Professional Documents
Culture Documents
400 Volt Model
400 Volt Model
400 Volt Model
2016−04
Processes
Multiprocess Welding
Description
XMT 400
(400 Volt Model)
File: MULTIPROCESS
Mil_Thank 2009−09
TABLE OF CONTENTS
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
D Always verify the supply ground − check and be sure that input
The symbols shown below are used throughout this manual power cord ground wire is properly connected to ground terminal in
to call attention to and identify possible hazards. When you
disconnect box or that cord plug is connected to a properly
see the symbol, watch out, and follow the related instructions
grounded receptacle outlet.
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information D When making input connections, attach proper grounding conduc-
found in the Safety Standards listed in Section 1-5. Read and tor first − double-check connections.
follow all Safety Standards. D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
Only qualified persons should install, operate, maintain, and D Frequently inspect input power cord and ground conductor for
repair this unit. damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
During operation, keep everybody, especially children, away. 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.
ELECTRIC SHOCK can kill.
D If earth grounding of the workpiece is required, ground it directly
Touching live electrical parts can cause fatal shocks with a separate cable.
or severe burns. The electrode and work circuit is D Do not touch electrode if you are in contact with the work, ground,
electrically live whenever the output is on. The input or another electrode from a different machine.
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automatic D Do not touch electrode holders connected to two welding ma-
wire welding, the wire, wire reel, drive roll housing, chines at the same time since double open-circuit voltage will be
and all metal parts touching the welding wire are present.
electrically live. Incorrectly installed or improperly D Use only well-maintained equipment. Repair or replace damaged
grounded equipment is a hazard.
parts at once. Maintain unit according to manual.
D Do not touch live electrical parts. D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats D Clamp work cable with good metal-to-metal contact to workpiece
or covers big enough to prevent any physical contact with the work or worktable as near the weld as practical.
or ground. D Insulate work clamp when not connected to workpiece to prevent
D Do not use AC output in damp areas, if movement is confined, or if contact with any metal object.
there is a danger of falling. D Do not connect more than one electrode or work cable to any
D Use AC output ONLY if required for the welding process. single weld output terminal. Disconnect cable for process not in
use.
D If AC output is required, use remote output control if present on
unit. D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
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
SIGNIFICANT DC VOLTAGE exists in inverter weld-
as floors, gratings, or scaffolds; when in cramped positions such ing power sources AFTER removal of input power.
as sitting, kneeling, or lying; or when there is a high risk of unavoid- D Turn Off inverter, disconnect input power, and discharge input
able or accidental contact with the workpiece or ground. For these capacitors according to instructions in Maintenance Section
conditions, use the following equipment in order presented: 1) a before touching any parts.
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder HOT PARTS can burn.
is recommended. And, do not work alone!
D Do not touch hot parts bare handed.
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to D Allow cooling period before working on
OSHA 29 CFR 1910.147 (see Safety Standards). equipment.
D Properly install, ground, and operate this equipment according to D To handle hot parts, use proper tools and/or wear heavy, insu-
its Owner’s Manual and national, state, and local codes. lated welding gloves and clothing to prevent burns.
OM-217769 Page 1
D Remove stick electrode from holder or cut off welding wire at
FUMES AND GASES can be hazardous. contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
Welding produces fumes and gases. Breathing (leather, heavy cotton, wool). Body protection includes oil-free
these fumes and gases can be hazardous to your clothing such as leather gloves, heavy shirt, cuffless trousers, high
health.
shoes, and a cap.
D Keep your head out of the fumes. Do not breathe the fumes. D Remove any combustibles, such as a butane lighter or matches,
D If inside, ventilate the area and/or use local forced ventilation at the from your person before doing any welding.
arc to remove welding fumes and gases. The recommended way D After completion of work, inspect area to ensure it is free of sparks,
to determine adequate ventilation is to sample for the composition glowing embers, and flames.
and quantity of fumes and gases to which personnel are exposed. D Use only correct fuses or circuit breakers. Do not oversize or by-
D If ventilation is poor, wear an approved air-supplied respirator. pass them.
