Miller XMS 403 Owner's Manual

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Page 1

OM-244 243B 2009−10

Processes

Multiprocess Welding

Description

Arc Welding Power Source

XMS 403

(400 Volts) CE

Visit our website at

www.MillerWelds.com

Page 2

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.

Working as hard as you do

− every power source from Miller is backed by the most hassle-free warranty in the business.

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.

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TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Arc Welding Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3. Additional Symbols For Installation, Operation, And Maintenance 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-4. California Proposition 65 Warnings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-5. Principal Safety Standards 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-6. EMF Information 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 − DEFINITIONS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Manufacturer’s Warning Label Definitions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. WEEE Label 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Symbols And Definitions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Important Information Regarding CE Products (Sold Within The EU) 9. . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Serial Number And Rating Label Location 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Duty Cycle And Overheating 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Volt-Ampere Curves 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Installing Turntable for Wire Feeder on Power Source (Optional) 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Dimensions And Weight 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Selecting a Location 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Weld Output Terminals And Selecting Cable Sizes 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Remote 7 Receptacle Information (TIG And Stick Only) 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Circuit Breakers 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-12. Filling Coolant Tank 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-13. Electrical Service Guide 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-14. Connecting 3-Phase Input Power 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATION 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Front Panel Controls 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Switching On the Unit and Recalling Factory Parameters 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Welding Power Source Setup Menu 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. Remote Receptacle (RCTY) 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-5. Welding Process Selection 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-6. Wire Type Selection in Synergic MIG or Synergic Pulsed MIG Welding 20. . . . . . . . . . . . . . . . . . . . . . . . .

4-7. Wire Diameter Selection In Synergic MIG Or Synergic Pulsed MIG Welding 20. . . . . . . . . . . . . . . . . . . .

4-8. Gas Selection in Synergic MIG or Synergic Pulsed MIG Welding 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-9. Trigger Mode Selection (L-TIG and Stick Processes) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-10. Welding Parameter Setup Menu (Double Pulsed-MIG/L-TIG And Stick) 22. . . . . . . . . . . . . . . . . . . . . . . .

4-11. Preparing Power Source For MIG (GMAW) Welding Process 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-12. Selecting Manual MIG Welding 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-13. Selecting Synergic MIG Welding 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-14. Selecting Synergic Pulsed MIG Welding 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-15. Preparing Unit For TIG Welding 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-16. TIG Lift-Arc Welding 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-17. Preparing Unit For Stick Welding 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − MAINTENANCE & TROUBLESHOOTING 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Routine Maintenance 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Help Displays 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Troubleshooting 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − ELECTRICAL DIAGRAM 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − PARTS LIST 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

Page 4

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 de clares 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

Council Directives:

015 029 083

• 2006/95/EC Low Voltage

• 2004/108/EC Electromagnetic Compatibility

• 2006/42/EEC Machinery Directive

Standards:

• IEC 609741 Arc Welding Equipment  Welding Power Sources: edition 3.0, 200507.

• IEC 609742 Arc Welding Equipment  Water cooling systems: edition 2.0, 200711.

• IEC 6097410 Arc Welding Equipment Electromagnetic Compatibility Requirements: edition 2.0, 200708

• 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 (0Hz300Hz)

EU Signatory:

November 12, 2009

______________________________________________________________________________

Mark Lowther

EUROPEAN DIRECTOR, TECHNOLOGY & PRODUCT DEVELOPMENT

Date of Declaration

956 142 700

Page 5

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

Protect yourself and others from injury — read and follow these precautions.

1-1. Symbol Usage

som _2009−08

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.

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.

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 follow-

ing 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).

. 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.

D Properly install and ground this equipment according to its

Owner’s Manual and national, state, and local codes.

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 conduc-

tor 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.

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 ma-

chines 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 inputpower.

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 equip-

ment.

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

Page 6

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 op-

erations. 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.

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 by-

pass 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 shielding gas supply when not in use. D Always ventilate confined spaces or use

approved air-supplied respirator.

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

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-244 243 Page 2

workpiece, and hot equipment can cause fires and

ELECTRIC AND MAGNETIC FIELDS (EMF can affect ImplantedMedical 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.

Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

D Protect compressed gas cylinders from excessive heat, mechani-

cal 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 shielding gas cylinders, regulators, hoses, and fit-

tings 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 num-

ber 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.

Page 7

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.

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.

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 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.

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.

