Miller XMT 350 CC, XMT 350 CV User Manual

OM-233865R 2016-06
Processes

Multiprocess Welding

Description

Arc Welding Power Source

R

XMT 350 CC/CV

™

Auto-Line

CE

For product information,

Owner’s Manual translations,

and more, visit

www.MillerWelds.com

File: MULTIPROCESS

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.

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. Additional Safety Symbols And Definitions 5................................................

2-2. Miscellaneous Symbols And Definitions 7..................................................

SECTION 3 − SPECIFICATIONS 8..............................................................

3-1. Serial Number And Rating Label Location 8................................................

3-2. Unit Specifications 8....................................................................

3-3. Dimensions And Weight 8...............................................................

3-4. Environmental Specifications 8...........................................................

3-5. Duty Cycle And Overheating 10...........................................................

3-6. Volt-Ampere Curves 11..................................................................

SECTION 4 − INSTALLATION 12................................................................

4-1. Selecting A Location 12..................................................................

4-2. Selecting Cable Sizes* 13................................................................

4-3. Weld Output Terminals 13................................................................

4-4. Remote 14 Receptacle Information 14......................................................

4-5. 115 Volts AC Duplex Receptacle And Supplementary Protectors 14.............................

4-6. Optional Gas Valve Operation And Shielding Gas Connection 15...............................

4-7. Electrical Service Guide 16...............................................................

4-8. Connecting 3-Phase Input Power 18.......................................................

SECTION 5 − OPERATION 20...................................................................

5-1. Front Panel Controls 20..................................................................

5-2. Meter Functions 21......................................................................

5-3. Mode Switch Settings 21.................................................................

5-4. Lift-Arc Trigger Hold TIG 22...............................................................

5-5. Stick Start Procedure 22.................................................................

SECTION 6 − MAINTENANCE & TROUBLESHOOTING 23.........................................

6-1. Routine Maintenance 23.................................................................

6-2. Blowing Out Inside Of Unit 23.............................................................

6-3. Voltmeter/Ammeter Help Displays 24.......................................................

6-4. Troubleshooting 24......................................................................

SECTION 7 − ELECTRICAL DIAGRAM 26........................................................

SECTION 8 − PARTS LIST 28...................................................................

WARRANTY

DECLARATION OF CONFORMITY

for European Community (CE marked) products.

ITW Welding Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of the
stated Council Directive(s) and Standard(s).

Product/Apparatus Identification:

Product Stock Number

XMT 350 CC/CV AUTOLINE, CE 907371

Council Directives:

• 2006/95/EC Low Voltage

• 2004/108/EC Electromagnetic Compatibility

• 2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment

Standards:

• IEC 60974-1:2012 Arc Welding Equipment - Part 1: Welding Power Sources

• IEC 60974-10:2007 Arc Welding Equipment - Part 10: Electromagnetic Compatibility Requirements

EU Signatory:

July 17th, 2015

___________________________________________________________________________________
Massimigliano Lavarini Date of Declaration

ITW WELDING ITALY PRODUCTION MANAGER

956 172 219

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

s
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y

7

Protect yourself and others from injury — read, follow , and save these important safety precautions and operating instructions.

1-1. Symbol Usage

som 2015−09

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 shock
or severe burns. The electrode and work circuit i
electrically live whenever the output is on. The inpu
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automati
wire welding, the wire, wire reel, drive roll housing
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperl
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 D C manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt­age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!

D Disconnect input power or stop engine before installing or

servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).

D Properly install, ground, and operate this equipment according to

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

. Indicates special instructions.

This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING P ARTS, and HOT PARTS hazards. Consult sym­bols and related instructions below for necessary actions to avoid the
hazards.

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 and ground conductor for

damage or bare wiring – replace immediately if damaged – bare
wiring can kill.

D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
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. Disconnect cable for process not in
use.

D Use GFCI protection when operating auxiliary equipment in damp

or wet locations.

SIGNIFICANT DC VOLTAGE exists in inverter weld­ing power sources AFTER removal of input power.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section
before touching any parts.

HOT PARTS can burn.

D Do not touch hot parts bare handed.
D Allow cooling period before working on

equipment.

D To handle hot parts, use proper tools and/or wear heavy, insu-

lated welding gloves and clothing to prevent burns.

OM-233865 Page 1

FUMES AND GASES can be hazardous.

F)

d

r
t

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. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.

D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

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.

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 body protection made from durable, flame−resistant mate-

rial (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.

WELDING can cause fire or explosion.

D Remove stick electrode from holder or cut off welding wire at

contact tip when not in use.

D Wear body protection made from durable, flame−resistant material

(leather, heavy cotton, wool). Body protection includes oil-free
clothing 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.

D Read and understand the Safety Data Sheets (SDSs) and the

manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.

FLYING META L o r 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 o f f compressed gas supply when not in use.
D Always ventilate confined spaces or use

approved air-supplied respirator.

ELECTRIC AND MAGNETIC FIELDS (EM
can affect Implanted Medical Devices.

D Wearers of Pacemakers and other Implante

Medical Devices should keep away.

D Implanted Medical Device wearers should consult their docto

and the device manufacturer before going near arc welding, spo
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 lev-

el is high.

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 containers that have held combustibles, or on

closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).

D Do not weld where the atmosphere can 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- 233865 Page 2

workpiece, and hot equipment can cause fires and

CYLINDERS can explode if damaged.

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

D Protect compressed gas cylinders from excessive heat, 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 compressed gas cylinders, regulators, hoses,

and fittings designed for the specific application; maintain them
and associated parts in good condition.

D Turn face away from valve outlet when opening cylinder valve. Do

not stand in front of or behind the regulator when opening the 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 n u m -

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.

