XMT 350 CC/CV Auto-Line: OM-233 865J Processes

OM-233 865J 2011-04
Processes
Multiprocess Welding
Description
Arc Welding Power Source
XMT 350 CC/CV

™
Auto-Line CE
File: MULTIPROCESS
Visit our website at

www.MillerWelds.com
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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 Working as hard as you do
− every power source from
tradition. They’re just as committed to providing equipment and service Miller is backed by the most
that meets the high standards of quality and value established in 1929. hassle-free warranty in the
business.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They will
help you protect yourself against potential hazards on the worksite. We’ve
made installation and operation quick and easy. With Miller you can
count on years of reliable service with proper maintenance. And if for
some reason the unit needs repair, there’s a Troubleshooting section that
will help you figure out what the problem is. The parts list will then help
you to decide which exact part you may need to fix the problem.
Warranty and service information for your particular model are also
provided.
Miller Electric manufactures a full line of

welders and welding related equipment. For
information on other quality Miller products, contact your local Miller
distributor to receive the latest full line catalog or individual catalog sheets.

TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1-4. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-5. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1-6. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 2 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-1. Manufacturer’s Warning Label Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2-2. WEEE Label (For Products Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-3. Symbols And Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 3 − INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-1. Important Information Regarding CE Products (Sold Within The EU) . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-2. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-3. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3-4. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3-5. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 4 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-1. Selecting a Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4-2. Connecting 3-Phase Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4-3. Electrical Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4-4. Weld Output Terminals And Selecting Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4-5. Remote 14 Receptacle Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-6. 115 Volts AC Duplex Receptacle And Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4-7. Optional Gas Valve Operation And Shielding Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 5 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-1. Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5-2. Meter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-3. Mode Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5-4. Lift-Arc Trigger Hold TIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5-5. Stick Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SECTION 6 − MAINTENANCE & TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-2. Blowing Out Inside Of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6-3. Voltmeter/Ammeter Help Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6-4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SECTION 7 − ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SECTION 8 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
WARRANTY

DECLARATION OF CONFORMITY
for European Community (CE marked) products.
ITW Welding Products Italy S.r.l Via Privata Iseo 6/E, 20098 San Giuliano M.se, (MI) Italy declares
that the product(s) identified in this declaration conform to the essential requirements and provi
sions of the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product Stock Number

XMT 350 CC/CV AUTOLINE,CE 907371
Council Directives:
• 2006/95/EC Low Voltage
• 2004/108/EC Electromagnetic Compatibility
Standards:
• IEC 609741 Arc Welding Equipment Welding Power Sources: edition 3, 200507.
• IEC 6097410 Arc Welding Equipment Electromagnetic Compatibility Requirements: edition 2.0, 200708.
• EN 50445:2008 Product family standard to demonstrate compliance of equipment for resistance welding, arc
welding and allied processes with the basic restrictions related to human exposure to electromagnetic fields
(0Hz300Hz)
EU Signatory:
December 13th, 2010
___________________________________________________________________________________
Massimigliano Lavarini Date of Declaration
ELECTRONIC ENGINEER R&D TECH. SUPPORT
956 142 832

SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2011−01
7
Protect yourself and others from injury — read and follow these precautions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if . Indicates special instructions.

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
This group of symbols means Warning! Watch Out! ELECTRIC
hazards are shown in the adjoining symbols or ex-
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
plained in the text.
bols and related instructions below for necessary actions to avoid the
NOTICE − Indicates statements not related to personal injury. hazards.
1-2. Arc Welding Hazards
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
repair this unit. D Frequently inspect input power cord for damage or bare wiring −
replace cord 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 poorly spliced cables.
ELECTRIC SHOCK can kill. D Do not drape cables over your body.
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
electrically live whenever the output is on. The input D Do not touch electrode if you are in contact with the work, ground,
power circuit and machine internal circuits are also or another electrode from a different machine.
live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing, D Do not touch electrode holders connected to two welding ma-
and all metal parts touching the welding wire are chines at the same time since double open-circuit voltage will be
electrically live. Incorrectly installed or improperly present.
grounded equipment is a hazard. D Use only well-maintained equipment. Repair or replace damaged
D Do not touch live electrical parts. parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats D Keep all panels and covers securely in place.
or covers big enough to prevent any physical contact with the work D Clamp work cable with good metal-to-metal contact to workpiece
or ground. or worktable as near the weld as practical.
D Do not use AC output in damp areas, if movement is confined, or if D Insulate work clamp when not connected to workpiece to prevent
there is a danger of falling. contact with any metal object.
D Use AC output ONLY if required for the welding process.
D Do not connect more than one electrode or work cable to any
D If AC output is required, use remote output control if present on single weld output terminal.
unit.
D Additional safety precautions are required when any of the follow- SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing electrically hazardous conditions are present: in damp
ing power sources AFTER removal of input power.
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such D Turn Off inverter, disconnect input power, and discharge input
as sitting, kneeling, or lying; or when there is a high risk of unavoid- capacitors according to instructions in Maintenance Section
able or accidental contact with the workpiece or ground. For these before touching any parts.
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt- HOT PARTS can burn.
age. In most situations, use of a DC, constant voltage wire welder
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 D Allow cooling period before working on equip-
servicing this equipment. Lockout/tagout input power according to ment.
OSHA 29 CFR 1910.147 (see Safety Standards). D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
D Properly install and ground this equipment according to its
clothing to prevent burns.
Owner’s Manual and national, state, and local codes.
OM-233 865 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 oil-free protective garments such as leather gloves, heavy
Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.
these fumes and gases can be hazardous to your
health. D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D Keep your head out of the fumes. Do not breathe the fumes.
D After completion of work, inspect area to ensure it is free of sparks,
D If inside, ventilate the area and/or use local forced ventilation at the glowing embers, and flames.
arc to remove welding fumes and gases.
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 Material Safety Data Sheets (MSDSs) D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
and the manufacturer’s instructions for metals, consumables, for hot work and have a fire watcher and extinguisher nearby.
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while FLYING METAL or DIRT can injure eyes.
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and D Welding, chipping, wire brushing, and grinding
lower the oxygen level causing injury or death. Be sure the breath- cause sparks and flying metal. As welds cool,
ing air is safe. they can throw off slag.
D Do not weld in locations near degreasing, cleaning, or spraying op- D Wear approved safety glasses with side
erations. The heat and rays of the arc can react with vapors to form shields even under your welding helmet.
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 BUILDUP OF GAS can injure or kill.
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements D Shut off compressed gas supply when not in use.
can give off toxic fumes if welded. D Always ventilate confined spaces or use
approved air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense

ELECTRIC AND MAGNETIC FIELDS (EMF)
visible and invisible (ultraviolet and infrared) rays can affect Implanted Medical Devices.
that can burn eyes and skin. Sparks fly off from the
weld. D Wearers of Pacemakers and other Implanted
D Wear an approved welding helmet fitted with a proper shade of Medical Devices should keep away.
filter lenses to protect your face and eyes from arc rays and D Implanted Medical Device wearers should consult their doctor
sparks when welding or watching (see ANSI Z49.1 and Z87.1 and the device manufacturer before going near arc welding, spot
listed in Safety Standards). welding, gouging, plasma arc cutting, or induction heating
D Wear approved safety glasses with side shields under your operations.
helmet.
D Use protective screens or barriers to protect others from flash, NOISE can damage hearing.
glare and sparks; warn others not to watch the arc.
D Wear protective clothing made from durable, flame-resistant Noise from some processes or equipment can
material (leather, heavy cotton, or wool) and foot protection. damage hearing.
WELDING can cause fire or explosion. D Wear approved ear protection if noise level 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 CYLINDERS can explode if damaged.
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause Compressed gas cylinders contain gas under high
sparks, explosion, overheating, or fire. Check and be sure the area is pressure. If damaged, a cylinder can explode. Since
safe before doing any welding. gas cylinders are normally part of the welding
process, be sure to treat them carefully.
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 Protect compressed gas cylinders from excessive heat, mechani-
D Do not weld where flying sparks can strike flammable material. cal shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
D Protect yourself and others from flying sparks and hot metal.
support or cylinder rack to prevent falling or tipping.
D Be alert that welding sparks and hot materials from welding can D Keep cylinders away from any welding or other electrical circuits.
easily go through small cracks and openings to adjacent areas.
D Never drape a welding torch over a gas cylinder.
D Watch for fire, and keep a fire extinguisher nearby. D Never allow a welding electrode to touch any cylinder.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can D Never weld on a pressurized cylinder − explosion will result.
cause fire on the hidden side. D Use only correct compressed gas cylinders, regulators, hoses,
D Do not weld on closed containers such as tanks, drums, or pipes, and fittings designed for the specific application; maintain them
unless they are properly prepared according to AWS F4.1 (see and associated parts in good condition.
Safety Standards). D Turn face away from valve outlet when opening cylinder valve.
D Do not weld where the atmosphere may contain flammable dust, D Keep protective cap in place over valve except when cylinder is in
gas, or liquid vapors (such as gasoline). use or connected for use.
D Connect work cable to the work as close to the welding area as D Use the right equipment, correct procedures, and sufficient num-
practical to prevent welding current from traveling long, possibly ber of persons to lift and move cylinders.
unknown paths and causing electric shock, sparks, and fire D Read and follow instructions on compressed gas cylinders,
hazards. associated equipment, and Compressed Gas Association (CGA)
D Do not use welder to thaw frozen pipes. publication P-1 listed in Safety Standards.
OM-233 865 Page 2

1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard. MOVING PARTS can injure.

D Do not install or place unit on, over, or near D Keep away from moving parts such as fans.
combustible surfaces. D Keep all doors, panels, covers, and guards
D Do not install unit near flammables. closed and securely in place.
D Do not overload building wiring − be sure power supply system is D Have only qualified persons remove doors, panels, covers, or
properly sized, rated, and protected to handle this unit. guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
FALLING EQUIPMENT can injure. finished and before reconnecting input power.
D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.
READ INSTRUCTIONS.
D Use equipment of adequate capacity to lift and
support unit.
D Read and follow all labels and the Owner’s
D If using lift forks to move unit, be sure forks are long enough to Manual carefully before installing, operating, or
extend beyond opposite side of unit. servicing unit. Read the safety information at
the beginning of the manual and in each
D Keep equipment (cables and cords) away from moving vehicles section.
when working from an aerial location.
D Use only genuine replacement parts from the manufacturer.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu- D Perform maintenance and service according to the Owner’s
ally lifting heavy parts or equipment. Manuals, industry standards, and national, state, and local
codes.
OVERUSE can cause OVERHEATING

