Miller XPS 350 Owner's Manual

OM-249 332G 2015−06

Processes

MIG (GMAW) Welding
Flux Cored (FCAW)

Description

Arc Welding Power Source

XPS 350 And 450

CE

www.MillerWelds.com

OWNER’S MANUAL

From Miller to You

Thank you and congratulations on choosing Miller. Now you can get the
job done and get it done right. We know you don’t have time to do it any
other way.

That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior quality.
Like you, his customers couldn’t afford anything less. Miller products had
to be more than the best they could be. They had to be the best you could
buy.

Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.

This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can
count on years of reliable service with proper maintenance. And if for
some reason the unit needs repair, there’s a Troubleshooting section that
will help you figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your particular model are also
provided.

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. Specifications 8........................................................................

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

3-4. Duty Cycle Chart 9.....................................................................

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

SECTION 4 − INSTALLATION 11..................................................................

4-1. Selecting A Location 11...................................................................

4-2. Typical MIG Connections 12...............................................................

4-3. Installing Single Bottle And Upper Bracket Support (All Models: Optional) 13......................

4-4. Installing Double Bottle And Upper Bracket Support (All Models: Optional) 14......................

4-5. Installing Input Gas And Water Cooler Hoses (All Models: Optional) 15...........................

4-6. Weld Output Terminals And Selecting Cable Sizes* 16.........................................

4-7. Weld Output Terminals 16.................................................................

4-8. Remote 14 Receptacle RC1 16............................................................

4-9. Electrical Service Guide 17................................................................

4-10. Positioning Jumper Links (230/400 VAC 3-Phase) 18..........................................

4-11. Connecting 3-Phase Input Power 20........................................................

SECTION 5 − OPERATION 22....................................................................

5-1. Controls For The XPS 350 22..............................................................

5-2. Controls For The XPS 450 23..............................................................

SECTION 6 − MAINTENANCE AND TROUBLESHOOTING 24........................................

6-1. Routine Maintenance 24..................................................................

6-2. Unit Overload 24........................................................................

6-3. Troubleshooting 24......................................................................

SECTION 7 - ELECTRICAL DIAGRAM 26..........................................................

SECTION 8 - PARTS LIST 42.....................................................................

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 prod
uct(s) identified in this declaration conform to the essential requirements and provisions of the stat
ed Council Directive(s) and Standard(s).

Product/Apparatus Identification:

Product Stock Number

XPS 350,400VAC 029015528

XPS 450,400VAC 029015529
XPS 350, BASIC 400VAC 029015531
XPS 450, BASIC 400VAC 029015532

XPS 350, 230/400VAC 029015534

XPS 450 ,230/400VAC 029015535
XPS 350, BASIC 230/400VAC 029015537
XPS 450, BASIC 230/400VAC 029015538

Council Directives:

·2006/95/EC Low Voltage

·2004/108/EC Electromagnetic Compatibility

·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:

June 30th, 2015

___________________________________________________________________________________

Massimigliano Lavarini Date of Declaration

ITW WELDING ITALY PRODUCTION MANAGER

956 172 228

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING

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

1-1. Symbol Usage

som 2013−09

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.

D Always verify the supply ground − check and be sure that input

power cord ground wire is properly connected to ground terminal in

. 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.

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 equip-

ment.

D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and
clothing to prevent burns.

OM-249 332 Page 1

FUMES AND GASES can be hazardous.

F)

d

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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 ME TA 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 may contain flammable dust,

gas, or liquid vapors (such as gasoline).

D Connect work cable to the work as close to the welding area as

practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.

D Do not use welder to thaw frozen pipes.

OM-249 332 Page 2

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 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-249 332 Page 3

1-4. California Proposition 65 Warnings

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

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).

Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060

1-6. EMF Information

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.

Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).

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

25 West 43rd Street, New York, NY 10036 (phone: [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, PA 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 30333 (phone: [phone], website:
www.cdc.gov/NIOSH).

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 may interfere with some medical implants, e.g. pace­makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con­duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:

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

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

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

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-249 332 Page 4

SECTION 2 − DEFINITIONS

2-1. Additional Safety Symbols And Definitions

. Some symbols are found only on CE products.

Disconnect input plug or power before working on machine.

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

Disconnect input plug or power before working on machine.

?

V

?

A

Consult rating label for input power requirements.

Safe5 2012−05

Safe20 2012−05

Safe30 2012−05

<10°

Safe34 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.

Falling unit can cause injury. Do not move or operate unit where it could tip.

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

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

Keep your head out of the fumes.

Safe37 2012−05

Safe53 2012−05

Safe57 2012−05

Safe58 2012−06

Use forced ventilation or local exhaust to remove the fumes.

Safe59 2012−05

Safe60 2012−06

OM-249 332 Page 5

Use ventilating fan to remove fumes.

Safe61 2012−06

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

Safe62 2012−06

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

Safe63 2012−06

Do not weld on drums or any closed containers.