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

p
g

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.

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 c a r efully 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 installation, maintenance, and service according to the

Owner’s Manuals, industry standards, and national, state, and
local codes.

H.F. RADIATION can cause interference.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with

proper guards in a safe location wearing proper
face, hand, and body protection.

D Sparks can cause fires — keep flammables away.

STATIC (ESD) can damage PC boards.

D 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.

BATTERY EXPLOSION can injure.

D Do not use welder to charge batteries or jum

start vehicles unless it has a battery chargin
feature designed for this purpose.

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 t o 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-233865 Page 3

1-4. California Proposition 65 Warnings

Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)

1-5. Principal Safety Standards

Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org o r purchased from Global Engineering Documents
(phone: [phone], website: www.global.ihs.com).

Safe Practices for the Preparation of Containers and Piping for W elding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-

al Engineering Documents (phone: [phone], website:
www.global.ihs.com).

Safe Practices for W elding and Cutting Containers that have Held Com­bustibles, American Welding Society Standard AWS A6.0, from Global

Engineering Documents (phone: [phone],
website: www.global.ihs.com).

National Electrical Code, NFPA Standard 70, from National Fire Protec­tion Association, Quincy, MA 02269 (phone: [phone], website:
www.nfpa.org and ww w. sparky .org).

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: [phone], website:www.cga­net.com).

This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: [phone], website: www.csagroup.org).

Safe Practice For Occupational And Educational Eye And Face Protec­tion, ANSI Standard Z87.1, from American National Standards Institute,

25 West 43rd Street, New York, NY 10036 (phone: [phone], web­site: www.ansi.org).

Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFP A Standard 51B, from National Fire Protection Association,

Quincy, M A 0 2 2 6 9 ( p h o n e : 1 - 8 0 0 - 3 4 4 - 3 555, website : w w w.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, P A 15250-7954
(phone: [phone]) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).

Applications Manual for the Revised NIOSH Lifting Equation, The Na­tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: [phone], website:
www.cdc.gov/NIOSH).

1-6. EMF Information

Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro­cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace­makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con­duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:

1. Keep cables close together by twisting or taping them, or using a
cable cover.

2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.

3. Do not coil or drape cables around your body.

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- 233865 Page 4

SECTION 2 − DEFINITIONS

2-1. Additional Safety Symbols And Definitions

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

Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.

Protect yourself from electric shock by insulating yourself from work and ground.

Safe1 2012−05

Safe2 2012−05

Safe3 2012−05

Disconnect input plug or power before working on machine.

Keep your head out of the fumes.

Use forced ventilation or local exhaust to remove the fumes.

Use ventilating fan to remove fumes.

Keep flammables away from welding. Do not weld near flammables.

Safe5 2012−05

Safe6 2012−05

Safe8 2012−05

Safe10 2012−05

Safe12 2012−05

Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.

Do not remove or paint over (cover) the label.

OM-233 865 Page 5

Safe14 2012−05

Safe20 2012−05

When power is applied failed parts can explode or cause other parts to explode.

Always wear long sleeves and button your collar when servicing unit.

After taking proper precautions as shown, connect power to unit.

Do not use one handle to lift or support unit.

Do not weld on drums or any closed containers.

Safe26 2012−05

Safe28 2012−05

Safe29 2012−05

Safe31 2012−05

Safe16 2012−05

Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection

facility.
Contact your local recycling office or your local distributor for further information.

Safe37 2012−05

Disconnect input plug or power before working on machine.

Safe30 2012−05

Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.

Safe38 2012−05

Become trained and read the instructions before working on the
machine or welding.

Safe40 2012−05

=<60°

Always lift and support unit using both handles. Keep angle of lifting
device less than 60 degrees.

Use a proper cart to move unit.

V

OM-233 865 Page 6

>60s

Safe44 2012−05

Hazardous voltage remains on input capacitors after power is turned

V

off. Do not touch fully charged capacitors. Always wait 60 seconds
after power is turned off before working on unit, OR check input ca­pacitor voltage, and be sure it is near 0 before touching any parts.

V

Safe42 2012−05

2-2. Miscellaneous Symbols And Definitions

%

I

U

IP

I

U

I

A

V

Amperage

Alternating

Current (AC)

Voltage

On

Voltage Input

Protective Earth

(Ground)

Line Connection

U

Gas Metal Arc

Welding (GMAW)

2

Rated Welding

2

Foot Control

Conventional
Load Voltage

Current

Panel

1eff

Lift-Arc Trigger
Hold Operation

(GTAW)

Maximum Effec­tive Supply Cur-

rent

Voltage Sensing

Feeder

Output

Off

Direct Current

(DC)

X

Three Phase

Static Frequency

Converter-

Transformer-

Rectifier

Duty Cycle

Percent

Three Phase

Lift-Arc Operation

(GTAW)

Remote

Negative

Inductance

Single Phase

Circuit Breaker

Gas Tungsten Arc

Welding

Positive

Constant Voltage

Shielded Metal

Arc Welding

(SMAW)

1

Primary Voltage

Degree Of
Protection

0

Hz

1max

Constant Current

Arc Force

Rated No Load

Voltage (A verage)

Hertz

Pulsed

Rated Maximum

Supply Current

Scratch Start TIG

Increase

OM-233 865 Page 7

SECTION 3 − SPECIFICATIONS

)

3-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the rear 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.

3-2. Unit Specifications

. Do not use information in unit specifications table to determine electrical service requirements. See Sections 4-7 and 4-8 for information on con-

necting input power.

Input

Power

3-Phase 350 A at 34

*See Section 3-5 for Duty Cycle Rating.