H.F. RADIATION can cause interference.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before D High-frequency (H.F.) can interfere with radio
starting to weld again. navigation, safety services, computers, and
D Do not block or filter airflow to unit. communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
FLYING SPARKS can injure.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
D Wear a face shield to protect eyes and face.
tion.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper D If notified by the FCC about interference, stop using the
face, hand, and body protection. equipment at once.
D Sparks can cause fires — keep flammables away. 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
STATIC (ESD) can damage PC boards. minimize the possibility of interference.
D Put on grounded wrist strap BEFORE handling

boards or parts.
ARC WELDING can cause interference.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards. D Electromagnetic energy can interfere with
sensitive electronic equipment such as
MOVING PARTS can injure. computers and computer-driven equipment
such as robots.
D Keep away from moving parts. D Be sure all equipment in the welding area is
D Keep away from pinch points such as drive electromagnetically compatible.
rolls. 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-
WELDING WIRE can injure. tronic equipment.
D Do not press gun trigger until instructed to do D Be sure this welding machine is installed and grounded
so. according to this manual.
D Do not point gun toward any part of the body, D If interference still occurs, the user must take extra measures
other people, or any metal when threading such as moving the welding machine, using shielded cables,
welding wire. using line filters, or shielding the work area.
OM-233 865 Page 3

1-4. California Proposition 65 Warnings
For Gasoline Engines:
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of
cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc-
Health & Safety Code Section 25249.5 et seq.) tive harm.
Battery posts, terminals and related accessories contain lead For Diesel Engines:
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other Diesel engine exhaust and some of its constituents are
reproductive harm. Wash hands after handling. known to the State of California to cause cancer, birth
defects, and other reproductive harm.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards

Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
from Global Engineering Documents (phone: 1-877-413-5184, website: site: www.ansi.org).
www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot
Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, from National Fire Protection Association,
and Cutting, American Welding Society Standard AWS F4.1, from Glob- Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
al Engineering Documents (phone: 1-877-413-5184, website: OSHA, Occupational Safety and Health Standards for General Indus-
www.global.ihs.com). try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
National Electrical Code, NFPA Standard 70, from National Fire Protec- and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website: intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
www.nfpa.org and www. sparky.org). (phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, phone for Region 5, Chicago, is 312-353-2220, website:
from Compressed Gas Association, 4221 Walney Road, 5th Floor, www.osha.gov).
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com). U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Safety in Welding, Cutting, and Allied Processes, CSA Standard Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
W117.2, from Canadian Standards Association, Standards Sales, 5060 www.cpsc.gov).
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: Applications Manual for the Revised NIOSH Lifting Equation, The Na-
800-463-6727, website: www.csa-international.org). tional Institute for Occupational Safety and Health (NIOSH), 1600
Safe Practice For Occupational And Educational Eye And Face Protec- Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
tion, ANSI Standard Z87.1, from American National Standards Institute, www.cdc.gov/NIOSH).
1-6. EMF Information

Electric current flowing through any conductor causes localized electric 4. Keep head and trunk as far away from the equipment in the
and magnetic fields (EMF). Welding current creates an EMF field welding circuit as possible.
around the welding circuit and welding equipment. EMF fields may inter-
fere with some medical implants, e.g. pacemakers. Protective 5. Connect work clamp to workpiece as close to the weld as
measures for persons wearing medical implants have to be taken. For possible.
example, access restrictions for passers−by or individual risk assess-
ment for welders. All welders should use the following procedures in 6. Do not work next to, sit or lean on the welding power source.
order to minimize exposure to EMF fields from the welding circuit:
7. Do not weld whilst carrying the welding power source or wire
feeder.
1. Keep cables close together by twisting or taping them, or using a
cable cover. About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
2. Do not place your body between welding cables. Arrange cables device manufacturer before performing or going near arc welding, spot
to one side and away from the operator. welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
3. Do not coil or drape cables around your body. mended.
OM-233 865 Page 4

SECTION 2 − DEFINITIONS
2-1. Manufacturer’s Warning Label Definitions
Warning! Watch Out! There are

possible hazards as shown by the
symbols.
1 Electric shock from welding
electrode or wiring can kill.
1.1 Wear dry insulating gloves.
Do not touch electrode with
bare hand. Do not wear wet or
damaged gloves.
1.2 Protect yourself from electric
shock by insulating yourself
from work and ground.
1.3 Disconnect input plug or
power before working on
machine.
2 Breathing welding fumes can
1 1.1 1.2 1.3 be hazardous to your health.
2.1 Keep your head out of the
fumes.
2.2 Use forced ventilation or local
exhaust to remove the fumes.
2.3 Use ventilating fan to remove
2 2.1 2.2 2.3 fumes.
3 Welding sparks can cause
explosion or fire.
3.1 Keep flammables away from
welding. Do not weld near
flammables.
3 3.1 3.2 3.3 3.2 Welding sparks can cause
fires. Have a fire extinguisher
nearby, and have a
watchperson ready to use it.
3.3 Do not weld on drums or any
closed containers.
4 Arc rays can burn eyes and
4 4.1 injure skin.
+ + + 4.1 Wear hat and safety glasses.

Use ear protection and button
shirt collar. Use welding
helmet with correct shade of
filter. Wear complete body
5 6 protection.
+ 5 Become trained and read the

instructions before working on
the machine or welding.
6 Do not remove or paint over
(cover) the label.
S-179 310
1/96
OM-233 865 Page 5

1 Warning! Watch Out! There
are possible hazards as
shown by the symbols.
2 Electric shock from wiring can
kill.
3 Disconnect input plug or
1 2 3 4 5 6 power before working on
machine.
4 Hazardous voltage remains
on input capacitors after
power is turned off. Do not
V touch fully charged
V capacitors.
5 Always wait 60 seconds after
> 60 s V S-179 190-A power is turned off before
working on unit, OR
6 Check input capacitor voltage,
and be sure it is near 0 before
touching any parts.
4/96

shown by the symbols.
2 When power is applied failed
parts can explode or cause
other parts to explode.
1 2 3 4 5
3 Flying pieces of parts can
cause injury. Always wear a
face shield when servicing
unit.
4 Always wear long sleeves and
button your collar when
servicing unit.
S-179 304-A 5 After taking proper
precautions as shown,
connect power to unit.
4/96