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.

H.F. RADIATION can cause interference.

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.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installation.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.

D 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.

ARC WELDING can cause interference.

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.

D To reduce possible interference, keep weld cables as short as

possible, close together, and down low, such as on the floor.

D Locate welding operation 100 meters from any sensitive elec-

tronic equipment.

D Be sure this welding machine is installed and grounded

according to this manual.

D 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

Page 8

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.

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 Glob-

al 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,

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.

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 Indus-

try, 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.

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.

OM-244 243 Page 4

Page 9

SECTION 2 − DEFINITIONS

2-1. Manufacturer’s Warning Label 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.

2-2. WEEE Label

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-244 243 Page 5

Page 10

6 7

Warning! Watch Out! There are possible hazards as shown by the symbols.

1 Electric shock from wiring can

kill.

2 Disconnect input plug or

power before working on machine.

3 Hazardous voltage remains

on input capacitors after power is turned off. Do not touch fully charged capacitors.

> 60 s

4 Always wait 60 seconds after

power is turned off before working on unit, OR

5 Check input capacitor voltage,

and be sure it is near 0 before touching any parts.

6 When power is applied failed

S-185 836

parts can explode or cause other parts to explode.

7 Flying pieces of parts can

cause injury. Always wear a face shield when servicing unit.

8 Always wear long sleeves and

button your collar when servicing unit.

9 After taking proper

precautions as shown, connect power to unit.

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.

2 Read Owner’s Manual and

inside labels for connection

points and procedures. 3 Not Applicable 4 Having a loop of extra length,

connect grounding conductor

first. 5 Not Applicable

OM-244 243 Page 6

Page 11

21 3

100 h. std.

1 Warning! Watch Out! There are

possible hazards as shown by the symbols.

2 Disconnect input plug or power before

working on machine.

3 Wear approved safety glasses with

side shields while working on the unit.

4 Plugged filter or hoses can cause

overheating to the power source and torch.

(B) 050024004

956 142 617

5 Every 100 hours, check and clean filter

and check condition of hoses. 6 Read Owner’s Manual. 7 Use coolant suggested by

manufacturer.

1 Warning! Watch Out! There

are possible hazards as shown by the symbols.

2 Falling unit can cause injury.

Do not move or operate unit where it could tip.

3 Cylinders can expolde if

damaged. Protect compressed gas cylinders from excessive heat, mechanical shock, slag, open flames, sparks, and arcs.

S-176 106

1 Warning! Watch Out! There

are possible hazards as shown by the symbols.

2 Moving parts can cause injury.

Keep away from moving parts such as fans.

OM-244 243 Page 7

Page 12

2-3. Symbols And Definitions

U U U

Amperage

Remote On Off

Line connection Three Phase

Constant Voltage Constant Current

Three Phase Static

Frequency Con-

verter-

Transformer-

Rectifier

Primary Voltage

Conventional Load Voltage

Rated No Load

Voltage (Average)

1max

Voltage

Gas Metal Arc

Welding (GMAW)

Rated Maximum

Supply Current

Rated Welding

Current X

Degree Of Protection

1eff

Alternating

Current (AC)

Direct Current

(DC)

Lift-Arc Operation

(GTAW)

Shielded Metal Arc

Welding (SMAW)

Maximum Effective

Supply Current

Duty Cycle

Purge Wire ’Jog’

Hertz

Protective Earth

(Ground)

Increase

Gas Tungsten Arc

Welding

Recycle or dispose

of used coolant in

an environmentally

safe way

Wire Feed Speed

Percent

Set-Up MIG Synergic

Circuit Breaker 2T Trigger Mode Memory Store 4T Trigger Mode

Material Thickness

Mini-Logic

Trigger Mode

. Symbols not shown here are detailed in this manual when they are relevant.

MIG Pulsed

Synergic Welding

Arc Length

(Trim)

MIG Double

Pulsed Synergic

Welding

Read Instructions

OM-244 243 Page 8

Page 13

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 The EMF assessment on this equipment was conducted at 0.5 meter.

S At a distance of 1 meter the EMF exposure values were less than 20% of the permissible values.

3-2. 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.

3-3. Specifications

Rated Welding

Output

300 A @

32 Volts DC,

60% Duty Cycle

*While idling

Voltage

Range

10 − 35 V 5 − 400 A 90 23S

Amperage

Range

3-4. Duty Cycle And Overheating

Maximum

Open-Circuit

Voltage DC

60% Duty Cycle

IP Rating

Amperes Input

at Rated Load

Output 50/60 Hz

400 V KVA KW

17.0

(0,15*)

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.