Rated

Output

VDC, 60%

Duty Cycle

Voltage
Range in
CV Mode

10−38 V 5−425 A 75 VDC 36.1 22.3 20.6 17.8 14.2 13.6

Amperage

Range in
CC Mode

3-3. Dimensions And Weight

Hole Layout Dimensions

A (298 mm) 11-3/4 in.

B (42 mm) 1-11/16 in.

C (400 mm) 15-3/4 in.

D (485 mm) 19-3/32 in.

E (221 mm) 8-11/16 in.

F (39 mm) 1-17/32 in.

D

C

Max.

Open-

Circuit

Voltage

F

RMS Amps Input at Rated Load Output,

50/60 Hz 3-Phase at NEMA Load Voltages and

Class I Rating

230 V 380 V 400 V 460 V

A
E

G

(610 mm)

24 in.

KVA KW

(432 mm

17 in.

G 1/4-20 UNC -2B thread

Weight

B

94.8 lb (43 kg)

3-4. Environmental Specifications

A. IP Rating

IP Rating Operating Temperature Range Storage Temperature Range

IP23

This equipment is designed for outdoor use. It
may be stored, but is not intended to be used
for welding outside during precipitation unless
sheltered.

OM-233865 Page 8

804 801-A

14 to 104 °F (−10 to 40°C)

(318 mm)
12-1/2 in.

−4 to 131 °F (−20 to 55°C)

IP23 2014−06

B. Information On Electromagnetic Fields (EMF)

Notes

! 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.

C. Information On Electromagnetic Compatibility (EMC)

! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−

This equipment complies with IEC61000-3-11 and IEC 61000−3−12 and can be connected to public low-voltage systems provided that the public
low-voltage system impedance Z
2,055,437.437 VA). It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator
if necessary, that the system impedance complies with the impedance restrictions.

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

voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations, due to con­ducted as well as radiated disturbances.

at the point of common coupling is less than 77.84 mW (or the short−circuit power Ssc is greater than

max

ce-emf 1 2010-10

ce-emc 1 2014-07

OM-233865 Page 9

3-5. Duty Cycle And Overheating

Notes

Duty Cycle is percentage of 10 mi n ­utes 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 voltage, or duty cycle before
welding.

NOTICE − Exceeding duty cycle
can damage unit and void warranty.

Overheating

60% Duty Cycle

6 Minutes Welding 4 Minutes Resting

0

15

Minutes

A or V

OR

Reduce Duty Cycle

Ref. 219 523-A

OM-233865 Page 10

3-6. Volt-Ampere Curves

A. CC Mode

Notes

100

90
80
70
60
50

VOLTS

40
30

GTAW
MN

20
10

0

0 100 200 300 400 500

B. CV Mode

100

90
80

SMAW
80A

0%

25%

ARC
CONTROL

50%

75%

100%

AMPERAGE

SMAW
MAX

GTAW
MAX

Volt-ampere curves show minimum
and maximum voltage and amper­age output capabilities of welding
power source. Curves of other set­tings fall between curves shown.

70
60
50

VOLTS

40

MAX

30
20
10

0

0 100 200 300 400 500

MIN

AMPERAGE

217 836-A / 217 837-B

OM-233865 Page 11

SECTION 4 − INSTALLATION

4-1. Selecting A Location

Notes

Movement

Location And Airflow

(460 mm)

18 in.

OR

2

2

3

1

4

18 in.

(460 mm)

! Do not move or operate unit

where it could tip.

! Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 2 0 .

1 Lifting Forks
Extend forks beyond opposite side

of unit.
2 Lifting Handles
Use handles to lift unit.
3 Hand Cart
Use cart or similar device to move

unit.
4 Line Disconnect Device
Locate unit near correct input

power supply.

OM-233865 Page 12

loc_med 2015-04

4-2. Selecting Cable Sizes*

4-3. Weld Output Terminals

NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine
cable size.

Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit

Not Exceeding***

30 m (100 ft) or Less

10 − 60%

mm

Duty

Cycle

2

(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)
250 35 (2) 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2x2/0) 2x70 (2x2/0)
300 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2x2/0) 2x95 (2x3/0) 2x95 (2x3/0)
350 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2x2/0) 2x95 (2x3/0) 2x95 (2x3/0) 2x120 (2x4/0)
400 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2x2/0) 2x95 (2x3/0) 2x120 (2x4/0) 2x120 (2x4/0)
500 70 (2/0) 95 (3/0) 120 (4/0) 2x70 (2x2/0) 2x95 (2x3/0) 2x120 (2x4/0) 3x95 (3x3/0) 3x95 (3x3/0)
600 95 (3/0) 120 (4/0) 2x70 (2x2/0) 2x95 (2x3/0) 2x120 (2x4/0) 3x95 (3x3/0) 3x120 (3x4/0) 3x120 (3x4/0)

* 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-L 2015−02

60 − 100%

Duty Cycle

2

mm

(AWG)

45 m (150

ft)

60 m (200 ft)

70 m (250

ft)

90 m (300

ft)

10 − 100% Duty Cycle

2

mm

(AWG)

105 m (350

ft)

120 m (400

ft)

! Turn off power before connecting

to weld output terminals.

! Do not use worn, damaged, un-

dersized, or repaired cables.

1 Positive (+) Weld Output Terminal
2 Negative (−) Weld Output Terminal

1

2

Ref. 803 692-B / output term1 2015−02

OM-233865 Page 13

4-4. Remote 14 Receptacle Information

4-5. 115 Volts AC Duplex Receptacle And Supplementary Protectors

Socket* Socket Information

AJ

K

B

L

C

D

*The remaining sockets are not used.