?

Safe64 2012−06

Read Owner’s Manual and inside labels for connection points and procedures.

31

Safe67 2012−06

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

Safe65 2012−06

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

Safe66 2012−06

Move jumper links as shown on inside label to match input voltage at
job site. Include extra length in grounding conductor and connect
grounding conductor first. Connect line input conductors as shown on
inside label. Double-check all connections, jumper link positions, and
input voltage before applying power.

Safe49 2012−05

OM-249 332 Page 6

2-2. Miscellaneous Symbols And Definitions

A

Notes

V

Amperage

Volts

Alternating

Current (AC)

Direct Current

(DC)

Remote

On

Off

Protective Earth

(Ground)

Line Connection

U

1

I1max

I1eff

U

2

I

2

X

U

0

Gas Metal Arc

Welding (GMAW)

Primary Voltage

Rated Maximum

Supply Current

Maximum

Effective

Supply Current

Conventional
Load Voltage

Rated Welding

Current

Duty Cycle

Percent

Rated No Load

Voltage (OCV)

Circuit Breaker

Three Phase

Transformer

Rectifier

Water (Coolant)

Input

Water (Coolant)

Output

Gas Input

Gas Output

Voltage Input

Low Inductance

High Inductance

Hz

Three Phase

Hertz

IP

Degree Of
Protection

Read Operator’s

Manual

OM-249 332 Page 7

SECTION 3 − SPECIFICATIONS

t

3-1. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the back of the unit . Use rating label to determine input power requirements
and/or rated output. For future reference, write serial number in space provided on back cover of this manual.

3-2. Specifications

. Do not use information in unit specifications table to determine electrical service requirements. See Sections4-9, 4-10 and 4-11 for information

on connecting input power.

Amperes Input At Rated

Load Output, 50/60 Hz,

Three-Phase

230 V 400 V

KVA/KW Dimensions Weigh

15.2 KW

21.2 KW

Length: 860 mm

Height: 570 mm

Width: 930 mm

Length: 860 mm

Height: 570 mm

Width: 930 mm

125 kg

153 kg

Rated Welding

Model

350 350 A @ 31.5

450 450 A @ 36.5

Output

Volts DC, 45%

Duty Cycle

Volts DC, 50%

Duty Cycle

Amperage
Range DC

30 -350 A 43V 40 A 23 A 16 KVA

30 -450 A 47V 56 A 32 A 22.2 KVA

Max.

Open-Circuit

Voltage DC

3-3. Environmental Specifications

A. IP Rating

IP Rating Operating Temperature Range Storage Temperature Range

IP22S

This equipment is designed for indoor use and

is not intended to be used or stored outside.

−10 to 40°C (14 to 104 °F)

20 to 25°C (68 to 77 °F)

B. Information On Electromagnetic Fields (EMF)

! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.

This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.

Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.

S 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.

ce-emf 1 2010-10

IP22S 2014−06

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−

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

This equipment complies with 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
2,562,107.1 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.

OM-249 332 Page 8

at the point of common coupling is less than 62.4mW (or the short−circuit power Ssc is greater than

max

ce-emc 1 2014-07

3-4. Duty Cycle Chart

500

450

400

350

300

Weld Amperes

450 Amp Model

Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.

If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.

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

250

200

150

0 10 20 30 40 50 60 70 80 90 100

% Duty Cycle

50% Duty Cycle at 450A

5 Minutes Welding 5 Minutes Resting

100% Duty Cycle at 320V

60% Duty Cycle at 410A

6 Minutes Welding 4 Minutes Resting

Overheating

0

Minutes

Continuous Welding

15

A

OR

Reduce Duty Cycle

duty1 4/95 / Ref. 168 919

OM-249 332 Page 9

3

-5. Volt-Ampere Curves

XPS 350

50
45
40

35
30

Max

25

DC Volts

20
15

Min

10

5
0

020

40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400

DC Amperes

DC Volts

50
45
40

35
30
25
20
15

10

5
0

020

XPS 450

Max

Min

40 60 80 100 120140 160 180 200 220240 260 280 300 320 340 360 380 400 420 440 460 480 500

DC Amperes

OM-249 332 Page 10

SECTION 4 − INSTALLATION

4-1. Selecting A Location

Movement

Location A n d A i r f l o w

1

OR

500 mm

2

3

500 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 Eye
2 Lifting Forks
Use lifting eye or lifting forks to

move unit.
If using lifting forks, extend forks

beyond opposite side of unit.
3 Line Disconnect Device
Locate unit near correct input

power supply.

500 mm

956142796_1-10_D

loc_large 2015-04

OM-249 332 Page 11

4-2. Typical MIG Connections

5

A

1 Power source
2 Work clamp (connect to receptacle as shown)
3 Cylinder (chain to running gear)
4 Cylinder valve
Open valve slightly so gas flow blows dirt from valve.