12.4

(0,09*)

11.5

(0,04*)

Overheating

6 Minutes Welding 4 Minutes Resting

Minutes

Reduce Duty Cycle

Ref. SA-178 651

OM-244 243 Page 9

Page 14

3-5. 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

ARC CONTROL

B. CV Mode

va_curve1 4/95 − SA-178 652 / SA-178 653

3-6. Installing Turntable for Wire Feeder on Power Source (Optional)

! Turn off welding power

source and disconnect input power before proceeding.

Remove wire spool.

1 Turntable

2 Screw

Remove the 4 screws and the plastic cap on the power source upper cover and keep them for future use.

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.

OM-244 243 Page 10

Ref. 956142645-5-5

Page 15

3-7. Dimensions And Weight

Weight

90 kg (198 lb)

3-8. Selecting a Location

860 mm (33.8 in.)

490 mm (19.3 in.)

1010 mm (39.7 in.)

Dimensions

Ref. 956142645-3-5

Location

500 mm

(19.7 in.)

500 mm

(19.7 in.)

1 Handle

Do not use handle to lift unit.

2 Line Disconnect Device

Locate unit near correct input power supply.

! Special installation may be

required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20.

Movement

! Do not move or operate unit

where it could tip.

500 mm

(19.7 in.)

500 mm

(19.7 in.)

Ref. 956142645-3-5

OM-244 243 Page 11

Page 16

3-9. 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

Weld Output

Terminals

! Turn off power be-

fore connecting to weld output terminals.

! Do not use worn,

damaged, undersized, or poorly spliced cables.

Positive

receptacle

TIG/Stick

Positive

receptacle

MIG

30 m (100 ft) or Less

10 − 60%

Duty

Cycle

(AWG)

Welding

Amperes

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)

60 − 100%

Duty

Cycle

(AWG)

(150 ft)

Not Exceeding***

45 m

60 m

(200 ft)

70 m

(250 ft)

90 m

(300 ft)

10 − 100% Duty Cycle

(AWG)

105 m

(350 ft)

120 m

(400 ft)

250 35 (2) 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0)

300 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0)

350 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0)

400 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0)

Gas

500 70 (2/0) 95 (3/0) 120 (4/0)

Negative receptacle

MIG/TIG/Stick

* This 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-G 2009−08

600 95 (3/0) 120 (4/0)

2x70

(2 ea. 2/0)

2x70

(2 ea. 2/0)

2x95

(2 ea. 3/0)

2x70

(2 ea. 2/0)

2x70

(2 ea. 2/0)

2x95

(2 ea. 3/0)

2x120

(2 ea. 4/0)

2x70

(2 ea. 2/0)

2x95

(2 ea. 3/0)

2x95

(2 ea. 3/0)

2x120

(2 ea. 4/0)

3x95

(3 ea. 3/0)

2x70

(2 ea. 2/0)

2x95

(2 ea. 3/0)

2x95

(2 ea. 3/0)

2x120

(2 ea. 4/0)

3x95

(3 ea. 3/0)

3x120

(3 ea. 4/0)

2x70

(2 ea. 2/0)

2x95

(2 ea. 3/0)

2x120

(2 ea. 4/0)

2x120

(2 ea. 4/0)

3x95

(3 ea. 3/0)

3x120

(3 ea. 4/0)

OM-244 243 Page 12

Page 17

3-10. Remote 7 Receptacle Information (TIG And Stick Only)

Socket 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-Pin Remote Receptacle

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.

3-11. Circuit Breakers

Circuit breakers with numbers 7 and 10 are placed on the rear panel

of the welder as shown.

1 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. 956142645-4-5

OM-244 243 Page 13

Page 18

3-12. 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 Coolant Tank Cap 2 Coolant Level Indicator

. Remove shielding gas cylinder

from rear of unit to fill coolant

Rear View

tank.

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.

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.).

GTAW Or Where

HF* Is Used

MILLER Low Conductivity Coolant No. 043 810**; Distilled Or Deionized Water

OK Above 32° F (0° C)

3-13. Electrical Service Guide

GMAW Or Where

HF* Is Not Used

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)

Where Coolant Contacts

Aluminum Parts

MILLER Aluminum Protecting Coolant No. 043 809**

Ref. 956142645-4-5

Elec Serv 2009−08

. 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.