D Read and understand the Safety Data Sheets (SDSs) and the D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
manufacturer’s instructions for adhesives, coatings, cleaners, for hot work and have a fire watcher and extinguisher nearby.
consumables, coolants, degreasers, fluxes, and metals. D Read and understand the Safety Data Sheets (SDSs) and the
D Work in a confined space only if it is well ventilated, or while manufacturer’s instructions for adhesives, coatings, cleaners,
wearing an air-supplied respirator. Always have a trained watch- consumables, coolants, degreasers, fluxes, and metals.
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath- FLYING METAL or DIRT can injure eyes.
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op- D Welding, chipping, wire brushing, and grinding
erations. The heat and rays of the arc can react with vapors to form cause sparks and flying metal. As welds cool,
highly toxic and irritating gases. they can throw off slag.
D Do not weld on coated metals, such as galvanized, lead, or D Wear approved safety glasses with side
cadmium plated steel, unless the coating is removed from the weld shields even under your welding helmet.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements BUILDUP OF GAS can injure or kill.
can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin. D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
Arc rays from the welding process produce intense approved air-supplied respirator.
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the ELECTRIC AND MAGNETIC FIELDS (EMF)
weld. can affect Implanted Medical Devices.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and D Wearers of Pacemakers and other Implanted
sparks when welding or watching (see ANSI Z49.1 and Z87.1 Medical Devices should keep away.
listed in Safety Standards). D Implanted Medical Device wearers should consult their doctor
D Wear approved safety glasses with side shields under your and the device manufacturer before going near arc welding, spot
helmet. welding, gouging, plasma arc cutting, or induction heating
D Use protective screens or barriers to protect others from flash, operations.
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant mate- NOISE can damage hearing.
rial (leather, heavy cotton, wool). Body protection includes Noise from some processes or equipment can
oil-free clothing such as leather gloves, heavy shirt, cuffless damage hearing.
trousers, high shoes, and a cap.
D Wear approved ear protection if noise lev-
WELDING can cause fire or explosion. el is high.
OM-217769 Page 3
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to
which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other
cause birth defects and, in some cases, cancer. (California reproductive harm. Wash hands after use.
Health & Safety Code Section 25249.5 et seq.)
OM-217769 Page 4
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION
fre_som_2015−09
7
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
OM-217769 Page 7
D N’utiliser que les pièces de rechange recommandées par le
constructeur. LE SOUDAGE À L’ARC risque de
D Effectuer l’installation, l’entretien et toute intervention selon les provoquer des interférences.
manuels d’utilisateurs, les normes nationales, provinciales et de D L’énergie électromagnétique risque de
l’industrie, ainsi que les codes municipaux. provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
LE RAYONNEMENT HAUTE l’équipement commandé par ordinateur tel que
FRÉQUENCE (H.F.) risque de les robots.
provoquer des interférences.
D Le rayonnement haute fréquence (H.F.) peut D Veiller à ce que tout l’équipement de la zone de soudage soit com-
provoquer des interférences avec les équi- patible électromagnétiquement.
pements de radio−navigation et de communication, les services D Pour réduire la possibilité d’interférence, maintenir les câbles de
de sécurité et les ordinateurs. soudage aussi courts que possible, les grouper, et les poser aussi
D Demander seulement à des personnes qualifiées familiarisées avec bas que possible (ex. par terre).
des équipements électroniques de faire fonctionner l’installation. D Veiller à souder à une distance de 100 mètres de tout équipement
D L’utilisateur est tenu de faire corriger rapidement par un électricien électronique sensible.
qualifié les interférences résultant de l’installation. D Veiller à ce que ce poste de soudage soit posé et mis à la terre
D Si le FCC signale des interférences, arrêter immédiatement l’appareil. conformément à ce mode d’emploi.