I

NH

M

G

F

E

A 24 volts AC. Protected by supplementary protect-

24 VOLTS AC

REMOTE

OUTPUT

CONTROL

A/V

AMPERAGE

VOLTAGE

GND

1

or CB2.

B Contact closure to A completes 24 volts AC

contactor control circuit.

C Output to remote control; 0 to +10 volts DC, +10

volts DC in MIG mode.
D Remote control circuit common.
E 0 to +10 volts DC input command signal from

remote control.
M CC/CV select
F Current feedback; +1 volt DC per 100 weld am-

peres.
H Voltage feedback; +1 volt DC per 10 weld volts.
G Circuit common for 24 and 115 volts AC circuits.
K Chassis common.

1 115 V 10 Amp. AC

Receptacle
2 Supplementary Protector CB1
3 Supplementary Protector CB2
CB1 protects the duplex receptacle

from overload.
CB2 protects 24 volts AC portion of

Remote 14 receptacle from
overload.

Press button to reset protector.

2 3

OM-233865 Page 14

Ref. 803 879-B

4-6. Optional Gas Valve Operation And Shielding Gas Connection

4

GAS IN

2

3

1

5

GAS OUT

Obtain gas cylinder and chain to
running gear, wall, or other station­ary support so cylinder cannot fall
and break off valve.

1 Cylinder
2 Regulator/Flowmeter
Install so face is vertical.
3 Gas Hose Connection
Fitting has 5/8-18 right-hand

threads. Obtain and install gas
hose.

4 Gas In Fitting
5 Gas Out Fitting
The Gas In and Gas Out fittings

have 5/8-18 right-hand threads.
Obtain proper size, type, and length
hose and make connections as fol­lows:

Connect hose from shielding gas
supply regulator/flowmeter to Gas
In fitting.

Connect hose coupler to torch.
Connect one end of gas hose to
hose coupler. Connect remaining
end of gas hose to Gas Out fitting.

Operation

The gas solenoid controls gas flow
during the TIG process as follows:

Remote TIG

Gas flow starts with remote contac­tor on.

Gas flow stops at end of post−flow
if current was detected, or with re­mote contactor off if no current was
detected.

Lift−Arc Trigger Hold TIG

Gas flow starts when output switch
is depressed.

Gas flow stops at end of post−flow.

Scratch Start TIG

Gas flow starts when current is de­tected.

Gas flow stops at end of post−flow.
Post−flow time is factory set to 5

seconds per 100 amps of weld cur­rent. The minimum post−flow time
is 5 seconds. The maximum post−
flow is 20 seconds (post flow set­tings are not adjustable by the end
user).

Ref. 803 705-B / Ref. 803 879-B

OM-233865 Page 15

4-7. Electrical Service Guide

Elec Serv 2014−0

1

Notes

NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input
voltage.

NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be be available.

Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda­tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.

In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and

630.12.
60 Hz Three Phase

Input Voltage (V) 230 380 400 460
Input Amperes (A) At Rated Output 36.1 22.3 20.6 17.8
Max Recommended Standard Fuse Rating In

Amperes

Min Input Conductor Size In AWG
Max Recommended Input Conductor Length In

Feet (Meters)
Min Grounding Conductor Size In AWG

Reference: 2014 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 O perating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and

above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table

310.15(B)(16). If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable

requirements.

1

Time-Delay

Normal Operating

2

3

4

4

40 25 25 20
50 30 30 25
10 12 12 14
96

(29)

10 12 12 14

158
(48)

175
(53)

150
(46)

OM-233865 Page 16

Notes

OM-233865 Page 17

4-8. Connecting 3-Phase Input Power

3

= GND/PE Earth Ground

4

7

2

L1

3

6

L2
L3

5

1

1

Tools Need e d :

OM-233865 Page 18

Input2 2012−05 − Ref. 803 766-C / Ref. 802 136-A / Ref. 803 879-B

! Installation must meet all National and

4-8. Connecting 3-Phase Input Power (Continued)

Notes

Local Codes − have only qualified per­sons make this installation.

! Disconnect and lockout/tagout input

power before connecting input con­ductors from unit. Follow established
procedures regarding the installation
and removal of lockout/tagout
devices.

! Always connect green or green/yellow

conductor t o supply grounding termi­nal first, and never to a line terminal.

NOTICE − The Auto-Line circuitry in this unit
automatically adapts the power source to the
primary voltage being applied. Check input

voltage available at site. This unit can be con­nected to any input power between 208 and
575 VAC without removing cover to relink the
power source.

See rating label on unit and check input volt­age available at site.

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 t o 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 protec-

tion using Section 4-7 (fused disconnect
switch shown).

Close and secure door on disconnect device.
Follow established lockout/tagout procedures
to put unit in service.

Input2 2012−05

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

OM-233865 Page 19

5-1. Front Panel Controls

1 Power Switch

. The fan motor is thermostatically

controlled and only runs when cooling is
needed.

2 Voltmeter
3 Ammeter
4 V/A (Voltage/Amperage) Adjustment

Control
5 Mode Switch
The Mode switch setting determines both the

process and output On/Off control (see
Section 5-3).

For Air Carbon Arc (CAC-A) cutting and
gouging, place switch in Stick position. For
best results, place Arc Control in the
maximum position.

SECTION 5 − OPERATION

6 Remote 14 Receptacle
For remote control, make connections to

Remote 1 4 receptacle. In TIG modes and the
REMOTE STICK mode, remote control is a
percent of V/A Adjust control setting (value
selected on V/A Adjust is maximum available
on remote). In ELECTRODE HOT STICK
mode the remote control is not used. In the
MIG mode, remote control provides full range
of unit output regardless of V/A Adjust control
setting.

7 Arc Control
Control adjusts Dig when Stick or CC mode is

selected on mode switch. When set towards
minimum, short-circuit amperage at low arc

23 4

voltage is the same as normal welding
amperage.

When set towards maximum, short-circuit
amperage is increased at low arc voltage to
assist with arc starts as well as reduce
sticking while welding.

Select setting best suited for application.
Control adjusts inductance when MIG or

V-Sense Feeder position is selected on the
mode switch. Inductance determines the
“wetness” of the weld puddle. When set
towards maximum, “wetness” (puddle fluidity)
increases.

When Pulsed MIG or one of the TIG modes is
selected, this control is not functional.

OM-233865 Page 20

ELECTRODE HOT

6

5

7

1

Ref. 803 692-B / Ref. 219 341-A

5-2. Meter Functions

. The meters display the actual weld output values for approximately three seconds after the arc is broken.

Mode Meter Reading At Idle Meter Reading While Welding

Scratch

Start TIG

Lift-Arc Trigger Hold TIG

TIG

MIG

Pulsed

MIG

CC

Stick

V-Sense

Feeder

VA

71.7 85

Actual Volts (OCV) Preset Amps

VA

85

Blank Preset Amps

VA

85

Blank Preset Amps

VA

24.5

Preset Volts Blank

VA

PPP PPP

Pulse Display Pulse Display

VA

85

Blank Preset Amps

VA

71.7 85

Actual Volts (OCV) Preset Amps

VA

71.7

Flashes OCV And Preset Blank

VA

10.3 85

Actual Volts Actual Amps

VA

10.3 85

Actual Volts Actual Amps

VA

10.3 85

Actual Volts Actual Amps

VA

24.5 250

Actual Volts Actual Amps

VA

24.5 250

Actual Volts Actual Amps

VA

24.5 85

Actual Volts Actual Amps

VA

24.5 85

Actual Volts Actual Amps

VA

24.5 250

Actual Volts Actual Amps

5-3. Mode Switch Settings

. The Stick and CC modes provide the Adaptive Hot Start™ feature, which automatically increases the output amperage at the start of a weld should

the start require it. This eliminates electrode sticking at arc start.

Mode Switch Setting Process Output On/Off Control

Scratch Start TIG GTAW Electrode Hot

Lift-Arc Trigger Hold TIG GTAW − See Section 5-4 At Remote 14

TIG GTAW With HF Unit, Pulsing Device, Or Remote Control At Remote 14

MIG GMAW At Remote 14

Pulsed MIG GMAW-P (Requires an external pulsing device.) At Remote 14

CC Stick (SMAW) With Remote On/Off At Remote 14

Stick SMAW Electrode Hot

V-Sense Feeder MIG (GMAW) With V oltage Sensing Wire Feeder Electrode Hot

OM-233865 Page 21

5-4. Lift-Arc Trigger Hold TIG

“Touch”

Do NOT Strike Like A Match!

1

1 − 2

Seconds

1 TIG Electrode
2 Workpiece

. Procedure requires:

control

2

Start sequence:

• Touch tungsten electrode to

workpiece at weld start point.

• Momentarily depress output

switch.

• Slowly lift electrode. An arc will

form when electrode is lifted.

• To stop welding, momentarily

depress output switch and out­put will shut off.

Note: If output switch is momen­tarily depressed and tungsten is
not touching workpiece:

Do not touch tungsten to work.
Output will shut off in 3 seconds.
Start sequence over.

5-5. Stick Start Procedure

Ref. S-156 279

With Stick selected, start arc as fol­lows:

1 Electrode
2 Workpiece
3 Arc
Drag electrode across workpiece

like striking a match; lift electrode
slightly after touching work. If arc

1

2

3

goes out electrode was lifted to high.
If electrode sticks to workpiece, use
a quick twist to free it.

Low OCV Stick

The unit can be optionally config­ured for low open circuit voltage
(OCV) operation. When the unit is
configured for low OCV operation
only a low sensing voltage (approxi­mately 15 V DC) is present between
the electrode and the workpiece
prior to the electrode touching the
workpiece. Consult a Factory
Authorized Service Agent for infor­mation regarding how to configure
the unit for low OCV stick welding
operation.

OM-233865 Page 22

SECTION 6 − MAINTENANCE & TROUBLESHOOTING

6-2. Blowing Out Inside Of Unit

6-1. Routine Maintenance

Replace

Damaged Or

Unreadable

Labels

! Disconnect power

before maintaining.

3 Months

6 Months

Blow Out Inside

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

! Do not remove case when

blowing out inside of unit.

To blow out unit, direct airflow
through front and back louvers as
shown.

Ref. 803 879-B

OM-233865 Page 23

6-3. Voltmeter/Ammeter Help Displays

1

HE.L P−1

2

HE.L P−2

3

HE.L P−3

. All directions are in reference to the front

of the unit. All circuitry referred to is lo-

cated inside the unit.

1 Help 1 Display
Indicates a malfunction in the primary power

circuit. If this display is shown, contact a Fac­tory Authorized Service Agent.

2 Help 2 Display
Indicates a malfunction in the thermal protec-

tion circuitry. If this display is shown, contact
a Factory Authorized Service Agent.

3 Help 3 Display

AV

4

HE.L P−5

AV

5

HE.L P−6

AV

6

HE.L P−8

Indicates the left side of the unit has over­heated. The unit has shut down to allow the
fan to cool it (see Section 3-5). Operation will
continue when the unit has cooled.

4 Help 5 Display
Indicates the right side of the unit has over-

heated. The unit has shut down to allow the
fan to cool it (see Section 3-5). Operation will
continue when the unit has cooled.