1 shown by the symbols.
2 Falling equipment can cause
injury and damage to unit.
3 Always lift and support unit
using both handles. Keep
angle of lifting device less
than 60 degrees.
∠ = <60 ° 4 Use a proper cart to move
unit.
∠ 5 Do not use one handle to lift
or support unit.
S-179 309-A
2 3 4 5
1/96
OM-233 865 Page 6

2-2. WEEE Label (For Products Sold Within The EU)
Do not discard product (where ap-

plicable) with general waste.
Reuse or recycle Waste Electrical
and Electronic Equipment (WEEE)
by disposing at a designated collec-
tion facility.
Contact your local recycling office
or your local distributor for further
information.
2-3. Symbols And Definitions
A Amperage Panel
Alternating
Current (AC) V Voltage
Output Circuit Breaker Remote On
Gas Tungsten Arc

Off Negative Voltage Input
Welding
Direct Current Protective Earth

Positive Inductance
(DC) (Ground)
Constant Current Constant Voltage Foot Control Line Connection
Three Phase Static

Frequency Con-
Shielded Metal Arc Gas Metal Arc
Arc Force verter-
Welding (SMAW) Welding (GMAW)
Transformer-
Rectifier
U0 Rated No Load
Voltage (Average) U1 Primary Voltage
U2 Conventional
Load Voltage X Duty Cycle
Hz Hertz IP Degree Of
Protection I2 Rated Welding
Current % Percent
Lift-Arc Trigger
Pulsed Hold Operation Single Phase Three Phase
(GTAW)
I1max Rated Maximum

Supply Current I1eff Maximum Effective
Supply Current
Increase
Lift-Arc Operation
(GTAW)
Voltage Sensing
Scratch Start TIG
Feeder
OM-233 865 Page 7

SECTION 3 − INTRODUCTION
3-1. Important Information Regarding CE Products (Sold Within The EU)

A. Information On Electromagnetic Fields (EMF)
! This equipment shall not be used by the general public as the EMF limits for the general public might be exceeded during welding.
This equipment is built in accordance with EN 60974−1 and is intended to be used only in an occupational environment (where the general public
access is prohibited or regulated in such a way as to be similar to occupational use) by an expert or an instructed person.
Wire feeders and ancillary equipment (such as torches, liquid cooling systems and arc striking and stabilizing devices) as part of the welding
circuit may not be a major contributor to the EMF. See the Owner’s Manuals for all components of the welding circuit for additional EMF exposure
information.
S 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.
B. Information On Electromagnetic Compatibility (EMC)

! This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low−
voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to
conducted as well as radiated disturbances.
This equipment complies with IEC 61000−3−12 provided that the short−circuit power Ssc is greater than or equal to 2,055,437.437 at the interface
point between the user’s supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation
with the distribution network operator if necessary, that the equipment is connected only to a supply with a short−circuit power Ssc greater than
or equal to 2,055,437.437.
ce-emc 1 2010-10
3-2. Serial Number And Rating Label Location

The serial number and rating information for this product is located on the rear panel. Use rating label to determine input power requirements and/or
rated output. For future reference, write serial number in space provided on back cover of this manual.
3-3. Specifications
Input Rated Voltage Amperage Max. IP RMS Amps Input at Rated Load Output, KVA KW
Power Output Range Range in Open- Rating 60 Hz 3-Phase at NEMA Load Voltages
in CV CC Mode Circuit and Class I Rating
Mode Voltage
230 V 380 V 400 V 460 V
3-Phase 350 A at 34 10−38 V 5−425 A 75 VDC 23 36.1 22.3 20.6 17.8 14.2 13.6
VDC, 60%
Duty Cycle
*See Section 3-5 for Duty Cycle Rating.
OM-233 865 Page 8

3-4. Volt-Ampere Curves
A. CC Mode Volt-ampere curves show minimum

and maximum voltage and amper-
age output capabilities of welding
100 power source. Curves of other set-
90 tings fall between curves shown.
80
70
60
VOLTS
50 SMAW GTAW
MAX MAX
40
30 GTAW
SMAW
80A
MN
20 0% ARC
25% CONTROL
10 50%
75%
100%
0
0 100 200 300 400 500
AMPERAGE
B. CV Mode
100
90
80
70
60
VOLTS
50
MAX
40
30
20
MIN
10
0
0 100 200 300 400 5 00
AMPERAGE
217 836-A / 217 837-B
OM-233 865 Page 9

3-5. 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 and
cooling fan runs. Wait fifteen min-
utes for unit to cool. Reduce amper-
age or voltage, or duty cycle before
welding.
NOTICE − Exceeding duty cycle
can damage unit and void warranty.
60% Duty Cycle
6 Minutes Welding 4 Minutes Resting
Overheating
0 A or V
15
OR
Minutes Reduce Duty Cycle
Ref. 219 523-A
Notes
OM-233 865 Page 10

SECTION 4 − INSTALLATION
4-1. Selecting a Location
24 in.
(610 mm)
Dimensions And Weight

94.8 lb (43 kg)
17 in.
(432 mm)
12-1/2 in.
(318 mm)
Movement 1 Lifting Handles

1
Use handles to lift unit.
! Do not move or operate unit 2 Hand Cart
1 where it could tip. Use cart or similar device to move
unit.
3 Line Disconnect Device
Locate unit near correct input
power supply.
! Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
2
Location
3
18 in.
(460 mm)
18 in.
(460 mm)
loc_2 3/96 - Ref. ST-151 556 / Ref. 803 879-B
OM-233 865 Page 11