D Effectuer régulièrement le contrôle et l’entretien de l’installation. D En cas d’interférences après avoir pris les mesures précédentes,
D Maintenir soigneusement fermés les portes et les panneaux des il incombe à l’utilisateur de prendre des mesures supplémentaires
sources de haute fréquence, maintenir les éclateurs à une distan- telles que le déplacement du poste, l’utilisation de câbles blindés,
ce correcte et utiliser une terre et un blindage pour réduire les l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
interférences éventuelles. de travail.
Les équipements de soudage et de coupage produisent des Ce produit contient des produits chimiques, notamment du
fumées et des gaz qui contiennent des produits chimiques plomb, dont l’État de Californie reconnaît qu’ils provoquent
dont l’État de Californie reconnaît qu’ils provoquent des mal- des cancers, des malformations congénitales ou d’autres
formations congénitales et, dans certains cas, des cancers. problèmes de procréation. Se laver les mains après
(Code de santé et de sécurité de Californie, chapitre 25249.5 utilisation.
et suivants)
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
Safe2 2012−05
Protect yourself from electric shock by insulating yourself from work and ground.
Safe3 2012−05
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.
Safe14 2012−05
Safe16 2012−05
OM-217769 Page 9
Do not remove or paint over (cover) the label.
Safe20 2012−05
Safe30 2012−05
Flying pieces of parts can cause injury. Always wear a face shield when servicing unit.
Safe27 2012−05
Always wear long sleeves and button your collar when servicing unit.
Safe28 2012−05
Safe29 2012−05
Safe31 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
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk
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.
Safe44 2012−05
OM-217769 Page 10
3-2. Miscellaneous Symbols And Definitions
Off
U1 Primary Voltage
Increase
Hold Operation
Constant Current
(GTAW) On
Maximum Effec-
Arc Force I1eff tive Supply Cur-
rent Voltage Input
Alternating
U0 Rated No Load
Voltage (Average)
Current (AC) Protective Earth
(Ground)
Remote
Hz Hertz
Negative
Line Connection
Circuit Breaker
Foot Control
X Duty Cycle
Welding (GMAW)
Positive Three Phase
OM-217769 Page 11
SECTION 4 − SPECIFICATIONS
Amperes Input
Maximum at Rated Load
Rated Welding Voltage Amperage
Open-Circuit IP Rating Output 50/60 Hz
Output Range Range
Voltage DC
400 V KVA KW
300 A @
17.0 12.4 11.5
32 Volts DC, 10 − 35 5 − 400 90 23
(0.15*) (0.09*) (0.04*)
60% Duty Cycle
*While idling
12-1/2 in.
G 1/4-20 UNC -2B thread
(318 mm)
Weight
B
76 lb (34.6 kg)
804 801-A
OM-217769 Page 12
4-4. Duty Cycle And Overheating
Duty Cycle is percentage of 10 min-
utes that unit can weld at rated load
without overheating.
If unit overheats, output stops, a
Help message is displayed (see
Section 7-3), and cooling fan runs.
Wait fifteen minutes for unit to cool.
Reduce amperage or duty cycle be-
fore welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
Overheating
0 A
15
OR
Minutes Reduce Duty Cycle
Ref. SA-178 651
OM-217769 Page 13
4-5. Volt-Ampere Curves
Volt-ampere curves show minimum
and maximum voltage and amper-
age output capabilities of unit.
Curves of other settings fall be-
A. CC Mode tween curves shown.
ARC CONTROL
B. CV Mode
OM-217769 Page 14
SECTION 5 − INSTALLATION
Movement
2 ! Do not move or operate unit
where it could tip.
OR 3
loc_med 2015-04
Notes
OM-217769 Page 15
5-2. Selecting Cable Sizes*
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
150 ft 200 ft 250 ft 300 ft 350 ft 400 ft
100 ft (30 m) or Less
(45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 − 60%
60 − 100%
Welding Duty 10 − 100% Duty Cycle
Duty Cycle
Amperes Cycle AWG (mm2)
AWG (mm2)
AWG (mm2)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
500 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x3/0 (3x95)
600 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 3x3/0 (3x95) 3x4/0 (3x120) 3x4/0 (3x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm2 for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-L 2015−02
OM-217769 Page 16
5-4. Remote 14 Receptacle Information
Notes
OM-217769 Page 17
5-5. Electrical Service Guide Elec Serv 2014−01
NOTICE − INCORRECT INPUT POWER can damage this welding power source. This welding power source requires a CONTINUOUS supply of
input power at rated frequency(+10%) and voltage (+10%). Phase to ground voltage shall not exceed +10% of rated input voltage. Do not use a genera-
tor with automatic idle device (that idles engine when no load is sensed) to supply input power to this welding power source.
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 recommenda-
tions are for a dedicated circuit sized for the rated output and duty cycle of the welding power source.
In dedicated circuit installations, the National Electrical Code (NEC) allows the receptacle or conductor rating to be less than the rating
of the circuit protection device. All components of the circuit must be physically compatible. See NEC articles 210.21, 630.11, and
630.12.
50/60 Hz Three Phase
Input Voltage (V) 400
Input Amperes (A) At Rated Output 18
Max Recommended Standard Fuse Rating In Amperes 1
Time-Delay Fuses 2 20
Normal Operating Fuses 3 25
Min Input Conductor Size In AWG 4 14
133
Max Recommended Input Conductor Length In Feet (Meters)
(41)
Min Grounding Conductor Size In AWG 4 14
Notes
OM-217769 Page 18
Notes
OM-217769 Page 19
5-6. Connecting 3-Phase Input Power
L1
3 L2 5
6 L3
Tools Needed:
OM-217769 Page 20
5-6. Connecting 3-Phase Input Power (Continued)
! Installation must meet all National and See rating label on unit and check input volt- Connect green or green/yellow grounding
Local Codes − have only qualified per- age available at site. conductor to disconnect device grounding ter-
sons make this installation. minal first.
For Three-Phase Operation
Connect input conductors L1, L2, and L3 to
! Disconnect and lockout/tagout input 1 Input Power Cord.
disconnect device line terminals.
power before connecting input con- 2 Disconnect Device (switch shown in the
ductors from unit. Follow established OFF position) 7 Over-Current Protection
procedures regarding the installation Select type and size of over-current protec-
and removal of lockout/tagout 3 Green Or Green/Yellow Grounding
Conductor tion using Section 5-5 (fused disconnect
devices. switch shown).
4 Disconnect Device Grounding Terminal
! Always connect green or green/yellow Close and secure door on disconnect device.
conductor to supply grounding termi- 5 Input Conductors (L1, L2 And L3) Follow established lockout/tagout procedures
nal first, and never to a line terminal. 6 Disconnect Device Line Terminals to put unit in service.
input2 2012−05
OM-217769 Page 21
SECTION 6 − OPERATION
1 2 3 4
7 5 6
1 Power On/Off Switch best results, place Inductance/Dig control in When set lower, short-circuit amperage at
the maximum position. low arc voltage is the same as normal welding
. The fan motor is thermostatically 6 Voltage/Amperage Control Switch amperage.
controlled and only runs when cooling is For front panel control, place switch in Panel
needed. When set higher, short-circuit amperage is in-
position. creased at low arc voltage to assist with arc
2 Voltmeter (see Section 6-2) For remote control, make connections to Re- starts as well as reduce sticking while weld-
3 Ammeter (see Section 6-2) mote 14 receptacle, and place switch in ing (see volt-ampere curves in Section 4-5).
Remote position. In most modes, remote
4 Voltage/Amperage Adjustment Control control is a percent of the Voltage/Amperage Select setting best suited for application.
5 Mode Switch Adjustment control setting (the value se-
lected on Voltage/Amperage Adjustment Control adjusts inductance when a MIG
The Mode switch setting determines both the control is maximum available on remote). In (GMAW) position is selected on the mode
process and output On/Off control (see Sec- the MIG mode, remote control provides full switch. Inductance determines the “wetness”
tion 6-3. Source of control (panel or remote) range of unit output regardless of V/A Adjust of the weld puddle. When set higher, “wet-
for the amount of output is selected on the control setting. ness” (puddle fluidity) increases.
Voltage/Amperage Control switch.
7 Inductance/Dig Control When pulsed MIG, or one of the TIG (GTAW)
For Air Carbon Arc (CAC-A) cutting and Control adjusts Dig when a Stick (SMAW) processes is selected, this control is not func-
gouging, place switch in Stick position. For welding position is selected on mode switch. tional.
OM-217769 Page 22
6-2. Meter Functions
. The meters display the actual weld output values for approximately three seconds after the arc is broken.
V A
V A
Lift-Arc TIG
(GTAW) 7.5 85
Blank Preset Amps
V A
TIG (GTAW) 85
Blank Preset Amps
V A
V A
Pulsed MIG
(GMAW-P)
PPP PPP
Pulse Display Pulse Display
V A
Remote
Control SMAW
85
Blank Preset Amps
V A
Panel Control
SMAW 80.0 85
Actual Volts (OCV) Preset Amps
V A
Voltage-Sensing
Wirefeeder
80.0
Flashes (OCV) And Preset Blank
OM-217769 Page 23
6-3. Mode Switch Settings
. The SMAW 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.
Select: or Amp
Scratch Start TIG (GTAW)
Weld
Select: or Amp
Lift-Arc TIG
(GTAW)
Weld
Select: or Volt
MIG (GMAW)
Requires: Feeder
Pulsed MIG
(GMAW-P) Select: Volt
(Requires an
external
pulsing device.) Requires: Feeder or Control
Select: or Amp
Remote
Control SMAW
Requires: Control
Select: or Amp
Panel Control
SMAW
Weld
Select: or Volt
Voltage-Sensing
Wirefeeder
Requires: Feeder
OM-217769 Page 24
6-4. Lift-Arc TIG Procedure
With Process Switch in the Lift-Arc
TIG position, start an arc as follows:
1 TIG Electrode
2 Workpiece
Touch tungsten electrode to work-
piece at weld start point, hold
electrode to workpiece for 1-2
seconds, and slowly lift electrode.
1 2 An arc will form when electrode is
lifted.
Normal open-circuit voltage is not
present before tungsten electrode
touches workpiece; only a low
sensing voltage is present between
1−2 electrode and workpiece. The
“Touch” Seconds solid-state output contactor does
not energize until after electrode is
touching workpiece. This allows
electrode to touch workpiece with-
out overheating, sticking, or getting
contaminated.
Notes
OM-217769 Page 25
SECTION 7 − MAINTENANCE & TROUBLESHOOTING
3 Months
Replace Repair Or
Damaged Or Replace Replace Cracked
Unreadable Cracked Torch Body
Labels Cables
Repair Or Replace
Cracked Cables
And Cords
Clean
And
Tighten Weld
Connections
6 Months
ST-801 192
OM-217769 Page 26
7-3. Help Displays
. All directions are in reference to the front of the unit. All circuitry referred to
V A is located inside the unit.
OM-217769 Page 27
7-4. Troubleshooting
Trouble Remedy
No weld output; unit completely inop- Place line disconnect switch in On position (see Section 5-5).
erative.
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 5-6).
No weld output; meter display On. If using remote control, be sure Mode Selector switch is in a position that provides output control at
Remote 14 receptacle.
Unit overheated. Allow unit to cool with fan On (see Section 4-4).
Erratic or improper weld output. Use proper size and type of weld cable (see Section 5-2).
OM-217769 Page 28
SECTION 8 − ELECTRICAL DIAGRAM
254 107-A
OM-217769 Page 30
2 17 18
3
1 16 20
22 23
15
14
61 62 21
9 13
10
7 11
63 6
5
4
60
24
59
44 25
43 26
50
38
52 51 45 37 31
54 53 46
20 56 12
47 9
55 36 34
57 35 32
803 687-E
Item Dia. Part
No. Mkgs. No. Description Quantity
. . . 1 . . . . . . . . . . . . . . +175148 . . Wrapper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 175256 . . Insulator, Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . . . . . . 208015 . . Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . . 179309 . . Label, Caution Falling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . HD1 . . . . . 182918 . . Transducer, Current 400A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . . . . . . 203342 . . Bus Bar, Current Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . . . . . . 203341 . . Bus Bar, Output Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . 181853 . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 8 . . . . . D1,2 . . . . . 201531 . . Kit Diode, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 9 . . . . . . . . . . . . . . . 179276 . . Bushing, Snap-In Nyl 1.000 ID x 1.375Mtg Hole . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . C5,6 R1 . . . 175194 . . Resistor/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . RT1,2 . . . . 173632 . . Thermistor, NTC 30K Ohm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . . . . . . . . . . . 219844 . . Label, Warning Electric Shock/Exploding Parts−Wdles . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . . . . . +183551 . . Windtunnel, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 234126 . . Nut, Conduit 1.000 Npt Knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . CB1 . . . . . 089807 . . Supplementary Protector, Man Reset 1P 2.5A 250VAC . . . . . . . . . . . . . 1
. . . 16 . . . . . CB2 . . . . . 083432 . . Supplementary Protector, Man Reset 1P 10A 250VAC . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 206460 . . Panel, Rear (Without Aux. Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . . . . . . 213099 . . Bushing, Strain Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 178563 . . Nut, Nylon 1.000 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 186439 . . Ftg, Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 210346 . . Cable, Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . . . . . . . . . . . . . . . . . Plate, Ident Rear (Order By Model And Serial Number) . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . . . . . . 175138 . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 21 . . . . . . . . . . . . . . . 192853 . . Bracket, Mtg Contactor/Capacitor/PC Board . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . PC1 . . . . . 229959 . . Circuit Card, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG2 . . . . 131056 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG3 . . . . 130203 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG5 . . . . . 115091 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG7 . . . . . 115093 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . RC10 . . . . 166679 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 24 . . . . . . T2 . . . . . . 217322 . . Transformer, Control 200/400VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . +207727 . . Windtunnel, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . . . . . . 153403 . . Bushing, Snap-In Nyl .750 Id X 1.000Mtg . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . . . . . . . . . . . 177547 . . Bushing, Snap-In Nyl 1.125Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . CT1 . . . . . 175199 . . Transformer, Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . . . . . . 025248 . . Stand-Off, Insul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 30 . . . . . C1 . . . . . 188446 . . Capacitor, Polyp Film .5Uf 900VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . C3,4 . . . . . 234104 . . Capacitor, Elctlt 2700Uf 450VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 32 . . . . . PC2 . . . . . 256569 . . Circuit Card Assy, Interconnecting W/Cmpnts . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG13 . . . . 131204 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . PLG14,21 . . . 115093 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 33 . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . . . . . . 175140 . . Bracket, Di/Dt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . 175482 . . Coil, Di/Dt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 36 . . . . . . . . . . . . . . . 109056 . . Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 37 . . . . . SR1 . . . . . 179629 . . Kit Diode, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 38 . . . . PM1,2 . . . . 233043 . . Kit, Transistor IGBT Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . Z1 . . . . . . 173570 . . Stabilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . L1 . . . . . . 173563 . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . . . . . . . . . . . 207725 . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . . T1 . . . . . . 179616 . . Transformer, Hf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . . 207467 . . Heat Sink, Rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . . . . . . . . . . . 175255 . . Insulator, Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 175969 . . Insulator, PC Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . 181197 . . Gasket, Di/Dt Rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . . . . . . . . . . . 173693 . . Foot, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 46 . . . . . . . . . . . . . . . 176736 . . Screw, Mtg Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OM-217769 Page 31
Item Dia. Part
No. Mkgs. No. Description Quantity
. . . 47 . . . . . . . . . . . . . . . 175132 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 48 . . . . . PC3 . . . . . 240577 . . Circuit Card Assy, Front Panel & Display W/Program . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG11 . . . . . 115091 . . Connector & Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . FM . . . . . 175084 . . Fan, Muffin 24VDC 3000 RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . RC1 . . . . . 186706 . . Receptacle, W/Leads & Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . . 178548 . . Terminal, Connector Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 52 . . . . . C7,8 . . . . . 222488 . . Capacitor, Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 53 . . . . . . . . . . . . . . . 185732 . . Panel, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 54 . . . . . . . . . . . . . . . 129525 . . Receptacle, Twlk Insul Fem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 145088 . . Kit, Connection Dinse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 55 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, (Order By Model And Serial Number) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 070590 . . Tubing, Gl Acryl .325 (Order By Ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1ft
. . . 56 . . . . . . . . . . . . . . . 174992 . . Knob, Pointer .840 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 57 . . . . . . . . . . . . . . . 175855 . . Door, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . . . . . . . . . . . 174991 . . Knob, Pointer 1.250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 59 . . . . . . . . . . . . . . . 176226 . . Insulator, Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . S1 . . . . . 244920 . . Switch, Tgl 3Pst 40A 600VAC Scr Term Wide Tgl . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . . . . . . . . . . . 179310 . . Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . . 199840 . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 63 . . . . . . L5 . . . . . . 241027 . . Core, Toroidal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.
OM-217769 Page 32
Notes
Start Your Professional 400 Trade Square East, Troy, Ohio 45373
Over 80,000 trained
Welding Career Now! 1-800-332-9448 www.welding.org since 1930!
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
guarantees or warranties expressed or implied.
Warranty Questions?
LIMITED WARRANTY − Subject to the terms and conditions below, 5. 6 Months — Parts
Call Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original * Batteries
retail purchaser that new Miller equipment sold after the effective * Bernard Guns (No Labor)
1-800-4-A-MILLER date of this limited warranty is free of defects in material and
* Tregaskiss Guns (No Labor)
workmanship at the time it is shipped by Miller. THIS WARRANTY IS
for your local EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS 6. 90 Days — Parts
Miller distributor. OR IMPLIED, INCLUDING THE WARRANTIES OF * Accessory (Kits)
MERCHANTABILITY AND FITNESS. * Canvas Covers
Within the warranty periods listed below, Miller will repair or replace * Induction Heating Coils and Blankets, Cables, and
any warranted parts or components that fail due to such defects in Non-Electronic Controls
Your distributor also gives material or workmanship. Miller must be notified in writing within * M-Guns
you ... thirty (30) days of such defect or failure, at which time Miller will * MIG Guns and Subarc (SAW) Torches
provide instructions on the warranty claim procedures to be * Remote Controls and RFCS-RJ45
Service followed. If notification is submitted as an online warranty claim, the
You always get the fast, * Replacement Parts (No labor)
claim must include a detailed description of the fault and the
reliable response you * Roughneck Guns
troubleshooting steps taken to identify failed components and the
need. Most replacement cause of their failure. * Spoolmate Spoolguns
parts can be in your Miller’s True Blue® Limited Warranty shall not apply to:
Miller shall honor warranty claims on warranted equipment listed
hands in 24 hours. below in the event of such a failure within the warranty time periods. 1. Consumable components; such as contact tips,
All warranty time periods start on the delivery date of the equipment cutting nozzles, contactors, brushes, relays, work
Support to the original end-user purchaser, and not to exceed twelve months station table tops and welding curtains, or parts that
Need fast answers to the after the equipment is shipped to a North American distributor or fail due to normal wear. (Exception: brushes and
tough welding questions? eighteen months after the equipment is shipped to an International relays are covered on all engine-driven products.)
