Miller | MB027927D | Owner Manual | Miller XPS 350 CE User manual

Miller XPS 350 CE User manual
OM-249 332C
2011−09
Processes
MIG (GMAW) Welding
Flux Cored (FCAW)
Description
Arc Welding Power Source
XPS 350 And 450
CE
www.MillerWelds.com
OWNER’S MANUAL
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. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Duty Cycle Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Typical MIG Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Installing Single Bottle And Upper Bracket Support (All Models: Optional) . . . . . . . . . . . . . . . . . . . . . .
4-4. Installing Double Bottle And Upper Bracket Support (All Models: Optional) . . . . . . . . . . . . . . . . . . . . . .
4-5. Installing Input Gas And Water Cooler Hoses (All Models: Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Weld Output Terminals And Selecting Cable Sizes* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Remote 14 Receptacle RC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Positioning Jumper Links (230/400 VAC 3-Phase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Connecting Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Controls For The XPS 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Controls For The XPS 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Unit Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 - ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 - PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
1
1
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3
4
4
4
5
7
8
8
8
8
9
10
11
11
11
12
13
14
15
16
16
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40
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
XPS 350,400VAC
029015528
XPS 450,400VAC
029015529
XPS 350, BASIC 400VAC
029015531
XPS 450, BASIC 400VAC
029015532
XPS 350, 230/400VAC
029015534
XPS 450 ,230/400VAC
029015535
XPS 350, BASIC 230/400VAC
029015537
XPS 450, BASIC 230/400VAC
029015538
Council Directives:

2006/95/EC Low Voltage

2004/108/EC Electromagnetic Compatibility
Standards:

IEC 60974­1 Arc Welding Equipment ­ Welding Power Sources: edition 3, 2005­07.

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:
December 13th, 2010
___________________________________________________________________________________
Massimigliano Lavarini
Date of Declaration
ELECTRONIC ENGINEER R&D TECH. SUPPORT
956 142 839
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−01
7
Protect yourself and others from injury — read and follow these precautions.
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 and ground 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.
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-249 332 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 closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (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-249 332 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.
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.
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.
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.
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.
OVERUSE can cause OVERHEATING
H.F. RADIATION can cause interference.
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.
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.
D
D
D
D
STATIC (ESD) can damage PC boards.
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.
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
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-249 332 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.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
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,
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).
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, 4221 Walney Road, 5th Floor,
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).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
www.cpsc.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, access restrictions for passers−by or 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-249 332 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
Warning! Watch Out! There are possible
hazards as shown by the symbols.
1 Electric shock can kill.
1.1 Wear dry insulating gloves. Do not
touch electrode with bare hand. Do
not wear wet or damaged gloves.
1.2 Protect yourself from electric shock
by insulating yourself from work and
ground.
1.3 Disconnect input plug or power
before working on machine.
2 Breathing welding fumes can be
hazardous to your health.
2.1 Keep your head out of the fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove fumes.
3 Welding sparks can cause explosion
or fire.
3.1 Keep flammables away from welding.
Do not weld near flammables.
3.2 Welding sparks can cause fires.
Have a fire extinguisher nearby, and
have a watchperson ready to use it.
3.3 Do not weld on drums or any closed
containers.
4
Arc rays can burn eyes and injure
skin.
4.1 Wear hat and safety glasses. Use
ear protection and button shirt collar.
Use welding helmet with correct
shade of filter. Wear complete body
protection.
5
Become trained and read the
instructions before working on the
machine or welding.
6
Do not remove or paint over (cover)
the label.
1/96
Do not discard this product 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.
OM-249 332 Page 5
Warning! Watch Out! There are
possible hazards as shown by the
symbols.
Electric shock from wiring can kill.
Disconnect input plug or power
before working on machine.
Read the Owner’s Manual before
working on this machine.
1
Consult rating label for input
power requirements, and
check power available at the
job site − they must match.
Read Owner’s Manual and
inside labels for connection
points and procedures.
Move jumper links as shown
on inside label to match
voltage at job site.
Having a loop of extra length,
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.
2
3
4
5
1
1
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Moving parts, such as fans,
can cut fingers and hands and
cause injury. Keep away from
moving parts.
2
2
S-176 106
1
1
1
2
3
2
OM-249 332 Page 6
3
Warning! Watch Out! There
are possible hazards as
shown by the symbols.
Falling unit can cause injury.
Do not move or operate unit
where it could tip.
Cylinders can explode if
damaged. Protect
compressed gas cylinders
from excessive heat,
mechanical shock, slag, open
flames, sparks, and arcs.