50/60 Hz Three Phase

Input Voltage (V) 400

Input Amperes (A) At Rated Output 17

Max Recommended Standard Fuse Rating In Amperes

Time-Delay Fuses

Normal Operating Fuses

Min Input Conductor Size In mm2,

Max Recommended Input Conductor Length In Meters 41

Min Grounding Conductor Size In mm2,

Reference: 2008 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

310.16. 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 14

2.5

Page 19

3-14. Connecting 3-Phase Input Power

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.

Always connect green or green/ yellow conductor to supply grounding terminal first, and never to a line terminal.

= GND/PE Earth Ground

For Three-Phase Operation

1 Input Power Cord. 2 Disconnect Device (switch shown in

the OFF position)

3 Green Or Green/Yellow Grounding

Conductor

4 Disconnect Device Grounding

Terminal 5 Input Conductors (L1, L2 And L3) 6 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 Over-Current Protection

Select type and size of over-current protection using Section 3-13 (fused disconnect switch shown).

Close and secure door on disconnect device. Remove lockout/tagout device, and place switch in the On position.

Tools Needed:

input2 2008−01 − 803 766-C / 956142645-3-5

OM-244 243 Page 15

Page 20

SECTION 4 − OPERATION

4-1. Front Panel Controls

18 19

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 Negative Power Connection for all

welding processes.

4 Remote Control Receptacle for TIG

and Stick welding 5 Gas Connector (TIG Process) 6 Red Quick Connect Fitting

Coolant return from torch.

7 Blue Quick Connect Fitting

OM-244 243 Page 16

Coolant output to torch.

8 Handle 9 Control Panel 10 D1 (Display 1)

Displays values and parameters for selected welding process. During welding it displays actual arc voltage.

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).

Ref. 956142645-5-5

15 P2 (Setup Push Button)

Allows selecting setup or advanced programming menus.

16 P3 (Process Push Button)

Allows selecting welding process.

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).

Page 21

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.

P7P3

Ref. 956142645-5-5

OM-244 243 Page 17

Page 22

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.

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

OM-244 243 Page 18

Ref. 956142645-5-5

Page 23

4-4. Remote Receptacle (RCTY)

4-5. Welding Process Selection

1 7 Pin Remote Receptacle

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 determ-

ined 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.

Ref. 956142645-5-5

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 19

Page 24

4-6. Wire Type Selection in Synergic MIG or Synergic Pulsed MIG Welding

Ref. 956142645-5-5

L5 LED

L6 LED

L7 LED

L8 LED

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

is no program for the process, material, wire diameter, and shielding gas combination.

L5 selection is for carbon steel.

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

L10

L11

L12

Ref. 956142645-5-5

L9 LED

L10 LED

L11 LED

L12 LED

P5 Push Button

Press P5 until desired wire diameter LED illuminates.

OM-244 243 Page 20

. 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.

Page 25

4-8. Gas Selection in Synergic MIG or Synergic Pulsed MIG Welding

L13

Gas

Ref. 956142645-5-5

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

4-9. Trigger Mode Selection (L-TIG and Stick Processes)

L14

L15

L16

L17

PROG or alternate selection will not be possible when either process, material, wire diameter, and shielding gas combination is not permitted.

Ref. 956142645-5-5

. 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

P7 Push Button

Trigger mode can be set for TIG only.

In TIG welding, pressing P7 will change the trigger mode, but D1 and D2 will not change values.

In Stick welding, pressing P7 will enable welding (L17 ON, D1 shows open circuit voltage (OCV) or weld voltage.

D2 displays pre-set welding current or actu-

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.

L15 ON selects 4T trigger mode.

When trigger is pressed, welding starts at initial current level (IN).

When trigger is released, welding current increases to the set current level.

When trigger is pressed and held, welding current decreases to the set final current (FI-A) is achieved. Releasing trigger extinguishes welding arc.

L16 ON selects 3 levels trigger function.

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.

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.

. L16 trigger mode is useful for thin mate-

rials and for a crater fill sequence.

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.

OM-244 243 Page 21

Page 26

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.

D2 displays the parameter value.

E1 changes the welding parameter.

E2 changes the parameter value.

. Incorrect settings in any pro-

cess can result in a program with undesirable weld characteristics. Setup should only be used by operators familiar with various welding processes and parameters.