4-2. Connecting 3-Phase Input Power
! Installation must meet all National
and Local Codes − have only quali-
fied persons make this installation.
! Disconnect and lockout/tagout in-
3 put power before connecting input
conductors from unit.
! Always connect green or green/
yellow conductor to supply
= GND/PE Earth Ground grounding terminal first, and never
4 to a line terminal.
. The Auto-Line circuitry in this unit au-

tomatically adapts the power source
to the primary voltage being applied.
7 Check input voltage available at site.
This unit can be connected to any in-
put power between 208 and 575 VAC
without removing cover to relink the
power source.
2
See rating label on unit and check input
voltage available at site.
For Three-Phase Operation
1 Input Power Cord.
2 Disconnect Device (switch shown in
L1 the OFF position)
3 5 3 Green Or Green/Yellow Grounding
L2
Conductor
6 L3 4 Disconnect Device Grounding
Terminal
5 Input Conductors (L1, L2 And L3)
6 Disconnect Device Line Terminals
Connect green or green/yellow grounding
conductor to disconnect device grounding
1 terminal first.
Connect input conductors L1, L2, and L3
to disconnect device line terminals.
7 Overcurrent Protection
Select type and size of overcurrent protec-
tion using Section 4-3 (fused disconnect
1 switch shown).
Close and secure door on disconnect
device. Remove lockout/tagout device,
and place switch in the On position.
Tools Needed:
Ref. 802 136-A / Ref. 803 879-B
OM-233 865 Page 12

4-3. Electrical Service Guide
NOTICE − INCORRECT INPUT POWER can damage this welding power source. Phase to ground voltage shall not exceed +10% of rated input
voltage.
NOTICE − Actual input voltage should not be 10% less than minimum and/or 10% more than maximum input voltages listed in table. If actual input
voltage is outside this range, output may not be be available.
Failure to follow these electrical service guide recommendations could create an electric shock or fire hazard. These recommenda-
tions are for a dedicated branch circuit sized for the rated output and duty cycle of the welding power source.
60 Hz Three Phase
Input Voltage (V) 230 380 400 460
Input Amperes (A) At Rated Output 36.1 22.3 20.6 17.8
Max Recommended Standard Fuse Rating In
Amperes 1
Time-Delay 2 40 25 25 20
Normal Operating 3 50 30 30 25
Min Input Conductor Size In AWG 4 10 12 12 14
Max Recommended Input Conductor Length In 96 158 175 150
Feet (Meters) (29) (48) (53) (46)
Min Grounding Conductor Size In AWG 4 10 12 12 14
Reference: 2008 National Electrical Code (NEC) (including article 630)

1 If a circuit breaker is used in place of a fuse, choose a circuit breaker with time-current curves comparable to the recommended fuse.
2 “Time-Delay” fuses are UL class “RK5”. See UL 248.
3 “Normal Operating” (general purpose - no intentional delay) fuses are UL class “K5” (up to and including 60 amps), and UL class “H” ( 65 amps and
above).
4 Conductor data in this section specifies conductor size (excluding flexible cord or cable) between the panelboard and the equipment per NEC Table
310.16. If a flexible cord or cable is used, minimum conductor size may increase. See NEC Table 400.5(A) for flexible cord and cable requirements.
Notes
OM-233 865 Page 13

4-4. Weld Output Terminals And Selecting Cable Sizes
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is
30 m (100 ft) from the workpiece, the total cable length in the weld circuit is 60 m (2 cables x 30 m). Use the 60 m (200 ft) column to determine cable
size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
Weld Output
Terminals
! Turn off power be-
fore connecting to
weld output termi-
nals.
45 m 60 m 70 m 90 m 105 m 120 m
! Do not use worn, 30 m (100 ft) or Less
(150 ft) (200 ft) (250 ft) (300 ft) (350 ft) (400 ft)
damaged, under-
sized, or poorly
spliced cables.
10 − 60% 60 − 100%
Welding Duty Duty 10 − 100% Duty Cycle
Amperes Cycle Cycle mm2 (AWG)
mm2 (AWG) mm2 (AWG)
100 20 (4) 20 (4) 20 (4) 30 (3) 35 (2) 50 (1) 60 (1/0) 60 (1/0)
150 30 (3) 30 (3) 35 (2) 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 95 (3/0)
200 30 (3) 35 (2) 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) 120 (4/0)
2x70 2x70
250 35 (2) 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) (2 ea. (2 ea.
2/0) 2/0)
+
2x70 2x95 2x95
300 50 (1) 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) (2 ea. (2 ea. (2 ea.
2/0) 3/0) 3/0)
2x70 2x95 2x95 2x120

350 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) (2 ea. (2 ea. (2 ea. (2 ea.
2/0) 3/0) 3/0) 4/0)
2x70 2x95 2x120 2x120

− 400 60 (1/0) 70 (2/0) 95 (3/0) 120 (4/0) (2 ea. (2 ea. (2 ea. (2 ea.
Output Receptacles 2/0) 3/0) 4/0) 4/0)
2x70 2x95 2x120 3x95 3x95

500 70 (2/0) 95 (3/0) 120 (4/0) (2 ea. (2 ea. (2 ea. (3 ea. (3 ea.
2/0) 3/0) 4/0) 3/0) 3/0)
2x95 2x120 3x95 3x120 3x120

2x70
600 95 (3/0) 120 (4/0) (2 ea. (2 ea. (3 ea. (3 ea. (3 ea.
(2 ea. 2/0)
3/0) 4/0) 3/0) 4/0) 4/0)
* 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-G 2009−08
OM-233 865 Page 14

4-5. Remote 14 Receptacle Information
Socket* Socket Information
A 24 volts AC. Protected by circuit breaker CB2.