Close valve.
5 Regulator/Flow gauge
Install so face is vertical.
6 Flow adjust
7 Gas supply line
8 Wire feeder
9 MIG torch
10 Water Cooler (See Section 4-4)

9

6

7

3

8

1

10

4

2

956142796_9-10_

OM-249 332 Page 12

4-3. Installing Single Bottle And Upper Bracket Support (All Models: Optional)

Tools Needed:

M8 (13 mm)

Torx T30

1

2

4

10

4

5

3

9

8

. Chain cylinder to the support so cylin-

der cannot fall and break off valve.

1 Upper Cylinder Support Bracket
2 Upper Support Bracket Screw

Use screws to secure support bracket to
welding power source.

7

6

3 Bottle Support
4 Bottle Support Screw
Use screws to secure bottle support to

base.
5 Running Gear Shaft
Secure wheels to running gear.
6 Cylinder

956142796_6-10_B / 956142796_7-10_B

7 Regulator/Flowmeter
Install so face is vertical.
8 Input Gas Hose
9 Water Cooler
10 Plastic Grommet
Route hoses through grommet and along

track in base (see Section 4-5).

OM-249 332 Page 13

4-4. Installing Double Bottle And Upper Bracket Support (All Models: Optional)

Tools Needed:

M8 (13 mm)

Torx T30

1

2

4

10

4

5

3

9

11

8

7

6

. Chain cylinder to the support so cylin-

der cannot fall and break off valve.

1 Upper Cylinder Support Bracket
2 Upper Support Bracket Screw

Use screws to secure support bracket to
welding power source.

3 Bottle Support

OM-249 332 Page 14

4 Bottle Support Screw
Use screws to secure bottle support to

base.
5 Running Gear Shaft
Secure wheels to running gear.
6 Cylinder
7 Regulator/Flowmeter
Install so face is vertical.

956142796_4-10_B / 956142796_5-10_B

8 Input Gas Hose
9 Water Cooler
10 Plastic Grommet
Route hoses through grommet and along

track in base (see Section 4-5).
11 Water Cooler Mounting Bracket
Use bracket to secure cooler to bottle sup-

port.

4-5. Installing Input Gas And Water Cooler Hoses (All Models: Optional)

1 Hose Retaining Bracket
2 Hoses
Route hoses through track in base,

and use bracket to secure hoses.
3 Water Out Fitting (Cool)
4 Water In Fitting (Hot)
5 Gas Out Fitting

2

34

1

5

Tools Nee d e d :

Torx T30

956142796_8-10_C

OM-249 332 Page 15

4-6. Weld Output Terminals And Selecting Cable Sizes*

4-7. Weld Output Terminals

2

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)

* 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)

4-8. Remote 14 Receptacle RC1

AJ

K

B

L

C

D

I

NH

M

G

F

E

1

2

Socket* Socket Information

A 24 volts AC.

B Contact closure to A completes 24 volts AC contactor control circuit.
D Circuit Common.
F Current feedback.
G Circuit Common for 24 volts AC.

! Turn off power before connecting

to weld output terminals.

! Do no t use worn, damaged, un-

dersized, or repaired cables.

1 Electrode
2 Work

. See Sections 4-2 t for standard con-

nection diagrams.

956142796_1-10_D

output term1 2015−0

Pins D, F, and H are used in XPS digital models only.

OM-249 332 Page 16

H Voltage feedback.

4-9. Electrical Service Guide

Elec Serv 2011−08

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

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

630.12.

* Power cord supplied with 230 volt units.
** Larger power cord may be required for cable length greater than 3 meters. Consult national or local regulations.

XPS 350−50/60 Hz Three Phase XPS 450−50/60 Hz Three Phase

Input Voltage (V) 230 400 230 400
Input Amperes (A) At Rated Output 40 23 56 32
Max Recommended Standard Fuse Rating In Amperes

Time-Delay Fuses

Normal Operating Fuses

Min Input Conductor Size In mm

2

(AWG)

4 * **

Max Recommended Input Conductor Length In Meters (Feet)

4 *

2

Min Grounding Conductor Size In mm

(AWG)

1
2
3

50 25 60 40
60 35 80 50

6 (10) 4 (12) 10 (8) 6 (10)

26

(86)

**

6 (10) 4 (12) 10 (8) 6 (10)

48

(156)

29

(94)

57

186)

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 require-

ments.

OM-249 332 Page 17

4-10. Positioning Jumper Links (230/400 VAC 3-Phase)

! Disconnect and lockout/tag-

out input power before in­stalling or moving jumper
links. Follow established pro­cedures regarding the install­ation and removal of lockout/
tagout devices.

. All units have jumper links pre-

set to 400V.

Check input voltage available at site.
1 Jumper Link Label
Check label − only one is on unit.
2 Jumper Links
Move jumper links to match input

voltage.
Close and secure access door. Fol-

low established lockout/tagout pro­cedures to put unit in service.