Ref. 956142645-5-5

4-11. Preparing Power Source For MIG (GMAW) Welding Process

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).

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 3-12).

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.

Ref. 956142645-5-5

OM-244 243 Page 22

Page 27

4-12. Selecting Manual MIG Welding

D1 D2

Ref. 956142645-5-5

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 23

Page 28

4-13. Selecting Synergic MIG Welding

E1 D1 D2 E2

Ref. 956142645-5-5

P3 P6P4 P5

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

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.

OM-244 243 Page 24

Page 29

4-14. Selecting Synergic Pulsed MIG Welding

E1 D1 D2 E2

Ref. 956142645-5-5

P3 P6P4 P5

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.

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).

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.

Select gas using P6 push button.

Select trigger mode using P7 push button.

See wire feeder manual for all the remaining Synergic MIG settings.

Setting Cooler Status (see Section 4-3)

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.

. 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.

Press P2 to enter setup menu.

D1 displays DP.

D2 default setting is OFF.

Use E2 to change D2 value to ON. This setting will enable or disable Double Pulsed MIG Synergic welding.

. 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 25

Page 30

4-15. Preparing Unit For TIG Welding

E1 D1 D2 E2

To prepare unit for TIG welding, proceed as follows:

Follow safety precautions according to Section 1.

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 3-12).

Turn unit On.

Allow time for unit to complete its start up cycle.

Set TIG welding process using P3 push button.

P3 P7

. If D1 does not display TIG proceed as

follows:

Press P2 setup button. D1 will display STK. Rotating E2 encoder changes process to TIG mode.

Purge air from torch gas hose using Torch Trigger (Manual Purge).

Select trigger mode using P7 push button (see Section 4-9).

Setting Initial And Final Current

Use E1 to change D1 to IN−A (Initial 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 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.

Ref. 956142645-5-5

Setting Slope-Up Time

Press P2 to enter SET UP menu.

Use E1 to change D1 to SLUP.

D2 default setting is 0.1 second (range is

0.0 seconds to 10.0 A).

Setting Slope-Down Time

Press P2 to enter SET UP menu.

Use E1 to change D1 to SLDW.

D2 value is default setting of 0.1 second (range is 0.0 seconds to 10.0 A).

Setting Postflow

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.

OM-244 243 Page 26

Page 31

4-16. TIG Lift-Arc Welding

Do NOT Strike Like A Match!

“Touch”

1 − 2

Seconds

Lift-Arc Start

When process selector LED 4 is illuminated in TIG mode Lift-Arc TIG is enabled.

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 elec-

trode. 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:

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 27

Page 32

SECTION 5 − MAINTENANCE & TROUBLESHOOTING

5-1. Routine Maintenance

Replace

Damaged Or

Unreadable

Labels

Blow Out Inside

! Disconnect power

3 Months

6 Months

before maintaining.

Repair Or

Replace

Cracked

Cables

. Maintain more often

during severe conditions.

Replace Cracked

Torch Body

Repair Or Replace

Cracked Cables

And Cords

Clean

And

Tighten Weld

Connections

Replace Cracked

Hoses

Blow Out Heat

Exchanger Fins

Change

Coolant (If

Using Water)

12 Months

Change Coolant (If

Using MILLER Coolant)

OM-244 243 Page 28

Page 33

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

Indicates shorted thermistor RT2 on left side of unit. Contact a Factory Authorized Service Agent.

Help 1

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.

5-3. Troubleshooting

Help 4

Indicates a malfunction in the thermal protection circuitry on right side of unit. Contact a Factory Authorized Service Agent.

Help 5

Indicates overheating on right side of unit. Unit will shutdown and fan will run until internal temperature drops within operational range.

Help 6

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.

Help 8

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.

Trouble Remedy

No weld output: unit completely inoperative.

No weld output; meter display On.

Erratic or improper weld output.

Coolant system not working (HELP 15 is displayed).

Reduced or no coolant flow from cooling unit (HELP 15 can be displayed).

Place line disconnect switch in On position (see Section 3-13).

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 3-13).

Check for proper input power connections (see Section 3-13).

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 3-4).

Use proper size and type of weld cable (see Section 3-9).

Clean and tighten all weld connections.

Check and secure coolant hose connectors.

Reset circuit breaker CB7 (see Section 3-11).

Motor overheated. Allow motor to cool and restart operation.