24 VOLTS AC
B Contact closure to A completes 24 volts AC
A J contactor control circuit.
K I
B
I 115 volts AC. Protected by circuit breaker CB1.
C L N H 115 VOLTS AC
D M G J Contact closure to I completes 115 volts AC
E F contactor control circuit.
C Output to remote control; 0 to +10 volts DC, +10

volts DC in MIG mode.
REMOTE D Remote control circuit common.

OUTPUT
CONTROL E 0 to +10 volts DC input command signal from
remote control.
M CC/CV select
F Current feedback; +1 volt DC per 100 weld am-

A/V peres.
AMPERAGE
VOLTAGE H Voltage feedback; +1 volt DC per 10 weld volts.
G Circuit common for 24 and 115 volts AC circuits.

GND
K Chassis common.
*The remaining sockets are not used.
4-6. 115 Volts AC Duplex Receptacle And Circuit Breakers

1 115 V 10 Amp. AC
Receptacle
Power is shared between duplex
receptacle and Remote 14 recep-
1 tacle (see Section 4-5).
2 Circuit Breaker CB1
3 Circuit Breaker CB2
CB1 protects duplex receptacle
and 115 volts AC portion of Remote
14 receptacle from overload.
CB2 protects 24 volts AC portion of
Remote 14 receptacle from
overload.
Press button to reset breaker.
2 3
Ref. 803 879-B
OM-233 865 Page 15

‘
4-7. Optional Gas Valve Operation And Shielding Gas Connection

Obtain gas cylinder and chain to
running gear, wall, or other station-
ary support so cylinder cannot fall
and break off valve.
1 Cylinder
2 Regulator/Flowmeter
4 Install so face is vertical.
3 Gas Hose Connection
GAS IN Fitting has 5/8-18 right-hand
threads. Obtain and install gas
hose.
4 Gas In Fitting
2
5 Gas Out Fitting
The Gas In and Gas Out fittings
have 5/8-18 right-hand threads.
Obtain proper size, type, and length
hose and make connections as fol-
lows:
Connect hose from shielding gas
supply regulator/flowmeter to Gas
In fitting.
Connect hose coupler to torch.
Connect one end of gas hose to
hose coupler. Connect remaining
end of gas hose to Gas Out fitting.
Operation
3 The gas solenoid controls gas flow
during the TIG process as follows:
1
Remote TIG
Gas flow starts with remote contac-
tor on.
Gas flow stops at end of post−flow
if current was detected, or with re-
mote contactor off if no current was
detected.
Lift−Arc Trigger Hold TIG
Gas flow starts when output switch
is depressed.
Gas flow stops at end of post−flow.
Scratch Start TIG
5 Gas flow starts when current is de-
tected.
Gas flow stops at end of post−flow.
GAS OUT Post−flow time is factory set to 5
seconds per 100 amps of weld cur-
rent. The minimum post−flow time
is 5 seconds. The maximum post−
flow is 20 seconds (post flow set-
tings are not adjustable by the end
user).
Ref. 803 705-B / Ref. 803 879-B
OM-233 865 Page 16

SECTION 5 − OPERATION
5-1. Front Panel Controls
1 Power Switch 6 Remote 14 Receptacle voltage is the same as normal welding

amperage.
. The fan motor is thermostatically
For remote control, make connections to
controlled and only runs when cooling is Remote 14 receptacle. In TIG modes and the When set towards maximum, short-circuit
needed. amperage is increased at low arc voltage to
REMOTE STICK mode, remote control is a
2 Voltmeter percent of V/A Adjust control setting (value assist with arc starts as well as reduce
selected on V/A Adjust is maximum available sticking while welding.
3 Ammeter
on remote). In ELECTRODE HOT STICK
4 V/A (Voltage/Amperage) Adjustment Select setting best suited for application.
Control mode the remote control is not used. In the
MIG mode, remote control provides full range
5 Mode Switch Control adjusts inductance when MIG or
of unit output regardless of V/A Adjust control
V-Sense Feeder position is selected on the
The Mode switch setting determines both the setting.
mode switch. Inductance determines the
process and output On/Off control (see
“wetness” of the weld puddle. When set
Section 5-3). 7 Arc Control towards maximum, “wetness” (puddle fluidity)
For Air Carbon Arc (CAC-A) cutting and increases.
gouging, place switch in Stick position. For Control adjusts Dig when Stick or CC mode is
best results, place Arc Control in the selected on mode switch. When set towards When Pulsed MIG or one of the TIG modes is
maximum position. minimum, short-circuit amperage at low arc selected, this control is not functional.
2 3 4
ELECTRODE HOT
6 5 7
Ref. 803 692-B / Ref. 219 341-A
OM-233 865 Page 17

5-2. Meter Functions
. The meters display the actual weld output values for approximately three seconds after the arc is broken.
Mode Meter Reading At Idle Meter Reading While Welding

V A V A
Scratch
Start TIG 71.7 85 10.3 85
Actual Volts (OCV) Preset Amps Actual Volts Actual Amps
V A V A
Lift-Arc Trigger Hold TIG 85 10.3 85
Blank Preset Amps Actual Volts Actual Amps
V A V A
TIG 85 10.3 85
V A V A
MIG 24.5 24.5 250
Preset Volts Blank Actual Volts Actual Amps
V A V A
Pulsed
MIG PPP PPP 24.5 250
Pulse Display Pulse Display Actual Volts Actual Amps
V A V A
CC 85 24.5 85
V A V A
Stick 71.7 85 24.5 85
Actual Volts (OCV) Preset Amps Actual Volts Actual Amps
V A V A
V-Sense
Feeder 71.7 24.5 250
Flashes OCV And Preset Blank Actual Volts Actual Amps
5-3. Mode Switch Settings
. The Stick and CC modes provide the Adaptive Hot Start™ feature, which automatically increases the output amperage at the start of a weld should
the start require it. This eliminates electrode sticking at arc start.
Mode Switch Setting Process Output On/Off Control
Scratch Start TIG GTAW Electrode Hot
Lift-Arc Trigger Hold TIG GTAW − See Section 5-4 At Remote 14
TIG GTAW With HF Unit, Pulsing Device, Or Remote Control At Remote 14
MIG GMAW At Remote 14
Pulsed MIG GMAW-P (Requires an external pulsing device.) At Remote 14
CC Stick (SMAW) With Remote On/Off At Remote 14
Stick SMAW Electrode Hot
V-Sense Feeder MIG (GMAW) With Voltage Sensing Wire Feeder Electrode Hot
OM-233 865 Page 18

5-4. Lift-Arc Trigger Hold TIG
1 TIG Electrode
2 Workpiece
. Procedure requires:
control
Start sequence:
1 2
• Touch tungsten electrode to
workpiece at weld start point.
• Momentarily depress output
switch.
• Slowly lift electrode. An arc will
1−2 form when electrode is lifted.
“Touch” Seconds
• To stop welding, momentarily
depress output switch and out-
put will shut off.
Note: If output switch is momen-
tarily depressed and tungsten is
not touching workpiece:
Do not touch tungsten to work.
Output will shut off in 3 seconds.
Start sequence over.
Do NOT Strike Like A Match!
Ref. S-156 279
5-5. Stick Start Procedure

With Stick selected, start arc as fol-
lows:
1 Electrode
2 Workpiece
3 Arc
Drag electrode across workpiece
like striking a match; lift electrode
slightly after touching work. If arc
1 goes out electrode was lifted to high.
If electrode sticks to workpiece, use
a quick twist to free it.
Low OCV Stick
The unit can be optionally config-
2 ured for low open circuit voltage
(OCV) operation. When the unit is
configured for low OCV operation
only a low sensing voltage (approxi-
3 mately 15 VDC) is present between
the electrode and the workpiece
prior to the electrode touching the
workpiece. Consult a Factory
Authorized Service Agent for infor-
mation regarding how to configure
the unit for low OCV stick welding
operation.
OM-233 865 Page 19

SECTION 6 − MAINTENANCE & TROUBLESHOOTING
6-1. Routine Maintenance
! Disconnect power . Maintain more often

before maintaining. during severe conditions.
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
Blow Out Inside
6-2. Blowing Out Inside Of Unit

! Do not remove case when
blowing out inside of unit.
To blow out unit, direct airflow
through front and back louvers as
shown.
Ref. 803 879-B
OM-233 865 Page 20

6-3. Voltmeter/Ammeter Help Displays
V A V A
1 4
HE.L P−1 HE.L P−5

V A V A
2 5

V A V A
3 6

. All directions are in reference to the front Indicates the left side of the unit has over-
heated. The unit has shut down to allow the
current limit. As the line voltage decreases,
the required input current increases. If the line
of the unit. All circuitry referred to is lo-
fan to cool it (see Section 3-5). Operation will voltage is too low, the output power is limited
cated inside the unit.
continue when the unit has cooled. by the input current. When this limit is
1 Help 1 Display reached, the unit automatically reduces out-
4 Help 5 Display put power to continue operation. If this display
Indicates a malfunction in the primary power
circuit. If this display is shown, contact a Fac- Indicates the right side of the unit has over- is shown, have a qualified electrician check
tory Authorized Service Agent. heated. The unit has shut down to allow the the input voltage.
2 Help 2 Display fan to cool it (see Section 3-5). Operation will
6 Help 8 Display
continue when the unit has cooled.
Indicates a malfunction in the thermal protec- Indicates a malfunction in the secondary
tion circuitry. If this display is shown, contact 5 Help 6 Display
power circuit of the unit. If this display is
a Factory Authorized Service Agent. Indicates operation at maximum input cur- shown, contact a Factory Authorized Service
3 Help 3 Display rent. The unit has a maximum allowable input Agent.
6-4. Troubleshooting
Trouble Remedy
No weld output; unit completely inop- Place line disconnect switch in On position (see Section 4-2).
erative.
Check and replace line fuse(s), if necessary, or reset circuit breaker (see Section 4-2).
Check for proper input power connections (see Section 4-2).
No weld output; meter display On. Input voltage outside acceptable range of variation (see Sections 4-2, 4-3).
Check, repair, or replace remote control.
Unit overheated. Allow unit to cool with fan On (see Section 3-5).
Erratic or improper weld output. Use proper size and type of weld cable (see Section 4-4).
Clean and tighten all weld connections.
Check for correct polarity.
No 115 volts AC output at duplex re- Reset circuit breaker CB1 (see Section 4-6).
ceptacle or Remote 14 receptacle.
No 24 volts AC output at Remote 14 Reset circuit breaker CB2 (see Section 4-6).
receptacle.
OM-233 865 Page 21