5 Help 6 Display
Indicates operation at maximum input cur-

rent. The unit has a maximum allowable input

AV

AV

AV

current limit. As the line voltage decreases,
the required input current increases. If the line
voltage i s too low, the output power is limited
by the input current. When this limit is
reached, the unit automatically reduces out­put power to continue operation. If this display
is shown, have a qualified electrician check
the input voltage.

6 Help 8 Display
Indicates a malfunction in the secondary

power circuit of the unit. If this display is
shown, contact a Factory Authorized Service
Agent.

6-4. Troubleshooting

Trouble Remedy

No weld output; unit completely inop­erative.

No weld output; meter display On. Input voltage outside acceptable range of variation (see Sections 4-8, 4-7).

Erratic or improper weld output. Use proper size and type of weld cable (see Section 4-2).

No 115 volts AC output at duplex re­ceptacle or Remote 14 receptacle.

No 24 volts AC output at Remote 14
receptacle.

Place line disconnect switch in On position (see Section 4-8).

Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-8).
Check for proper input power connections (see Section 4-8).

Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 3-5).

Clean and tighten all weld connections.
Check for correct polarity.
Reset supplementary protector CB1 (see Section 4-5).

Reset supplementary protector CB2 (see Section 4-5).

OM-233865 Page 24

Notes

OM-233865 Page 25

SECTION 7 − ELECTRICAL DIAGRAM

OM-233865 Page 26

Figure 7-1. Circuit Diagram

219 484-E

OM-233865 Page 27

SECTION 8 − PARTS LIST

7

36

24

14

33

32

31

30

77

25

29

83

15

28

23

16

35

26

19

20

34

27

38

37

17

18

39

78

40

81

22

75

82

79

41

21

57

58

42

43

80

45

44

47

MOD 2

51

56

17

MOD 1

50

49

52

59

48

62

49

60

46

61

53

55

54

OM-233865 Page 28

76

12

11

8

13

74

63

10

9

6

5

3

4

64

65

66

2

67

1

62

69

3

68

70

71

72

Ref. 803 850-F

Figure 8.1. Parts Assembly

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 8.1. Parts Assembly

1 216034 Wrapper (Includes Insulators and Safety Labels) 1... ............... .. ...................

175256 Insulator, Side Rh (Not Shown) 1..................... .. ..................................

178551 Insulator, Side (Not Shown) 1..................... .. .....................................

2 179310 Label, General Precautionary Wordless, Intl, Small 2... ............... .. .................

3 179309 Label, Caution Falling Equipment Can Injure−wordles 2... ............... .. ...............

4 208015 Handle, Rubberized Carrying 2... ............... .. ....................................

5 135483 Label, Important Remove These Two Handle Screws 2... ............... .. ...............

6 R3/C4 233052 Resistor/Capacitor 1... .... .... .. .............................................

7 Deleted... ............... ..................................................................

8 SR1 201530 Kit, Diode Fast Recovery Bridge 1... ..... ..... .. .................................

9 199840 Bus Bar, Diode 2... ............... .. ................................................

10 196355 Insulator, Screw 4... ............... .. ...............................................

11 D1,D2 201531 Kit, Diode Power Module 2... .... .... .. ........................................

12 RT1 219343 Thermistor, NTC 30K Ohm @ 25 Deg C 18in Lead 1... ..... ..... .. .................

13 CR1 198549 Relay, Encl 24VDC Spst 35A/300VAC 4Pin Flange Mtg 1... ..... ..... .. .............

14 227927 Label, Warning Electric Shock/Exploding Parts−wdles 1... ............... .. ...............

15 010546 Bushing, Snap-In Nyl .375 Id X .500 Mtg Hole 1... ............... .. .....................

16 L4 218020 Inductor, Boost 1... ...... ...... .. ................................................

17 179276 Bushing, Snap-In Nyl 1.000 Id X 1.375 Mtg Hole Cent 3... ............... .. ..............

18 170647 Bushing, Snap-In Nyl 1.312 Id X 1.500 Mtg Hole 1... ............... .. ...................

19 L3 212150 Inductor, Output 1... ...... ...... .. ...............................................

20 T1 212132 XFMR, HF Litz/Litz W/Boost 1... ...... ...... .. .....................................

21 225097 Heat Sink, Lh Rect 1... ............... .. .............................................

22 L1 212091 Inductor, Input 1... ...... ...... .. .................................................

23 083147 Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High 4... ............... .. ...............

24 PC1 274574 Circuit Card Assy, Control W/Prgm 350 Prod Aux Pwr 1... ..... ..... .. ..............

216113 Stand-Off Support, PC Card .187 Dia W/P&l .375 2...................... .. ..................

PLG1 115091 Housing Plug+Pins (Service Kit) RC1 1.......... ..... .. .............................

PLG2 201665 Housing Plug+Pins (Service Kit) RC2 1.......... .... .. .............................

PLG3 131056 Housing Plug+Pins (Service Kit) RC3 1.......... .... .. .............................

PLG5 131204 Housing Plug+Pins (Service Kit) RC5 1.......... .... .. .............................

PLG7 131054 Housing Plug+Pins (Service Kit) RC7 1.......... .... .. .............................

PLG8 131054 Housing Plug+Pins (Service Kit) RC8 1.......... .... .. .............................

PLG9 115093 Housing Plug+Pins (Service Kit) RC9 1.......... ..... .. .............................

PLG10 115094 Housing Plug+Pins (Service Kit) RC10 1.......... ..... .. ............................

PLG11 115094 Housing Plug+Pins (Service Kit) RC11 1.......... ..... .. ............................