Have Factory Authorized Service Agent check cooling unit.

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 29

Page 34

SECTION 6 − ELECTRICAL DIAGRAM

OM-244 243 Page 30

Figure 6-1. Circuit Diagram For XMS 403

Page 35

956142623

OM-244 243 Page 31

Page 36

SECTION 7 − PARTS LIST

. Hardware is common and

not available unless listed.

956142645A-1-5

OM-244 243 Page 32

Figure 7-1. Unit Outer Assembly

Page 37

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 7-1. Unit Outer Assembly

1 +V17031284 Wrapper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 156012136 Turntable 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 000207235 Label, Warning, Tilting 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 +156005098 Cylinder Rack, Upper Support 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 956142616 Nameplate, Rear, Gas, 14 Pin & Fuse Terminals 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 956142617 Nameplate, Rear, Water & Dinse 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 956142621 Nameplate, Coolant Level 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 156087017 Pin, Split 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 156009067 Washer 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 056054075 Wheel, Rear, 250 o.d. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 156012119 Axle, Rear Wheels 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 000207233 Label, General Precautionary 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 +V16122287 Side Panel, R 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 V56142305 Nameplate, Front, Dinse Negativ 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 056054074 Wheel/Caster,Front 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 V56142303 Nameplate, Front, Dinse Positiv 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 000207291 Label, Primary Power Connections 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 +V16122288 Side Panel, L 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 156018115 Nut 5/8 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 057052044 Fitting, Hose Brs Barbed M 1/4Tbg x 5/8−18 SAE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 057052045 Fitting, Quick Connector 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 057052043 Adapter 5/8 UNC−3/8 BSP 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 058066057 Gas, Connection Kit 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Quantity

+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 33

Page 38

. Hardware is common and

not available unless listed.

OM-244 243 Page 34

956142645A-2-5

Figure 7-2. Unit Main Assembly

Page 39

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 7-2. Unit Main Assembly

1 316005010 LEM, Support 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 000201531 Kit Diode, Power Module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 000199840 Bus Bar, Diode 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 PC6 000185697 Circuit Card, Filter Board 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 HD1 000182918 Transducer, Current 400A Module Supply V +/− 15V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 RT2 000173632 Thermistor, NTC 30k ohms 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 PC1 000215042 Circuit Card, Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 T1 000179616 Transformer, HF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 L1 000173563 Inductor, Input 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Z1 000173570 Stabilizer 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 T2 000195829 Transformer, Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 PM1,2 000233043 Kit, Transistor IGBT Module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 SR1 000179629 Kit Diode, Power Module 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 C1 000188446 Capacitor, Polyp Film .5Uf 900VDC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 C3,4 000192935 Capacitor, Elctlt 2700Uf 450VDC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 V16117300 Wind Tunnel Extension, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 V16117360 Wind Tunnel Extension, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 156002045 Handle 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 000213051 Plastic, Upper 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 000193919 Knob, Pointer 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 V56032301 Nameplate, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 000176226 Switch, Power ON/OFF 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 PC2 000212210 Circuit Card, Interconnect 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 V57084081 Circuit Card, Control 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 V57084362 Circuit Card, Switch 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 V16118291 Panel, Front 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 057028110 Remote Control 14 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 656026097 Hose, 5x8,5x940 Black Gas 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 656026099 Hose, 6x11x470 Blu Water 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 656026102 Hose, 6x11x270 Red Water 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 000188192 Receptacle, Gas 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 000208967 Receptacle, Dinse 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 556049402 Water Connection, Quick Connect 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 556049401 Water Connection, Quick Connect 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 M V56126046 Fan Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 V56005296 Support, Module, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 V16039294 Box Louver 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 056082099 Radiator Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 656026100 Hose, 6x11x780 Blu Water 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 116117079 Plenum, Fan 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 156005141 Support, Radiator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 056061066 Flow-Meter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 656026111 Hose, 6x11x160 Red Water 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 V56031377 Support Switch, Pressure 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 556049398 Header 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 V16006289 Base 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 000176106 Label, Fan Warning 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 116122306 Mounting Bracket, Tank Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 656026098 Hose, 6x11x250 Blu Water 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 027042002 Tank, Water 8 Liter 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 000166564 Filter, In−line Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 V57011071 Pump Assy 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53 656026092 Hose, 6x11x350 Blu Water 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 WCP 057010059 Motor, 170W, 115 VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 V56118293 Panel, Intermediate 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

56 CB2 000083432 Circuit Breaker, Man Reset 1P 10A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57 CB1 000161078 Circuit Breaker, Man Reset 1P 7A 250VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

58 V56091091 Strain Relief, Primary Cord 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59 000228036 Valve, 24VAC 1 Way 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60 156076085 Receptacle, 14 Pin 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61 V56126161 Fan Assy, Radiator Cooling 115 V 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62 656026101 Hose, 6x11x590 Red Water 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63 +V16118292 Panel, Rear 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-244 243 Page 35

Quantity

Page 40

Item

No.