2

230V 400V

Tools Nee d e d :

8mm / .315 in

OM-249 332 Page 18

1

956142796_3-10_D

Notes

OM-249 332 Page 19

4-11. Connecting 3-Phase Input Power

4

3

= GND/PE Earth Ground

7

2

L1

3

6

1

L2
L3

5

OM-249 332 Page 20

Tools Needed:

input2 2012−05 − Ref. 803 766-C

! Installation must meet all National and

4-11. 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.

See rating label on unit and check input volt-

age 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 4-9 (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-249 332 Page 21

5-1. Controls For The XPS 350

1 Voltage Range Control S2
Allows selection of voltage in three

coarse ranges, A, B, or C.
2 Digital Voltmeter
3 Power On Light PL1
PL1 is lit when power is On.
4 High Temperature Light PL2
PL2 lights up when unit overheats

and shuts down.
5 Digital Ammeter.
6 Voltage Adjustment Control S3
This control allows for 10 voltage set-

tings in each of the three coarse
voltage ranges (A, B, or C) of S2.

7 Power Switch S1
Use switch to turn unit On and Off.
8 Positive (+) Weld Output Ter-

minal

9 Wire Feeder Power Cable

Receptacle

Use receptacle to supply power to a
wire feeder.

10 High Inductance Negative (−)

Weld Output Terminal

Connect work lead here for stainless
steel and spray arc applications.

11 Low Inductance Negative (−)

Weld Output Terminal

Connect work lead here for most
short arc applications.

12 Supplementary Protector CB1
CB1 protect the 24 volts AC portion of

the circuit from overload.
13 Supplementary Protector CB2
CB2 protect the 115 volts AC portion

of the circuit from overload.
14 115 AC Receptacle RCPT
Receptacle is located on the back

panel, and provides power for the gas
heater when welding with CO
shielding gas, and for the cooling sys­tem.

SECTION 5 − OPERATION

32

1

Front Panel

89 10

Basic Model

Digital Model

2

Back Panel

5

4

12

6

7

11

12

OM-249 332 Page 22

14

13

5-2. Controls For The XPS 450

1 Voltage Range Control S2
Allows selection of voltage in four

coarse ranges, A, B, C, or D.
2 Digital Voltmeter
3 Power On Light PL1
PL1 is lit when power is On.
4 High Temperature Light PL2
PL2 lights up when unit overheats

and shuts down.
5 Digital Ammeter.
6 Voltage Adjustment Control S3
This control allows for 10 voltage set-

tings in each of the four coarse
voltage ranges (A, B, C, or D) of S2.

7 Power Switch S1
Use switch to turn unit On and Off.
8 Positive (+) Weld Output Ter-

minal

9 Wire Feeder Power Cable

Receptacle

Use receptacle to supply power to a
wire feeder.

10 High Inductance Negative (−)

Weld Output Terminal

Connect work lead here for stainless
steel and spray arc applications.

11 Low Inductance Negative (−)

Weld Output Terminal

Connect work lead here for most
short arc applications.

12 Supplementary Protector CB1
CB1 protect the 24 volts AC portion of

the circuit from overload.
13 Supplementary Protector CB2
CB2 protect the 115 volts AC portion

of the circuit from overload.
14 115 AC Receptacle RCPT
Receptacle is located on the back

panel, and provides power for the gas
heater when welding with CO
shielding gas, and for the cooling sys­tem.

1

2

5

32

Front Panel

89 10

Back Panel

4

6

7

11

12

14

13

OM-249 332 Page 23

SECTION 6 − MAINTENANCE AND TROUBLESHOOTING

-

6-1. Routine Maintenance

! Disconnect power before maintaining.

. Maintain more often during severe conditions.

3 Months

Replace unreadable labels. Clean and tighten weld terminals.

Repair or replace cracked weld
cable.

Replace o-ring in electrode/gas
output receptacle if cracked.

Repair or replace cracked gas
hose.

6 Months

Blow out or vacuum inside.

OR

6-2. Unit Overload

Thermal switches TP2 in SR1 and TP3−TP4 in XFMR protect the unit from damage due to overheating. If thermal indicator PL2 illuminates, wait for
unit to cool (see Section 3-4) allowing fan motor to run before trying to weld. If unit is cool and no weld output continues, contact a Factory Authorized
Service Agent.

6-3. Troubleshooting

Trouble Remedy

No weld output; unit completely inoper
ative.

No weld output; pilot light PL2 on. Unit overheated. Allow unit to cool (see Section 3-4).
Limited weld output, and low open cir-

cuit voltage.

Unit provides only maximum or minim­um weld output.

OM-249 332 Page 24

Place line disconnect switch in On position (see Section 4-11).
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-11).
Check for proper input power connections (see Section 4-11).

Check for proper jumper links position (see Section 4-10).

Have factory Authorized Service Agent check continuity of power switch S1, and replace if necessary.

Check for proper input power connections (see Section 4-11).
Check for proper jumper links position (see Section 4-10).

Clean and tighten all weld output connections.

Have factory Authorized Service Agent check control board PC1 and Hall device HD1, and replace if ne­cessary

Trouble Remedy

Notes

No 115 volts AC output at duplex
receptacle.

No 24 volts AC output at Remote 14 re­ceptacle.

Fan not operating; fan only runs when
cooling is necessary.

Wandering arc; poor control of arc direc­tion.

Digital meter not working properly.

Reset supplementary protector CB2 (See Section 5).

Reset supplementary protector CB1 (See Section 5).

Check for and remove anything blocking fan movement.

Have factory Authorized Service Agent check fan motor.

Have factory Authorized Service Agent check thermostat TP1 if available, and replace if necessary.

Reduce gas flow rate.

Have factory Authorized Service Agent check control board PC1 and connections, and replace if neces­sary.

Have factory Authorized Service Agent check meter display board PC2 settings and connections, and
replace if necessary.

OM-249 332 Page 25

SECTION 7 - ELECTRICAL DIAGRAM

Figure 7-1. Circuit Diagram for XPS 350 Digital (230/400 VAC)

OM-249 332 Page 26

956142739-G

OM-249 332 Page 27

Figure 7-2. Circuit Diagram for XPS 350 Digital (400 VAC)

OM-249 332 Page 28

956142740-G

OM-249 332 Page 29

Figure 7-3. Circuit Diagram for XPS 450 Digital (230/400 VAC)

OM-249 332 Page 30

956142741-F

OM-249 332 Page 31

Figure 7-4. Circuit Diagram for XPS 450 Digital (400 VAC)

OM-249 332 Page 32

956142742-F

OM-249 332 Page 33

Figure 7-5. Circuit Diagram for XPS 350 Basic (230/400 VAC)

OM-249 332 Page 34

956142801-B

OM-249 332 Page 35

Figure 7-6. Circuit Diagram for XPS 350 Basic (400 VAC)

OM-249 332 Page 36

956142802-C

OM-249 332 Page 37

Figure 7-7. Circuit Diagram for XPS 450 Basic (230/400 VAC)

OM-249 332 Page 38

956142803-C

OM-249 332 Page 39

Figure 7-8. Circuit Diagram for XPS 450 Basic (400 VAC)

OM-249 332 Page 40

956142804-D

OM-249 332 Page 41

SECTION 8 - PARTS LIST

8

9

30

23

71

24

22

12

72

21

25

6

10

55

51

56

54

57

58

50

7

4

61

60

59

52

68

69

49

11

64

63

13

26

29

20

28

18

17

16

14

15

66

19

36

37

35

34

65

62

67

53

43

5

3

2

1

70

32

33

31

OM-249 332 Page 42

42

45

41

40

38

39

Figure 8-1. Main Assembly for XPS 350

48

47

46

44

Ref. 956142796_2-10_G

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Description

Model

Basic Digital

Figure 8-1. Main Assembly for XPS 350

1 000207233 Label, general precautionary 2 2... ........... .. ............................... .... ..

2 [phone] Panel, side RH 1 1... .......... .. ........................................... .... ..

3 000207291 Label, primary power connections 1 1... ........... .. .......................... .... ..

4 000119503 Label, Miller logo 2 2... ........... .. ......................................... .... ..

5 000207235 Label Warning, tilt 1 1... ........... .. ........................................ .... ..

6 656089043 Seal, lift eye 1 1... ........... .. ............................................. .... ..

7 [phone] Cover, top 1 1... .......... .. ............................................... .... ..

8 [phone] Panel, side LH 1 1... .......... .. ........................................... .... ..

9 156005149 Plate, upper 1 1... ........... .. ............................................. .... ..

10 156005150 Bracket, side LH 1 1... ........... .. ......................................... .... ..

11 SR1 056050160 Rectifier, PTS 100x300 1 1... ... ... .. .................................... .... ..

12 HD1 056167008 Transducer, Current 400A, kit 1... ... ... .. ..................................... ..

13 TP2 056159026 Thermostat, 100° 10A 1 1... ... ... .. ..................................... .... ..

14 956142789 Rating Plate (230/400 VAC) 1... ........... .. ....................................... ..

14 956142791 Rating Plate (230/400 VAC) 1... ........... .. ................................ .........

14 956142785 Rating Plate (400 VAC) 1... ........... .. .......................................... ..

14 956142787 Rating Plate (400 VAC) 1... ........... .. ................................... .........

15 T2 058021151 Transformer, Aux, 220−230V 400V 40x80 1... .... ... .. .......................... ..

15 T2 058021154 Transformer, Aux, 220−230V 400V 40x50 1... .... ... .. ................... .........

16 PC1 057084155 Circuit Board, control 1... ... ... .. ..................................... .........

16 PC1 057084149 Circuit Board, control 1... ... ... .. ............................................ ..

17 056092099 Fuse Holder 2 2... ........... .. ............................................. .... ..