PLG12 115092 Housing Plug+Pins (Service Kit) RC12 1.......... ..... .. ............................

25 212072 Bracket, Mtg Capacitor/Pc Board 1... ............... .. .................................

26 C12, 13 245614 Capacitor, Elctlt 1800 Uf 500 VDC Can 2.52 Dia 2... ... ... .. ...................

27 RC2 604176 Rcpt, Str Dx Grd 2P3W 15A 125V *5−15R 1... ..... ..... .. ........................

28 CB2 083432 Circuit Breaker, Man Reset 1P 10A 250VAC Frict 1... ..... ..... .. ..................

29 CB1 083432 Circuit Breaker, Man Reset 1P 10A 250VAC Frict 1... ..... ..... .. ..................

30 +219470 Panel, Rear CE W/Aux 1... .............. .. .........................................

31 219335 Label, Warning Electric Shock Can Kill CE Wordless 1... ............... .. ................

32 Nameplate, Rear Aux/Gas/CE (Order by Model and Serial Number) 1... .......................... ..

33 217297 Cover, Receptacle Weatherproof Duplex Rcpt 1... ............... .. .....................

34 212945 Label, Warning Incorrect Connections CE Wordless 1... ............... .. ................

35 215980 Bushing, Strain Relief .709/.984 Id X1.375 Mtg Hole 1... ............... .. ................

36 244628 Cable, Power 12Ft 8Ga 4C (Non−Stripped End) 1... ............... .. ....................

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-233865 Page 29

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 8.1. Parts Assembly (Continued)

37 234126 Nut, Conduit 1.000 Npt Knurled 1... ............... .. ..................................

38 T2 270095 XFMR, Control Toroidal 665 VAC Pri 1536 Va 60 Hz 1... ...... ...... .. ................

212947 Plate, Mtg Toroid XFMR 1..................... .... .......................................

39 L2 218018 Inductor, Pre-Regulator 1... ...... ...... .. .........................................

40 218566 Gasket, Inductor Mounting 1... ............... .. ......................................

41 CT1 196231 XMFR, Current Sensing 200/1 1... ..... ..... .. ...................................

42 C15 196143 Capacitor, Polyp Met Film 16. Uf 400 VAC 10% 1... ..... ..... .. ....................

43 219472 Bracket, Mtg Capacitor Series 1... ............... .. ...................................

44 RT2 199798 Thermistor, NTC 30K Ohm @ 25 Deg C 18in Lead 1... ..... ..... .. .................

45 PC2 224661 Circuit Card Assy, Power Interconnect (Includes) 1... ..... ..... .. ...................

46 219335 Label, Warning Electric Shock Can Kill Ce Wordless 1... ............... .... ..............

223343 Clip, Wire Stdf .40−.50 Bndl .156Hole .031−.078Thk 2..................... .... ..............

PLG13 130203 Housing Plug+Pins (Service Kit) RC1 1.......... .... .. .............................

PLG14 201665 Housing Plug+Pins (Service Kit) RC2 1.......... .... .. .............................

PLG15 115092 Housing Plug+Pins (Service Kit) RC3 1.......... ..... .. .............................

PLG20 115093 Housing Plug+Pins (Service Kit) RC6 1.......... ..... .. .............................

47 153403 Bushing, Snap-In Nyl .750 Id X 1.000 Mtg Hole Cent 3... ............... .. ................

48 RM1 205751 Module, Power Resistor W/Plug 1... ..... ..... .. .................................

49 261556 Kit, Input/Pre-Regulator And Inverter Module (Includes) 1... ............... .. .............

MOD 1, SKiip 83 HEC 1.................................. ........................................

MOD 2, SKiip 83 EC 1.................................. ..........................................

50 212206 Windtunnel, Rh 1... ............... .. ................................................

51 196330 Heat Sink, Power Module 1... ............... .. .......................................

52 +175132 Base 1... .............. .. .........................................................

53 229325 Foot, Mtg Unit 4... ............... .. .................................................

54 176736 Screw, Mtg Foot 4... ............... .. ...............................................

55 212073 Label, Warning Exploding Parts Can CE Wordless 1... ............... .. ..................

56 212074 Bus Bar, Output 1... ............... .. ...............................................

57 HD1 182918 Transducer, Current 400A Module Supply V +/− 15V 1... ..... ..... .. ................

58 PC3 243654 Circuit Card Assy, Front Panel & Display W/Program 1... ..... ..... .. ...............

PLG18 131204 Housing Plug+Pins (Service Kit) RC2 1.......... .... .. .............................

RC50 210233 Rcpt, W/Pins (Service Kit) 1.......... .... .. .......................................

PLG21 212088 Plug, W/Leads 1.......... .... .. .................................................

RC21 167640 Housing Plug+Pins (Service Kit) 1.......... .... .. .................................

59 S1 244920 Switch, Tgl 3pst 40A 600VAC SCR Term Wide Tgl 1... ...... ..... .. .................

60 176226 Insulator, Switch Power 1... ............... .. .........................................

61 FM1 196313 Fan, Muffin 115V 50/60Hz 3000 RPM 6.378 Mtg Holes 1... ..... ..... .. ..............

PLG16 131054 Housing Plug+Pins (Service Kit) 1.......... .... .. .................................

RC16 135635 Housing Plug+Pins (Service Kit) 1.......... .... .. .................................

62 208967 Rcpt Assy, Tw Lk Insul Fem (Dinse Type) 50/70 Series (Includes) 2... ............... .. ....