64 T4 V58021080 Transformer, 400VAC 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

65 220805 Nut 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66 V57014066 Primary Cable, 4 Core 6,0 Mq 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+When ordering a component originally displaying a precautionary label, the label should also be ordered.

Dia.

Mkgs.

Part

No.

Figure 7-2. Unit Main Assembly (Continued)

Description

Quantity

Notes

OM-244 243 Page 36

Page 41

Notes

229895

MATERIAL THICKNESS GAUGE

Page 42

Notes

SOCKET/WRENCH SELECTION TABLE

(U.S. STANDARD)

Specifications Socket or Wrench Size Specifications Socket or Wrench Size

Bolt

Diameter

1/4 in .250 in 3/8 in 7/16 in 6 mm .2362 in 10 mm 10 mm

5/16 in .3125 in 1/2 in 9/16 in 8 mm .3150 in 14 mm 14 mm

3/8 in .375 in 9/16 in 5/8 in 10 mm .3937 in 17 mm 17 mm

7/16 in .4375 in 5/8 in 3/4 in 12 mm .4724 in 19 mm 19 mm

1/2 in .500 in 3/4 in 13/16 in 14 mm .5512 in 22 mm 22 mm

9/16 in .5625 in 7/8 in 7/8 in 16 mm .6299 in 24 mm 24 mm

5/8 in .625 in 15/16 in 1 in 18 mm .7087 in 27 mm 27 mm

3/4 in .750 in 1-1/8 in 1-1/8 in 22 mm .8661 in 32 mm 32 mm

7/8 in .875 in 1-5/16 in 1-5/16 in 24 mm .9449 in 36 mm 36 mm

1 in 1.000 in 1-1/2 in 1-1/2 in

Decimal

Equivalent

Bolt Nut

SOCKET/WRENCH SELECTION TABLE

(METRIC)

Bolt

Diameter

U.S.

Decimal

Equivalent

Bolt Nut

Page 43

Effective January 1, 2009

This limited warranty supersedes all previous Miller warranties and is exclusive with no other

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, not to exceed eighteen months after the equipment is shipped to an International distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers limited to only include

SCRs, diodes, and discrete rectifier components where applicable

* Inverters (Input and Output Rectifiers Only)

2. 3 Years — Parts and Labor

* Transformer/Rectifier Power Sources * Plasma Arc Cutting Power Sources * Semi-Automatic and Automatic Wire Feeders * Inverter Power Sources (Unless Otherwise Stated) * Water Coolant Systems (Integrated) * Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

3. 2 Years — Parts and Labor

* Motor Driven Guns (w/exception of Spoolmate

Spoolguns) * Process Controllers * RFCS Foot Controls * IHPS Power Sources and Coolers * Water Coolant Systems (Non-Integrated) * HF Units * Running Gear/Trailers * 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.)

4. 1 Year — Parts and Labor Unless Specified

* DC 253 & 403 Rectifier (April 06>) * Migmatic 171 (April 06>)

5. 6 Months — Batteries

guarantees or warranties expressed or implied.

6. 90 Days — Parts

* MIG Guns * Induction Heating Coils and Blankets * Remote Controls * Accessory (Kits) * Replacement Parts (No labor) * Spoolmate Spoolguns * Canvas Covers

Miller’s True Blue® Limited Warranty shall not apply to:

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, 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 2009−05

Page 44

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:

Contact the Delivering Carrier to:

Welding Supplies and Consumables

Options and Accessories

Service and Repair

Replacement Parts

Owner’s Manuals

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.

ITW Welding Products Italy S.r.l.

Via Privata Iseo, 6/E 20098 San Giuliano Milanese, Italy Phone: 39 (0) 2982901 Fax: 39 (0) 298290-203 email: miller@itw−welding.it

Miller XMS 403 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual