 Way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, Fan Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Bracket, Tank Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, 6x11x250 Blu Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tank, Water 8 Liter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter, In−line Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, 6x11x350 Blu Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor, 170W, 115 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, Man Reset 1P 10A 250VAC . . . . . . . . . . . . . . . .
Circuit Breaker, Man Reset 1P 7A 250VAC . . . . . . . . . . . . . . . . .
Strain Relief, Primary Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve, 24VAC 1 Way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receptacle, 14 Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Assy, Radiator Cooling 115 V . . . . . . . . . . . . . . . . . . . . . . . . .
Hose, 6x11x590 Red Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Panel, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
3
2
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
OM-244 243 Page 37
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 7-2. Unit Main Assembly (Continued)
. . . 63 . . . . . . . T4 . . . . . . . . V58021080 . . . Transformer, 400VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . . . . . . . . . . . . . . . . . . . 220805 . . . Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . . . . . V57014066 . . . Primary Cable, 4 Core 6,0 Mq . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
Notes
OM-244 243 Page 38
Effective January 1, 2013
(Equipment with a serial number preface of MD or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions
below, ITW Welding Products Italy warrants to its original retail
purchaser that new Miller equipment sold after the effective date
of this limited warranty is free of defects in material and
workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE
WARRANTIES OF MERCHANTABILITY AND FITNESS.
Within the warranty periods listed below, Miller will repair or
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim
procedures to be followed.
Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the date the
equipment was delivered to the original retail purchaser or one
year after the equipment is shipped to a European distributor or
eighteen months after the equipment is shipped to an
International distributor.
1.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Auto-Darkening Helmet Lenses (No Labor)
Migmatic 175
HF Units
Water
Coolant
Systems
(EU
Models,
Non-Integrated)
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
5.
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
Inverter Power Sources (Unless Otherwise Stated)
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Transformer/Rectifier Power Sources
Water Coolant System (Integrated)
2 Years — Parts
*
*
*
*
4.
Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules with
exclusion of STR, Si, STi, STH and MPi series.
Automatic Motion Devices
Field Options
(NOTE: Field options are covered under True Blue®
for the remaining warranty period of the product they
are installed in, or for a minimum of one year —
whichever is greater.)
Induction Heating Power Sources, Coolers, and
Electronic Controls/Recorders
Motor Driven Guns (w/exception of Spoolmate
Spoolguns)
Positioners and Controllers
Powered Air Purifying Respirator (PAPR) Blower
Unit (No Labor)
Racks
Running Gear and Trailers
Subarc Wire Drive Assemblies
Water
Coolant
Systems
(USA
Models,
Non-Integrated)
Work Stations/Weld Tables (No Labor)
6 Months — Parts
*
Batteries
90 Days — Parts
*
Accessory (Kits)
*
Canvas Covers
*
Induction Heating Coils and Blankets
*
MIG Guns
*
Remote Controls
*
Replacement Parts (No Labor)
*
Spoolmate Spoolguns
*
Cables and Non-Electronic Controls
Miller’s True Blue® Limited Warranty shall not apply to:
1.
Consumable components; such as contact tips,
cutting nozzles, contactors, brushes, switches, slip
rings, relays or parts that fail due to normal wear.
2.
Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.
3.
Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.
5 Years Parts — 3 Years Labor
*
2.
6.
MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the
exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
replacement at an authorized Miller service station; or (4)
payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
customer’s risk and expense. Miller’s option of repair or
replacement will be F.O.B., Factory at ITW Welding Products
Group Europe or F.O.B. at a Miller authorized service facility as
determined by Miller. Therefore no compensation or
reimbursement for transportation costs of any kind will be
allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
DIRECT,
INDIRECT,
SPECIAL,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
ANY
IMPLIED
WARRANTY,
GUARANTY
OR
REPRESENTATION AS TO PERFORMANCE, AND ANY
REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
INCLUDING
ANY
IMPLIED
WARRANTY
OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
BY MILLER.
milan_warr 2013−01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original customer.)
Distributor
Address
Country
Zip/Postal Code
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Service and Repair
Replacement Parts
Owner’s Manuals
ITW Welding Italy S.r.l.
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
© 2013 Miller Electric Mfg. Co. 2013−01
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39 (0) 2982901
Fax: 39 (0) 298290-203
email: miller@itw−welding.it