208968 Rcpt, Tw Lk Insul W/O-Ring 1..................... .... ...................................

185712 Insulator, Bulkhead Front 1..................... .... ......................................

185713 Insulator, Bulkhead Rear 1..................... .... ......................................

185714 Washer, Tooth 22mmid X 31.5mmod 1.310-1mmt Intern 1..................... .... ...........

185717 Nut, M20-1.5 1.00Hex .19H Brs Locking 1..................... .... .........................

185718 O-Ring, 0.989 Id X 0.070 H 1..................... .... ....................................

186228 O-Ring, 0.739 Id X 0.070 H 1..................... .... ....................................

63 212070 Panel, Front Standard 1... ............... .. ..........................................

64 C5,6,7 233668 Capacitor Assy, W/Plug & Leads (Voltage Feedback) 1... .... .... .. ...............

65 216112 Fastener, Panel Receptacle Quick Access 2... ................ .. ........................

66 Nameplate (Order by Model and Serial Number) 1... .......................... ...................

67 Nameplate, Connection (Order by Model and Serial Number) 1... .......................... ........

68 Nameplate, Power (Order by Model and Serial Number) 1... .......................... .............

69 174991 Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip−.21 2... ............... .. ...............

Quantity

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

OM-233865 Page 30

Item

No.

Dia.

Mkgs.

Part

No.

Description

Figure 8.1. Parts Assembly (Continued)

70 174992 Knob, Pointer .840 Dia X .250 Id W/Spring Clip−.21 1... ............... .. ................

71 218041 Door, W/Quick Access Ball Fasteners 1... ............... .. ............................

72 175138 Box, Louver 1... ............... .. ...................................................

73 Label (Order by Model and Serial Number) 1... .......................... ........................

74 +212207 Windtunnel, Lh 1... .............. .. ................................................

75 211503 Insulator, Heat Sink 1... ................ .. ............................................

76 C8 219191 Capacitor, Polyp Film .001 Uf 2000V W/Terms 1... ..... ..... .. .....................

77 L6 131447 Core, Toroidal 1.332 Id X 1.932 Od X .625 Thk 1... ...... ...... .. .....................

78 L5,L7 199122 Core, Toroidal .750 Id X 1.450 Od X .544 Thk 2... .... .... .. ......................

79 083147 Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High 2... ............... .. ...............

80 219471 Bracket, Mtg Filter Board 1... ............... .. .......................................

81 219473 Bracket, Mtg CE Filter Ground Plane 1... ............... .. .............................

82 PC4 229989 Circuit Card Assy, Filter 1... ..... ..... .. .........................................

83 227746 Gasket, Inductor Mounting 1... ............... .. ......................................

+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.

Quantity

OM-233865 Page 31

Notes

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at
the beginning
of this manual.

Notes

Effective January 1, 2016

(Equipment with a serial number preface of MG or newer)

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 t he 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. If notification is submitted as an
online warranty claim, the claim must include a detailed
description of the fault and the troubleshooting steps taken to
identify failed components and the cause of their failure.

Miller shall honor warranty claims on warranted equipment listed
below in the event of such a failure within the warranty time
periods. All warranty time periods start on the date the
equipment was delivered to the original retail purchaser or one
year after the equipment is shipped to a European distributor or
twelve months after the equipment is shipped to an International
distributor.

1. 5 Years Parts — 3 Years Labor

* Original main power rectifiers only to include SCRs,

diodes, and discrete rectifier modules with
exclusion of STR, Si, STi, STH and MPi series.

2. 3 Years — Parts and Labor

* Engine Driven Welding Generators

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

* Inverter Power Sources (Unless Otherwise Stated)
* Process Controllers
* Semi-Automatic and Automatic Wire Feeders
* Transformer/Rectifier Power Sources

3. 2 Years — Parts

* Auto-Darkening Helmet Lenses (No Labor)
* Migmatic 175
* HF Units

4. 1 Year — Parts and Labor Unless Specified

* Automatic Motion Devices
* Field Options

(NOTE: Field options are covered under True
Blue) for the remaining warranty period of the
product they are installed in, or for a minimum of
one year — whichever is greater.)

* Induction Heating Power Sources, Coolers, and

Electronic Controls/Recorders

* Motor-Driven Guns (w/exception of Spoolmate

Spoolguns)
* Positioners and Controllers
* Powered Air Purifying Respirator (PAPR) Blower

Unit (No Labor)
* Racks
* Running Gear and Trailers
* Subarc Wire Drive Assemblies
* Water Coolant Systems
* Work Stations/Weld Tables (No Labor)

5. 6 Months — Parts

* Batteries

guarantees or warranties expressed or implied.

6. 90 Days — Parts

* Accessory (Kits)
* Canvas Covers
* Induction Heating Coils and Blankets
* MIG Guns
* Remote Controls
* Replacement Parts (No Labor)
* Spoolmate Spoolguns
* Cables and Non-Electronic Controls

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

1. Consumable components; such as contact tips,

cutting nozzles, contactors, brushes, switches, slip
rings, relays or parts that fail due to normal wear.

2. Items furnished by Miller, but manufactured by others, such
as engines or trade accessories. These items are covered
by the manufacturer’s warranty, if any.

3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
improperly operated or misused based upon industry
standards, or equipment which has not had reasonable and
necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
equipment.

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 2016-01

Owner’s Record

Please complete and retain with your personal records.

Model Name Serial/Style Number

Purchase Date (Date which equipment was delivered to original customer.)

Distributor

Address

Country Zip/Postal Code

For Service

Contact a DISTRIBUTOR or SERVICE AGENCY near you.

Always provide Model Name and Serial/Style Number.

Contact your Distributor for:

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 Italy S.r .l.

Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Phone: [phone]
Fax: [phone]
email: miller@itw−welding.it

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2016 Miller Electric Mfg. Co. 2016−01