2-1. Symbols And Definitions
A
U1
I2
IP
V
Volts
Alternating Current
(AC)
Direct Current
(DC)
Remote
On
Off
Protective Earth
(Ground)
Line Connection
Three Phase
Hz
Hertz
Gas Metal Arc
Welding (GMAW)
I1eff
Maximum Effective
Supply Current
U2
Conventional Load
Voltage
U0
Rated No Load
Voltage (Average)
Amperes
Primary Voltage
I1max
Rated Maximum
Supply Current
Rated Welding
Current
X
Duty Cycle
Percent
Degree Of
Protection
Circuit Breaker
Three Phase
Transformer
Rectifier
Water (Coolant)
Input
Water (Coolant)
Output
Gas Input
Gas Output
Voltage Input
Low Inductance
High Inductance
Read Operator’s
Manual
Notes
OM-249 332 Page 7
SECTION 3 − INTRODUCTION
3-1. Important Information Regarding CE Products (Sold Within The EU)
A. Information On Electromagnetic Fields (EMF)
!
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.
B. 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 complies with IEC 61000−3−12 provided that the short−circuit power Ssc is greater than or equal to 2,562,107.1 at the interface
point between the user’s supply and the public 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 is connected only to a supply with a short−circuit power Ssc greater than
or equal to 2,562,107.1.
ce-emc 1 2011-09
3-2. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the back of the unit . 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.
3-3. Specifications
Amperes Input At
Rated Load Output,
50/60 Hz, Three-Phase
Rated Welding
Output
Amperage
Range DC
Max.
Open-Circuit
Voltage DC
IP Rating
230 V
400 V
KVA/KW
Dimensions
Weight
350
350 A @ 31.5
Volts DC, 45%
Duty Cycle
30 -350 A
43V
IP22S
40 A
23 A
16 KVA
15.2 KW
Length: 860 mm
Height: 570 mm
Width: 930 mm
125 kg
450
450 A @ 36.5
Volts DC, 50%
Duty Cycle
30 -450 A
47V
IP22S
56 A
32 A
22.2 KVA
21.2 KW
Length: 860 mm
Height: 570 mm
Width: 930 mm
153 kg
Model
OM-249 332 Page 8
3-4. Duty Cycle Chart
Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.
If unit overheats, thermostat(s)
opens, output stops, 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 or gun and void
warranty.
450 Amp Model
500
450
Weld Amperes
400
350
300
250
200
150
0
10
20
30
40
50
60
70
80
90
100
% Duty Cycle
60% Duty Cycle at 410A
50% Duty Cycle at 450A
5 Minutes Welding
5 Minutes Resting
6 Minutes Welding
4 Minutes Resting
100% Duty Cycle at 320V
Continuous Welding
Overheating
A
0
15
Minutes
OR
Reduce Duty Cycle
duty1 4/95 / Ref. 168 919
OM-249 332 Page 9
3-5. Volt-Ampere Curves
XPS 350
50
45
40
DC Volts
35
30
Max
25
20
15
Min
10
5
0
0
20
40
60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400
DC Amperes
XPS 450
50
45
40
DC Volts
35
Max
30
25
20
15
Min
10
5
0
0
20 40
60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500
DC Amperes
OM-249 332 Page 10
SECTION 4 − INSTALLATION
4-1. Selecting a Location
Position unit so air can circulate.
500 mm
500 mm
500 mm
956142796_1-10_D
4-2. Typical MIG Connections
5
1
Power source
2
Work clamp (connect to receptacle as shown)
3
Cylinder (chain to running gear)
4
Cylinder valve
4
6
Open valve slightly so gas flow blows dirt from valve.
Close valve.
5
Regulator/Flow gauge
Install so face is vertical.
6
Flow adjust
7
Gas supply line
8
Wire feeder
9
MIG torch
7
3
10 Water Cooler (See Section 4-4)
8
1
10
9
2
956142796_9-10_A
OM-249 332 Page 11
4-3. Installing Single Bottle And Upper Bracket Support (All Models: Optional)
Tools Needed:
M8 (13 mm)
Torx T30
1
2
4
10
4
5
3
7
9
6
8
956142796_6-10_B / 956142796_7-10_B
. Chain cylinder to the support so cylin-
3
Bottle Support
7
der cannot fall and break off valve.
4
Bottle Support Screw
Install so face is vertical.
1
Upper Cylinder Support Bracket
Use screws to secure bottle support to
base.
2
Upper Support Bracket Screw
5
Use screws to secure support bracket to
welding power source.
OM-249 332 Page 12
Running Gear Shaft
Secure wheels to running gear.
6
Cylinder
Regulator/Flowmeter
8
Input Gas Hose
9
Water Cooler
10 Plastic Grommet
Route hoses through grommet and along
track in base (see Section 4-5).
4-4. Installing Double Bottle And Upper Bracket Support (All Models: Optional)
Tools Needed:
M8 (13 mm)
Torx T30
1
2
4
10
4
5
3
9
7
11
6
8
956142796_4-10_B / 956142796_5-10_B
. Chain cylinder to the support so cylinder cannot fall and break off valve.
1
Upper Cylinder Support Bracket
2
Upper Support Bracket Screw
4
Bottle Support Screw
Use screws to secure bottle support to
base.
5
Running Gear Shaft
8
Input Gas Hose
9
Water Cooler
10 Plastic Grommet
Secure wheels to running gear.
Route hoses through grommet and along
track in base (see Section 4-5).
Use screws to secure support bracket to
welding power source.
6
Cylinder
7
Regulator/Flowmeter
11 Water Cooler Mounting Bracket
3
Install so face is vertical.
Bottle Support
Use bracket to secure cooler to bottle support.
OM-249 332 Page 13
4-5. Installing Input Gas And Water Cooler Hoses (All Models: Optional)
1
Hose Retaining Bracket
2
Hoses
Route hoses through track in base,
and use bracket to secure hoses.
3
Water Out Fitting (Cool)
4
Water In Fitting (Hot)
5
Gas Out Fitting
2
1
3
4
5
Tools Needed:
Torx T30
956142796_8-10_C
OM-249 332 Page 14
4-6. 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
30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cable
size.
Weld Output
Terminals
!
Turn off power before connecting to
weld output terminals.
!
Do not use worn,
damaged,
undersized, or poorly
spliced cables.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
30 m (100 ft) or Less
45 m
(150 ft)
60 m
(200 ft)
70 m
(250 ft)
90 m
(300 ft)
105 m
(350 ft)
120 m
(400 ft)
Electrode
Work
956142796_1-10_D
10 − 60%
Duty
Cycle
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)
Welding
Amperes
* This
10 − 100% Duty Cycle
mm2 (AWG)
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-249 332 Page 15
4-7. Remote 14 Receptacle RC1
Socket*
A
B
K
C L N
D M
E
J
I
H
F
G
Socket Information
A
24 volts AC.
B
Contact closure to A completes 24 volts AC contactor control circuit.
D
Circuit Common.
F
Current feedback.
G
Circuit Common for 24 volts AC.
H
Voltage feedback.
4-8. Electrical Service Guide
Elec Serv 2009−08
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.
* Power cord supplied with 230 volt units.
** Larger power cord may be required for cable length greater than 3 meters. Consult national or local regulations.
XPS 350−50/60 Hz Three Phase
XPS 450−50/60 Hz Three Phase
Input Voltage (V)
230
400
230
400
Input Amperes (A) At Rated Output
40
23
56
32
50
25
60
40
Max Recommended Standard Fuse Rating In
Amperes1
Time-Delay Fuses 2
Normal Operating Fuses
3
Min Input Conductor Size In mm2 (AWG) 4 * **
Max Recommended Input Conductor Length In Meters (Feet)
Min Grounding Conductor Size In mm2 (AWG)4 * **
60
35
80
50
6 (10)
4 (12)
10 (8)
6 (10)
26
(86)
48
(156)
29
(94)
57
186)
6 (10)
4 (12)
10 (8)
6 (10)
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-249 332 Page 16
4-9. Positioning Jumper Links (230/400 VAC 3-Phase)
!
Disconnect and lockout/tagout input power before installing or moving jumper links.
. All units have jumper links preset to 400V.
Check input voltage available at site.
1
Jumper Link Label
Check label − only one is on unit.
2
2
Jumper Links
Move jumper links to match input
voltage.
Close and secure access door.
230V
400V
Tools Needed:
1
8mm / .315 in
956142796_3-10_D
Notes
OM-249 332 Page 17
4-10. Connecting Input Power
3
Installation must meet all National
and Local Codes − have only qualified persons make this installation.
Disconnect and lockout/tagout input power before connecting input
conductors from unit.
4
Always connect green or green/
yellow conductor to supply
grounding terminal first, and never
to a line terminal.
For Three-Phase Operation
7
1
2
2
3
4
L1
3
L2
L3
6
Input Power Cord.
For 400 volt models, select size and length
of conductors using Section 4-8. Conductors must comply with national, state, and
local electrical codes. If applicable, use
lugs of proper amperage capacity and
correct hole size.
5
5
6
Disconnect Device (switch shown in
the OFF position)
Green Or Green/Yellow Grounding
Conductor
Disconnect Device Grounding
Terminal
Input Conductors (L1, L2 And L3)
Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
terminal first.