18 056092100 Fuse, 6x30 6.3A 250V 2 2... ........... .. .................................... .... ..

19 PC2 057084147 PC2 Circuit Card, Digital Display 1... ... ... .. .................................. ..

20 S2 056067272 Switch, 20A 3 pos. 1 1... .... ... .. ....................................... .... ..

21 356029217 Nameplate, front, upper 1... ........... .. .......................................... ..

21 356029216 Nameplate, front, upper 1... ........... .. ................................... .........

22 PL1 056072079 Pilot, 24V Lamp, white 1 1... ... ... .. .................................... .... ..

23 056020069 Knob, D.40 1 1... ........... .. .............................................. .... ..

24 PL2 056072080 Pilot, 24V Lamp, orange 1 1... ... ... .. ................................... .... ..

25 056020069 Knob, D.40 1 1... ........... .. .............................................. .... ..

26 056076265 Receptacle, 14 pin 1 1... ........... .. ........................................ .... ..

27 No Item 27... .......................... .........................................................

28 056076152 Dinse Socket, Female, 50Mmq 3 3... ........... .. ............................. .... ..

29 356029211 Nameplate, front, lower 1 1... ........... .. ................................... .... ..

30 000230124 Handle 2 2... ........... .. .................................................. .... ..

31 000222779 Front, bezel 1 1... ........... .. ............................................. .... ..

32 156005151 Bracket, front, lower, casters 1 1... ........... .. ............................... .... ..

33 056054084 Caster, D.125, rubber 2 2... ........... .. ..................................... .... ..

34 156118068 Panel, front 1 1... ........... .. .............................................. .... ..

35 S1 056067267 Switch, c/w protection 1 1... .... ... .. ..................................... .... ..

36 S3 056067269 Switch, 20A 10 pos. 1 1... .... ... .. ...................................... .... ..

37 FM1 057035009 Fan, P. 30 230V 1 1... ... ... .. .......................................... .... ..

38 057015107 Coil, 400V, 60x80x180 Al 3 3... ........... .. .................................. .... ..

39 T1 058021152 Transformer, 400V, 60x80x180 Al. 1 1... .... ... .. .......................... .... ..

40 556070015 Link, Primary Power Terminal Board, D5, brass 7 7... ........... .. ............... .... ..

41 116014052 Box, Primary Power Terminal Board 1 1... ........... .. ........................ .... ..

42 156005152 Bracket, upper, lift eye support 1 1... ........... .. ............................. .... ..

43 156011023 Lift Eye 1 1... ........... .. ................................................. .... ..

44 156005153 Bracket, lower, lift eye support 1 1... ........... .. ............................. .... ..

45 156012149 Shaft, D.16 L.590, lift eye support 1 1... ........... .. .......................... .... ..

46 156023157 Clip, Wheel retaining 2 2... ........... .. ...................................... .... ..

47 056054085 Wheel, D.250, rubber 2 2... ........... .. ..................................... .... ..

48 156009132 Washer, D.21x37 4 4... ........... .. ......................................... .... ..

49 156012150 Axle, Running Gear D.20 L.567 ZN 1 1... ........... .. ......................... .... ..

50 156005154 Bracket, rear, lower, wheels 1 1... ........... .. ................................ .... ..

51 156006068 Base 1 1... ........... .. ................................................... .... ..

52 Z 057098021 Impedance, D.8.5 L.320, Al. 1 1... .... .... .. ............................... .... ..

53 156118069 Panel, rear 1... ........... .. ..................................................... ..

53 156118071 Panel, rear 1... ........... .. .............................................. .........

OM-249 332 Page 43

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Description

Model

Basic Digital

Figure 8-1. Main Assembly for XPS 350 (continued)

54 [phone] Conveyor, Fan 1 1... .......... .. ........................................... .... ..

55 000176106 Label, Fan 1 1... ........... .. ............................................... .... ..

56 W 057079043 Contactor, 24V 40A (230/400VAC) 1 1... .... .... .. .......................... .... ..

56 W 057079041 Contactor, 24V 25A (400 VAC) 1 1... .... .... .. ............................. .... ..

57 156005155 Plate, rear, upper 1 1... ........... .. ......................................... .... ..

58 156005146 Corner, R.15, plastic 2 2... ........... .. ...................................... .... ..

59 656089026 Strain Relief, D.30 1 1... ........... .. ........................................ .... ..

60 057014229 Line Cable, 4x3 Mt 3, Neoprene (230/400 VAC) 1 1... ........... .. .............. .... ..

60 057014228 Line Cable, 4x4 Mt 3, Neoprene (400 VAC) 1 1... ........... .. .................. .... ..

61 217297 Cover, Receptacle Weatherproof Duplex RCPT 1... .............. .. ..................... ..

62 356029220 Nameplate, rear, w Aux 1... ........... .. .......................................... ..

62 356029226 Nameplate, rear 1... ........... .. .......................................... .........

63 ♦156005156 Bracket, upper bottle support 1 1... ......... .. .............................. .... ..

64 ♦156123004 Chain, D.4 L.750, zinced, bottle 1 1... ......... .. ............................ .... ..

65 RC2 000604176 RCPT, Str Dx Grd 2P3W 15A 125V * 5−15R 1... ... ... .. ........................ ..

66 CB1 056067273 Circuit Breaker, 6A w/rubber boot 1 1... ... ... .. ........................... .... ..

67 CB2 056067274 Circuit Breaker, 4A w/rubber boot 1... ... ... .. .................................. ..

68 ♦656089044 Grommet, 59x22, rubber 1 1... ......... .. .................................. .... ..

69 ♦156012151 Shaft, Running Gear, D.20 L.120 2 2... ......... .. ........................... .... ..

70 ♦058056003 Bottle Support, lower, 1 bottle. 1 1... ......... .. ............................. .... ..

70 ♦058056004 Bottle Support, lower, 2 bottle. 1 1... ......... .. ............................. .... ..

71 656089044 Grommet, 59x22, rubber 1 1... ........... .. .................................. .... ..

72 956142807 Label, front, lower, water stroke shielding gas connection 1 1... ........... .. ...... .... ..

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

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-249 332 Page 44

Notes

OM-249 332 Page 45

8

9

30

23

71

24

22

12

72

21

25

6

10

53

55

51

56

54

57

58

50

7

4

61

60

59

52

68

69

49

11

64

63

13

26

29

20

28

18

17

16

14

15

66

19

36

37

35

34

65

62

67

43

5

3

2

1

70

32

33

31

OM-249 332 Page 46

42

45

41

40

38

39

Figure 8-2. Main Assembly for XPS 450

48

47

46

44

Ref. 956142796_2-10_G

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Description

Model

Basic Digital

Figure 8-2. Main Assembly for XPS 450

1 000207233 Label, general precautionary 2 2... ........... .... ............................. ....

2 [phone] Panel, side RH 1 1... .......... .... ......................................... ....

3 000207291 Label, primary power connections 1 1... ........... .... ......................... ....

4 000119503 Label, Miller logo 2 2... ........... .... ....................................... ....

5 000207235 Label Warning, tilt 1 1... ........... .... ...................................... ....

6 656089043 Seal, lift eye 1 1... ........... .... ........................................... ....

7 [phone] Cover, top 1 1... .......... .... ............................................. ....

8 [phone] Panel, side LH 1 1... .......... .... ......................................... ....

9 156005149 Plate, upper 1 1... ........... .... ............................................ ....

10 156005150 Bracket, side LH 1 1... ........... .... ........................................ ....

11 SR1 056050161 Rectifier, PTS 450 1 1... ... ... .... ...................................... ....

12 HD1 058066075 Transducer, Current 600A, kit 1... ... ... .... ...................................

13 TP2 056159026 Thermostat, 100° 10A 1 1... ... ... .... ................................... ....

14 956142790 Rating Plate (230/400 VAC) 1... ........... .... .....................................

14 956142792 Rating Plate (230/400 VAC) 1... ........... .... .............................. .....

14 956142786 Rating Plate (400 VAC) 1... ........... .... .........................................

14 956142788 Rating Plate (400 VAC) 1... ........... .... .................................. .....

15 T2 058021151 Transformer, Aux, 220−230V 400V 40x80 1 1... .... ... .... .................. ....

16 PC1 057084150 Circuit Board, control 1 1... ... ... .... .................................... ....

17 056092099 Fuse Holder 2 2... ........... .... ........................................... ....

18 056092100 Fuse, 6x30 6.3A 250V 2 2... ........... .... ................................... ....

19 PC2 057084147 PC2 Circuit Card, Digital Display 1... ... ... .... .................................

20 S2 056067275 Switch, 25A 4 pos. 1 1... .... ... .... ...................................... ....

21 356029218 Nameplate, front, upper 1 1... ........... .... ................................. ....

22 PL1 056072079 Pilot, 24V Lamp, white 1 1... ... ... .... .................................. ....

23 056020069 Knob, D.40 1 1... ........... .... ............................................ ....

24 PL2 056072080 Pilot, 24V Lamp, orange 1 1... ... ... .... ................................. ....

25 056020069 Knob, D.40 1 1... ........... .... ............................................ ....

26 056076265 Receptacle, 14 pin 1 1... ........... .... ...................................... ....

27 No Item 27... ............................ ...................................................

28 056076266 Dinse Socket, Female, 95Mmq 3 3... ........... .... ........................... ....

29 356029211 Nameplate, front, lower 1 1... ........... .... .................................. ....