Contact your distributor. distributor. 2. Items furnished by Miller, but manufactured by others,
The expertise of the 1. 5 Years Parts — 3 Years Labor such as engines or trade accessories. These items are
distributor and Miller is * Original Main Power Rectifiers Only to Include SCRs, covered by the manufacturer’s warranty, if any.
there to help you, every Diodes, and Discrete Rectifier Modules 3. Equipment that has been modified by any party other than
step of the way. 2. 3 Years — Parts and Labor Miller, or equipment that has been improperly installed,
* Auto-Darkening Helmet Lenses (Except Classic improperly operated or misused based upon industry
Series) (No Labor) standards, or equipment which has not had reasonable
* Engine Driven Welder/Generators and necessary maintenance, or equipment which has
(NOTE: Engines are Warranted Separately by the been used for operation outside of the specifications for
Engine Manufacturer.) the equipment.
* Inverter Power Sources (Unless Otherwise Stated) MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* Plasma Arc Cutting Power Sources USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
TRAINED AND EXPERIENCED IN THE USE AND
* Process Controllers MAINTENANCE OF WELDING EQUIPMENT.
* Semi-Automatic and Automatic Wire Feeders In the event of a warranty claim covered by this warranty, the
* Transformer/Rectifier Power Sources exclusive remedies shall be, at Miller’s option: (1) repair; or (2)
3. 2 Years — Parts and Labor replacement; or, where authorized in writing by Miller in appropriate
* Auto-Darkening Helmet Lenses − Classic Series Only cases, (3) the reasonable cost of repair or replacement at an
(No Labor) authorized Miller service station; or (4) payment of or credit for the
* Fume Extractors − Capture 5, Filtair 400 and Industrial purchase price (less reasonable depreciation based upon actual
Collector Series 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
4. 1 Year — Parts and Labor Unless Specified Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility
* Automatic Motion Devices as determined by Miller. Therefore no compensation or
* CoolBelt and CoolBand Blower Unit (No Labor) reimbursement for transportation costs of any kind will be allowed.
* Desiccant Air Dryer System TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* External Monitoring Equipment and Sensors PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
* Field Options REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
(NOTE: Field options are covered for the remaining DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
warranty period of the product they are installed in, CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT),
WHETHER BASED ON CONTRACT, TORT OR ANY OTHER
or for a minimum of one year — whichever is
LEGAL THEORY.
greater.)
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY
* RFCS Foot Controls (Except RFCS-RJ45) IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS
* Fume Extractors − Filtair 130, MWX and SWX Series TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF
* HF Units CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH,
* ICE/XT Plasma Cutting Torches (No Labor) BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,
* Induction Heating Power Sources, Coolers OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF
(NOTE: Digital Recorders are Warranted Separately DEALING, INCLUDING ANY IMPLIED WARRANTY OF
by the Manufacturer.) MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
* LiveArc Welding Performance Management System
FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
* Load Banks MILLER.
* Motor-Driven Guns (except Spoolmate Spoolguns) Some states in the U.S.A. do not allow limitations of how long an
* PAPR Blower Unit (No Labor) implied warranty lasts, or the exclusion of incidental, indirect,
* Positioners and Controllers special or consequential damages, so the above limitation or
* Racks exclusion may not apply to you. This warranty provides specific
* Running Gear/Trailers legal rights, and other rights may be available, but may vary from
* Spot Welders state to state.
* Subarc Wire Drive Assemblies In Canada, legislation in some provinces provides for certain
additional warranties or remedies other than as stated herein, and to
* Water Coolant Systems
the extent that they may not be waived, the limitations and
* TIG Torches (No Labor) exclusions set out above may not apply. This Limited Warranty
* Wireless Remote Foot/Hand Controls and Receivers provides specific legal rights, and other rights may be available, but
* Work Stations/Weld Tables (No Labor) may vary from province to province. miller_warr 2016-01
Owner’s Record
Please complete and retain with your personal records.
Distributor
Address
City
State Zip
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Contact the Delivering Carrier to: File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2016 Miller Electric Mfg. Co. 2016−01