Connect input conductors L1, L2, and L3
to disconnect device line terminals.
7
1
Over-Current Protection
Select type and size of over-current
protection using Section 4-8 (fused disconnect switch shown).
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
Tools Needed:
956142796_10-10_A
OM-249 332 Page 18
SECTION 5 − OPERATION
5-1. Controls For The XPS 350
1
Voltage Range Control S2
2
Allows selection of voltage in three
coarse ranges, A, B, or C.
2
Digital Voltmeter
3
Power On Light PL1
3
4
5
6
1
PL1 is lit when power is On.
4
High Temperature Light PL2
PL2 lights up when unit overheats
and shuts down.
5
Digital Ammeter.
6
Voltage Adjustment Control S3
This control allows for 10 voltage settings in each of the three coarse
voltage ranges (A, B, or C) of S2.
7
Power Switch S1
Front Panel
Use switch to turn unit On and Off.
8
Positive (+) Weld Output Terminal
9
Wire Feeder Power Cable
Receptacle
Use receptacle to supply power to a
wire feeder.
10 High Inductance Negative (−)
Weld Output Terminal
8
7
9
11
10
Connect work lead here for stainless
steel and spray arc applications.
12
11 Low Inductance Negative (−)
Weld Output Terminal
Connect work lead here for most
short arc applications.
Basic Model
12 Supplementary Protector CB1
CB1 protect the 24 volts AC portion of
the circuit from overload.
13 Supplementary Protector CB2
CB2 protect the 115 volts AC portion
of the circuit from overload.
14 115 AC Receptacle RCPT
12
Digital Model
Back Panel
Receptacle is located on the back
panel, and provides power for the gas
heater when welding with CO2
shielding gas, and for the cooling system.
14
13
OM-249 332 Page 19
5-2. Controls For The XPS 450
1
Voltage Range Control S2
Allows selection of voltage in four
coarse ranges, A, B, C, or D.
2
Digital Voltmeter
3
Power On Light PL1
PL1 is lit when power is On.
4
High Temperature Light PL2
2
3
5
4
6
1
PL2 lights up when unit overheats
and shuts down.
5
Digital Ammeter.
6
Voltage Adjustment Control S3
This control allows for 10 voltage settings in each of the four coarse
voltage ranges (A, B, C, or D) of S2.
7
Power Switch S1
Use switch to turn unit On and Off.
8
Positive (+) Weld Output Terminal
9
Wire Feeder Power Cable
Receptacle
Front Panel
7
Use receptacle to supply power to a
wire feeder.
10 High Inductance Negative (−)
Weld Output Terminal
Connect work lead here for stainless
steel and spray arc applications.
8
9
11
10
11 Low Inductance Negative (−)
Weld Output Terminal
Connect work lead here for most
short arc applications.
12 Supplementary Protector CB1
CB1 protect the 24 volts AC portion of
the circuit from overload.
13 Supplementary Protector CB2
12
Back Panel
CB2 protect the 115 volts AC portion
of the circuit from overload.
14 115 AC Receptacle RCPT
Receptacle is located on the back
panel, and provides power for the gas
heater when welding with CO2
shielding gas, and for the cooling system.
14
OM-249 332 Page 20
13
SECTION 6 − MAINTENANCE AND TROUBLESHOOTING
6-1. Routine Maintenance
!
Disconnect power before maintaining.
. Maintain more often during severe conditions.
3 Months
Replace unreadable labels.
Clean and tighten weld terminals.
Repair or replace cracked weld
cable.
Repair or replace cracked gas
hose.
Replace o-ring in electrode/gas
output receptacle if cracked.
6 Months
Blow out or vacuum inside.
OR
6-2. Unit Overload
Thermal switches TP2 in SR1 and TP3−TP4 in XFMR protect the unit from damage due to overheating. If thermal indicator PL2 illuminates, wait for
unit to cool (see Section 3-4) allowing fan motor to run before trying to weld. If unit is cool and no weld output continues, contact a Factory Authorized
Service Agent.
6-3. Troubleshooting
Trouble
Remedy
No weld output; unit completely inoperative.
Place line disconnect switch in On position (see Section 4-10).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-10).
Check for proper input power connections (see Section 4-10).
Check for proper jumper links position (see Section 4-9).
Have factory Authorized Service Agent check continuity of power switch S1, and replace if necessary.
No weld output; pilot light PL2 on.
Unit overheated. Allow unit to cool (see Section 3-4).
Limited weld output, and low open circuit voltage.
Check for proper input power connections (see Section 4-10).
Check for proper jumper links position (see Section 4-9).
Clean and tighten all weld output connections.