30 000230124 Handle 2 2... ........... .... ................................................ ....

31 000222779 Front, bezel 1 1... ........... .... ............................................ ....

32 156005151 Bracket, front, lower, casters 1 1... ........... .... ............................. ....

33 056054084 Caster, D.125, rubber 2 2... ........... .... ................................... ....

34 156118068 Panel, front 1 1... ........... .... ............................................ ....

35 S1 056067267 Switch, c/w protection 1 1... .... ... .... ................................... ....

36 S3 056067276 Switch, 25A 10 pos. 1 1... .... ... .... ..................................... ....

37 FM1 057035020 Fan, P. 50 230V 1 1... ... ... .... ........................................ ....

38 057015108 Coil, 400V, 60x110x180 Al 3 3... ........... .... ............................... ....

39 T1 058021153 Transformer, 400V, 60x110x180 Al. 1 1... .... ... .... ....................... ....

40 556070017 Link, Primary Power Terminal Board, D5, brass 10 10... ........... .... ............. ....

41 116014052 Box, Primary Power Terminal Board 1 1... ........... .... ....................... ....

42 156005152 Bracket, upper, lift eye support 1 1... ........... .... ........................... ....

43 156011023 Lift Eye 1 1... ........... .... ................................................ ....

44 156005153 Bracket, lower, lift eye support 1 1... ........... .... ............................ ....

45 156012149 Shaft, D.16 L.590, lift eye support 1 1... ........... .... ......................... ....

46 156023157 Clip, Wheel retaining 2 2... ........... .... .................................... ....

47 056054085 Wheel, D.250, rubber 2 2... ........... .... ................................... ....

48 156009132 Washer, D.21x37 4 4... ........... .... ....................................... ....

49 156012150 Axle, Running Gear D.20 L.567 ZN 1 1... ........... .... ....................... ....

50 156005154 Bracket, rear, lower, wheels 1 1... ........... .... .............................. ....

51 156006068 Base 1 1... ........... .... .................................................. ....

52 Z 057098022 Impedance, D.10,8 L.360, Al. 1 1... .... .... .... ............................ ....

53 156118070 Panel, rear 1 1... ........... .... ............................................. ....

54 [phone] Conveyor, Fan 1 1... .......... .... ......................................... ....

55 000176106 Label, Fan 1 1... ........... .... ............................................. ....

OM-249 332 Page 47

Quantity

Item

No.

Dia.

Mkgs.

Part

No.

Description

Model

Basic Digital

Figure 8-2. Main Assembly for XPS 450 (continued)

56 W 057079039 Contactor, CN−65 24V (230/400 VAC) 1 1... .... .... .... ..................... ....

56 W 057079043 Contactor, 24V 40A (400 VAC) 1 1... .... .... .... ........................... ....

57 156005155 Plate, rear, upper 1 1... ........... .... ....................................... ....

58 156005146 Corner, R.15, plastic 2 2... ........... .... .................................... ....

59 656089026 Strain Relief, D.30 1 1... ........... .... ...................................... ....

60 057014230 Line Cable, 4x10 Mt 3, Neoprene (230/400 VAC) 1 1... ........... .... ............ ....

60 057014229 Line Cable, 4x6 Mt 3, Neoprene (400 VAC) 1 1... ........... .... ................. ....

61 217297 Cover, Receptacle Weatherproof Duplex RCPT 1 1... .............. .... ............. ....

62 356029220 Nameplate, rear, w Aux 1 1... ........... .... .................................. ....

63 ♦156005156 Bracket, upper bottle support 1 1... ......... .... ............................. ....

64 ♦156123004 Chain, D.4 L.750, zinced, bottle 1 1... ......... .... ........................... ....

65 RC2 000604176 RCPT, Str Dx Grd 2P3W 15A 125V * 5−15R 1 1... ... ... .... ............... ....

66 CB1 056067273 Circuit Breaker, 6A w/rubber boot 1 1... ... ... .... ......................... ....

67 CB2 056067274 Circuit Breaker, 4A w/rubber boot 1 1... ... ... .... ......................... ....

68 ♦656089044 Grommet, 59x22, rubber 1 1... ......... .... ................................. ....

69 ♦156012151 Shaft, Running Gear, D.20 L.120 2 2... ......... .... ......................... ....

70 ♦058056003 Bottle Support, lower, 1 bottle. 1 1... ......... .... ............................ ....

70 ♦058056004 Bottle Support, lower, 2 bottle. 1 1... ......... .... ............................ ....

71 656089044 Grommet, 59x22, rubber 1 1... ........... .... ................................. ....

72 956142807 Label, front, lower, water stroke shielding gas connection 1 1... ........... .... .... ....

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

To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.

OM-249 332 Page 48

Effective January 1, 2015

(Equipment with a serial number preface of MF 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 2015-01

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 © 2015 Miller Electric Mfg. Co. 2015−01