Unit provides only maximum or minim- Have factory Authorized Service Agent check control board PC1 and Hall device HD1, and replace if neum weld output.
cessary
OM-249 332 Page 21
Trouble
Remedy
No 115 volts AC output at duplex Reset supplementary protector CB2 (See Section 5).
receptacle.
No 24 volts AC output at Remote 14 re- Reset supplementary protector CB1 (See Section 5).
ceptacle.
Fan not operating; fan only runs when Check for and remove anything blocking fan movement.
cooling is necessary.
Have factory Authorized Service Agent check fan motor.
Have factory Authorized Service Agent check thermostat TP1 if available, and replace if necessary.
Wandering arc; poor control of arc direc- Reduce gas flow rate.
tion.
Digital meter not working properly.
Have factory Authorized Service Agent check control board PC1 and connections, and replace if necessary.
Have factory Authorized Service Agent check meter display board PC2 settings and connections, and
replace if necessary.
Notes
OM-249 332 Page 22
Notes
OM-249 332 Page 23
SECTION 7 - ELECTRICAL DIAGRAM
Figure 7-1. Circuit Diagram for XPS 350 Digital (230/400 VAC)
OM-249 332 Page 24
956142739-F
OM-249 332 Page 25
Figure 7-2. Circuit Diagram for XPS 350 Digital (400 VAC)
OM-249 332 Page 26
956142740-F
OM-249 332 Page 27
Figure 7-3. Circuit Diagram for XPS 450 Digital (230/400 VAC)
OM-249 332 Page 28
956142741-E
OM-249 332 Page 29
Figure 7-4. Circuit Diagram for XPS 450 Digital (400 VAC)
OM-249 332 Page 30
956142742-E
OM-249 332 Page 31
Figure 7-5. Circuit Diagram for XPS 350 Basic (230/400 VAC)
OM-249 332 Page 32
956142801-A
OM-249 332 Page 33
Figure 7-6. Circuit Diagram for XPS 350 Basic (400 VAC)
OM-249 332 Page 34
956142802-B
OM-249 332 Page 35
Figure 7-7. Circuit Diagram for XPS 450 Basic (230/400 VAC)
OM-249 332 Page 36
956142803-B
OM-249 332 Page 37
Figure 7-8. Circuit Diagram for XPS 450 Basic (400 VAC)
OM-249 332 Page 38
956142804-C
OM-249 332 Page 39
SECTION 8 - PARTS LIST
8
9
6
5
10
7
11
3
64
63
13
12
14
65
15
16
20
21
18
66
17
67
60
58
19
22
52
2
56
28
25
71 72
53
51
34
29
69
54
37
35
1
68
55
36
24
27
59
57
23
26
61
62
50
30
70
49
43
48
42
32
47
46
33
45
40
31
38
41
39
44
Ref. 956142796_2-10_F
Figure 8-1. Main Assembly for XPS 350
OM-249 332 Page 40
Quantity
Item
No.
Dia.
Mkgs.
Model
Part
No.
Description
Basic
Digital
Figure 8-1. Main Assembly for XPS 350
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
14
14
14
15
15
16
16
17
18
19
20
21
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
53
. . . . . . . . . . . 000207233
. . . . . . . . . . +156122083
. . . . . . . . . . . 000207291
. . . . . . . . . . . 000119503
. . . . . . . . . . . 000207235
. . . . . . . . . . . 656089043
. . . . . . . . . . +156121041
. . . . . . . . . . +156122084
. . . . . . . . . . . 156005149
. . . . . . . . . . . 156005150
. . . SR1 . . . 056050160
. . . HD1 . . . 056167008
. . . TP2 . . . 056159026
. . . . . . . . . . . 956142789
. . . . . . . . . . . 956142791
. . . . . . . . . . . 956142785
. . . . . . . . . . . 956142787
. . . . T2 . . . 058021151
. . . . T2 . . . 058021154
. . . PC1 . . . 057084155
. . . PC1 . . . 057084149
. . . . . . . . . . . 056092099
. . . . . . . . . . . 056092100
. . . PC2 . . . 057084147
. . . . S2 . . . 056067272
. . . . . . . . . . . 356029217
. . . . . . . . . . . 356029216
. . . PL1 . . . 056072079
. . . . . . . . . . . 056020069
. . . PL2 . . . 056072080
. . . . . . . . . . . 056020069
. . . . . . . . . . . 056076265
. . . . . . . . . . . 156118072
. . . . . . . . . . . 056076152
. . . . . . . . . . . 356029211
. . . . . . . . . . . 000230124
. . . . . . . . . . . 000222779
. . . . . . . . . . . 156005151
. . . . . . . . . . . 056054084
. . . . . . . . . . . 156118068
. . . . S1 . . . 056067267
. . . . S3 . . . 056067269
. . . FM1 . . . 057035009
. . . . . . . . . . . 057015107
. . . . T1 . . . 058021152
. . . . . . . . . . . 556070017
. . . . . . . . . . . 116014052
. . . . . . . . . . . 156005152
. . . . . . . . . . . 156011023
. . . . . . . . . . . 156005153
. . . . . . . . . . . 156012149
. . . . . . . . . . . 156023157
. . . . . . . . . . . 056054085
. . . . . . . . . . . 156009132
. . . . . . . . . . . 156012150
. . . . . . . . . . . 156005154
. . . . . . . . . . . 156006068
. . . . Z . . . . 057098021
. . . . . . . . . . . 156118069
. . . . . . . . . . . 156118071
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Label, general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . .
Panel, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Label, primary power connections . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Label, Miller logo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . .
Label Warning, tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Seal, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Cover, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Panel, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Plate, upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Bracket, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Rectifier, PTS 100x300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Transducer, Current 400A, kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .
Thermostat, 100 10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Rating Plate (230/400 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .
Rating Plate (230/400 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . .
Rating Plate (400 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .
Rating Plate (400 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . .
Transformer, Aux, 220−230V 400V 40x80 . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .
Transformer, Aux, 220−230V 400V 40x50 . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . .
Circuit Board, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . .
Circuit Board, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .
Fuse Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . .
Fuse, 6x30 6.3A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . .
PC2 Circuit Card, Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .
Switch, 20A 3 pos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Nameplate, front, upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .
Nameplate, front, upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . .
Pilot, 24V Lamp, white . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Knob, D.40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Pilot, 24V Lamp, orange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Knob, D.40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Receptacle, 14 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Panel, lower dinse connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Dinse Socket, Female, 50Mmq . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 3 . .
Nameplate, front, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . .
Front, bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Bracket, front, lower, casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Caster, D.125, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . .
Panel, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Switch, c/w protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Switch, 20A 10 pos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Fan, P. 30 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Coil, 400V, 60x80x180 Al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 3 . .
Transformer, 400V, 60x80x180 Al. . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Link, Primary Power Terminal Board, D5, brass . . . . . . . . . . . . . . . 7 . . . . 7 . .
Box, Primary Power Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Bracket, upper, lift eye support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Bracket, lower, lift eye support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Shaft, D.16 L.590, lift eye support . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Clip, Wheel retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . .
Wheel, D.250, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . .
Washer, D.21x37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . .
Axle, Running Gear D.20 L.567 ZN . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Bracket, rear, lower, wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Impedance, D.8.5 L.320, Al. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Panel, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .
Panel, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . .
OM-249 332 Page 41
Quantity
Item
No.
Dia.
Mkgs.
Model
Part
No.
Description
Basic
Digital
Figure 8-1. Main Assembly for XPS 350 (continued)
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54
55
56
56
57
58
59
60
60
61
62
62
63
64
65
66
67
68
69
70
70
71
72
. . . . . . . . . . +156120005
. . . . . . . . . . . 000176106
. . . . W . . . . 057079038
. . . . W . . . . 057079037
. . . . . . . . . . . 156005155
. . . . . . . . . . . 156005146
. . . . . . . . . . . 656089026
. . . . . . . . . . . 057014229
. . . . . . . . . . . 057014228
. . . . . . . . . . . 000175282
. . . . . . . . . . . 356029220
. . . . . . . . . . . 356029226
. . . . . . . . . 156005156
. . . . . . . . . 156123004
. . . RC2 . . . 000604176
. . . CB1 . . . 056067273
. . . CB2 . . . 056067274
. . . . . . . . . 656089044
. . . . . . . . . 156012151
. . . . . . . . . 058056003
. . . . . . . . . 058056004
. . . . . . . . . . . 656089044
. . . . . . . . . . . 956142807
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Conveyor, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Label, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Contactor, 24V 40A (230/400VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Contactor, 24V 25A (400 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Plate, rear, upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Corner, R.15, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . .
Strain Relief, D.30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Line Cable, 4x3 Mt 3, Neoprene (230/400 VAC) . . . . . . . . . . . . . . 1 . . . . 1 . .
Line Cable, 4x4 Mt 3, Neoprene (400 VAC) . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Cover, Receptacle Weatherproof Duplex RCPT . . . . . . . . . . . . . . . . . . . . . 1 . .
Nameplate, rear, w Aux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .
Nameplate, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . .
Bracket, upper bottle support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Chain, D.4 L.750, zinced, bottle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
RCPT, Str Dx Grd 2P3W 15A 125V * 5−15R . . . . . . . . . . . . . . . . . . . . . . . . 1 . .
Circuit Breaker, 6A w/rubber boot . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Circuit Breaker, 4A w/rubber boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .
Grommet, 59x22, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Shaft, Running Gear, D.20 L.120 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . .
Bottle Support, lower, 1 bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Bottle Support, lower, 2 bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Grommet, 59x22, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . .
Label, front, lower, water stroke shielding gas connection . . . . . . 1 . . . . 1 . .
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
Optional
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-249 332 Page 42
Notes
OM-249 332 Page 43
8
9
6
5
10
7
11
3
64
63
13
12
14
65
15
16
20
21
18
66
17
67
60
58
19
22
52
2
56
28
25
71 72
53
51
34
29
69
54
37
35
1
68
55
36
24
27
59
57
23
26
61
62
50
30
70
49
43
48
42
32
47
46
33
45
40
31
38
41
39
44
Ref. 956142796_2-10_F
Figure 8-2. Main Assembly for XPS 450
OM-249 332 Page 44
Quantity
Item
No.
Dia.
Mkgs.
Model
Part
No.
Description
Basic
Digital
Figure 8-2. Main Assembly for XPS 450
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
14
14
14
15
16
17
18
19
20
21
22
23
24
25
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
. . . . . . . . . . . 000207233
. . . . . . . . . . +156122083
. . . . . . . . . . . 000207291
. . . . . . . . . . . 000119503
. . . . . . . . . . . 000207235
. . . . . . . . . . . 656089043
. . . . . . . . . . +156121041
. . . . . . . . . . +156122084
. . . . . . . . . . . 156005149
. . . . . . . . . . . 156005150
. . . SR1 . . . 056050161
. . . HD1 . . . 058066075
. . . TP2 . . . 056159026
. . . . . . . . . . . 956142790
. . . . . . . . . . . 956142792
. . . . . . . . . . . 956142786
. . . . . . . . . . . 956142788
. . . . T2 . . . 058021151
. . . PC1 . . . 057084150
. . . . . . . . . . . 056092099
. . . . . . . . . . . 056092100
. . . PC2 . . . 057084147
. . . . S2 . . . 056067275
. . . . . . . . . . . 356029218
. . . PL1 . . . 056072079
. . . . . . . . . . . 056020069
. . . PL2 . . . 056072080
. . . . . . . . . . . 056020069
. . . . . . . . . . . 056020077
. . . . . . . . . . . 056076265
. . . . . . . . . . . 156118072
. . . . . . . . . . . 056076266
. . . . . . . . . . . 356029211
. . . . . . . . . . . 000230124
. . . . . . . . . . . 000222779
. . . . . . . . . . . 156005151
. . . . . . . . . . . 056054084
. . . . . . . . . . . 156118068
. . . . S1 . . . 056067267
. . . . S3 . . . 056067276
. . . FM1 . . . 057035020
. . . . . . . . . . . 057015108
. . . . T1 . . . 058021153
. . . . . . . . . . . 556070017
. . . . . . . . . . . 116014052
. . . . . . . . . . . 156005152
. . . . . . . . . . . 156011023
. . . . . . . . . . . 156005153
. . . . . . . . . . . 156012149
. . . . . . . . . . . 156023157
. . . . . . . . . . . 056054085
. . . . . . . . . . . 156009132
. . . . . . . . . . . 156012150
. . . . . . . . . . . 156005154
. . . . . . . . . . . 156006068
. . . . Z . . . . 057098022
. . . . . . . . . . . 156118070
. . . . . . . . . . +156120006
. . . . . . . . . . . 000176106
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
Label, general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
Panel, side RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Label, primary power connections . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Label, Miller logo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
Label Warning, tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Seal, lift eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Cover, top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Panel, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Plate, upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Bracket, side LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Rectifier, PTS 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Transducer, Current 600A, kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Thermostat, 100 10A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Rating Plate (230/400 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Rating Plate (230/400 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
Rating Plate (400 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Rating Plate (400 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . .
Transformer, Aux, 220−230V 400V 40x80 . . . . . . . . . . . . . . . . . . 1 . . . . 1
Circuit Board, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Fuse Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
Fuse, 6x30 6.3A 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
PC2 Circuit Card, Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Switch, 25A 4 pos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Nameplate, front, upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Pilot, 24V Lamp, white . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Knob, D.40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Pilot, 24V Lamp, orange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Knob, D.40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Knob, D.43 (230/400 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Receptacle, 14 pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Panel, lower dinse connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Dinse Socket, Female, 95Mmq . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 3
Nameplate, front, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
Front, bezel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Bracket, front, lower, casters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Caster, D.125, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
Panel, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Switch, c/w protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Switch, 25A 10 pos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Fan, P. 50 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Coil, 400V, 60x110x180 Al . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 3
Transformer, 400V, 60x110x180 Al. . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Link, Primary Power Terminal Board, D5, brass . . . . . . . . . . . . . 10 . . . . 10
Box, Primary Power Terminal Board . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Bracket, upper, lift eye support . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Lift Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Bracket, lower, lift eye support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Shaft, D.16 L.590, lift eye support . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Clip, Wheel retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
Wheel, D.250, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2
Washer, D.21x37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4
Axle, Running Gear D.20 L.567 ZN . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Bracket, rear, lower, wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Impedance, D.10,8 L.360, Al. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Panel, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Conveyor, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
Label, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1
OM-249 332 Page 45
Quantity
Item
No.
Dia.
Mkgs.
Model
Part
No.
Description
Basic
Digital
Figure 8-2. Main Assembly for XPS 450 (continued)
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
56
56
57
58
59
60
60
61
62
63
64
65
66
67
68
69
70
70
71
72
. . . . W . . . . 057079039
. . . . W . . . . 057079038
. . . . . . . . . . . 156005155
. . . . . . . . . . . 156005146
. . . . . . . . . . . 656089026
. . . . . . . . . . . 057014230
. . . . . . . . . . . 057014229
. . . . . . . . . . . 000175282
. . . . . . . . . . . 356029220
. . . . . . . . . 156005156
. . . . . . . . . 156123004
. . . RC2 . . . 000604176
. . . CB1 . . . 056067273
. . . CB2 . . . 056067274
. . . . . . . . . 656089044
. . . . . . . . . 156012151
. . . . . . . . . 058056003
. . . . . . . . . 058056004
. . . . . . . . . . . 656089044
. . . . . . . . . . . 956142807
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
Contactor, CN−65 24V (230/400 VAC) . . . . . . . . . . . . . . . . . . . . .
Contactor, 24V 40A (400 VAC) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plate, rear, upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Corner, R.15, plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strain Relief, D.30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Cable, 4x10 Mt 3, Neoprene (230/400 VAC) . . . . . . . . . . . .
Line Cable, 4x6 Mt 3, Neoprene (400 VAC) . . . . . . . . . . . . . . . . .
Cover, Receptacle Weatherproof Duplex RCPT . . . . . . . . . . . . .
Nameplate, rear, w Aux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bracket, upper bottle support . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chain, D.4 L.750, zinced, bottle . . . . . . . . . . . . . . . . . . . . . . . . . . .
RCPT, Str Dx Grd 2P3W 15A 125V * 5−15R . . . . . . . . . . . . . . .
Circuit Breaker, 6A w/rubber boot . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Breaker, 4A w/rubber boot . . . . . . . . . . . . . . . . . . . . . . . . .
Grommet, 59x22, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shaft, Running Gear, D.20 L.120 . . . . . . . . . . . . . . . . . . . . . . . . .
Bottle Support, lower, 1 bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bottle Support, lower, 2 bottle. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grommet, 59x22, rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Label, front, lower, water stroke shielding gas connection . . . .
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
....
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
Optional
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-249 332 Page 46
Effective January 1, 2011
(Equipment with a serial number preface of MB 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.
5 Years Parts — 3 Years Labor
*
2.
3 Years — Parts and Labor
*
*
*
*
*
*
3.
Auto-Darkening Helmet Lenses (No Labor)
Migmatic 171
1 Year — Parts and Labor Unless Specified
*
*
*
*
*
*
*
*
*
*
*
*
5.
Engine Driven Welding Generators
(NOTE: Engines are warranted separately by the
engine manufacturer.)
HF Units
Inverter Power Sources (Unless Otherwise Stated)
Process Controllers
Semi-Automatic and Automatic Wire Feeders
Transformer/Rectifier Power Sources
2 Years — Parts
*
*
4.
Original main power rectifiers only to include SCRs,
diodes, and discrete rectifier modules
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 (Hydramate 1 and 2)
Water
Coolant
Systems
(USA
Models,
Non-Integrated)
Work Stations/Weld Tables (No Labor)
6 Months — Parts
*
Batteries
6.
90 Days — Parts
*
*
*
*
*
*
*
Accessory (Kits)
Canvas Covers
Induction Heating Coils and Blankets
MIG Guns
Remote Controls
Replacement Parts (No Labor)
Spoolmate Spoolguns
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.
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 2011−01
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 Products 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
 2011 Miller Electric Mfg. Co. 2011−01
Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: 39 (0) 2982901
Fax: 39 (0) 298290-203
email: miller@itw−welding.it
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