SECTION 7 − ELECTRICAL DIAGRAM
Figure 7-1. Circuit Diagram
OM-233 865 Page 22

219 484-C
OM-233 865 Page 23

24
14 32 33
30 31
77
OM-233 865 Page 24

76 25
8 83 29
11 15 28
6 12 16 23
26 35
5
19
13
9 20
4 34

27
17 38 37
10 18
3 39
40 78 36
74
22 81
75
79 82
21 41
58 57
42
43
80
63 44 45
64
51
1 56 MOD 2
2 47
50
65 MOD 1
66 52 49 17
Figure 8.1. Parts Assembly

59
62 48
67
60 46 49
69 61
SECTION 8 − PARTS LIST
62 53
73
54
55
68
70
71
72
Ref. 803 850-F

Item Dia. Part
No. Mkgs. No. Description Quantity
Figure 8.1. Parts Assembly
. . . 1 . . . . . . . . . . . . . . . 216 034 . . Wrapper (Includes Insulators and Safety Labels) . . . . . . . . . . . . . . . . . . . 1

. . . . . . . . . . . . . . . . . . . . . 175 256 . . Insulator, Side Rh (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 178 551 . . Insulator, Side (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . . . . . . 179 310 . . Label, General Precautionary Wordless, Intl, Small . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . . . . . . 179 309 . . Label, Caution Falling Equipment Can Injure−wordles . . . . . . . . . . . . . . . 2
. . . 4 . . . . . . . . . . . . . . . 195 585 . . Handle, Rubberized Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 5 . . . . . . . . . . . . . . . 135 483 . . Label, Important Remove These Two Handle Screws . . . . . . . . . . . . . . . 2
. . . 6 . . . . R3/C4 . . . . 233 052 . . Resistor/Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . . . . . . Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . . . SR1 . . . . . 201 530 . . Kit, Diode Fast Recovery Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . . . . . . 199 840 . . Bus Bar, Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . . . . . . 196 355 . . Insulator, Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 11 . . . . D1,D2 . . . . 201 531 . . Kit, Diode Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 12 . . . . . RT1 . . . . . 219 343 . . Thermistor, NTC 30K Ohm @ 25 Deg C 18in Lead . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . CR1 . . . . . 198 549 . . Relay, Encl 24VDC Spst 35A/300VAC 4Pin Flange Mtg . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . . . . . . 227 927 . . Label, Warning Electric Shock/Exploding Parts−wdles . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . . . . . . 010 546 . . Bushing, Snap-In Nyl .375 Id X .500 Mtg Hole . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . L4 . . . . . . 218 020 . . Inductor, Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . . . . . . 179 276 . . Bushing, Snap-In Nyl 1.000 Id X 1.375 Mtg Hole Cent . . . . . . . . . . . . . . 3
. . . 18 . . . . . . . . . . . . . . . 170 647 . . Bushing, Snap-In Nyl 1.312 Id X 1.500 Mtg Hole . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . L3 . . . . . . 212 150 . . Inductor, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . T1 . . . . . . 212 132 . . XFMR, HF Litz/Litz W/Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . . . . . . 225 097 . . Heat Sink, Lh Rect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . L1 . . . . . . 212 091 . . Inductor, Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . . . . . . . . . . . . . 083 147 . . Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . . . 4
. . . 24 . . . . . PC1 . . . . . 242 341 . . Circuit Card Assy, Control/Aux Power W/Program . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 216 113 . . Stand-Off Support, PC Card .187 Dia W/P&l .375 . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . PLG1 . . . . 115 091 . . Housing Plug+Pins (Service Kit) RC1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG10 . . . . 115 094 . . Housing Plug+Pins (Service Kit) RC10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 25 . . . . . . . . . . . . . . . 212 072 . . Bracket, Mtg Capacitor/Pc Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 26 . . . . C12,13 . . . . 219 930 . . Kit, Capacitor Elctlt Replacement (Includes) . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 193 738 . . . . Capacitor, Elctlt 1800 Uf 500 VDC Can 2.52 Dia . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . 217 040 . . . . Nut, Nylon M12 Thread Capacitor Mounting . . . . . . . . . . . . . . . . . . . . . . 2
. . . 27 . . . . . RC2 . . . . . 604 176 . . Rcpt, Str Dx Grd 2P3W 15A 125V *5−15R . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . CB2 . . . . . 083 432 . . Circuit Breaker, Man Reset 1P 10A 250VAC Frict . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . CB1 . . . . . 083 432 . . Circuit Breaker, Man Reset 1P 10A 250VAC Frict . . . . . . . . . . . . . . . . . . 1
. . . 30 . . . . . . . . . . . . . . +219 470 . . Panel, Rear CE W/Aux . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 31 . . . . . . . . . . . . . . . 219 335 . . Label, Warning Electric Shock Can Kill CE Wordless . . . . . . . . . . . . . . . . 1
. . . 32 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Rear Aux/Gas/CE (Order by Model and Serial Number) . . 1
. . . 33 . . . . . . . . . . . . . . . 217 297 . . Cover, Receptacle Weatherproof Duplex Rcpt . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . . . . . . 212 945 . . Label, Warning Incorrect Connections CE Wordless . . . . . . . . . . . . . . . . 1
. . . 35 . . . . . . . . . . . . . . . 215 980 . . Bushing, Strain Relief .709/.984 Id X1.375 Mtg Hole . . . . . . . . . . . . . . . . 1
. . . 36 . . . . . . . . . . . . . . . 244 628 . . Cable, Power 12Ft 8Ga 4C (Non−Stripped End) . . . . . . . . . . . . . . . . . . . . 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-233 865 Page 25

Item Dia. Part
Figure 8.1. Parts Assembly (Continued)
. . . 37 . . . . . . . . . . . . . . . 234 126 . . Nut, Conduit 1.000 Npt Knurled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

. . . 38 . . . . . . T2 . . . . . . 211 968 . . XFMR, Control Toroidal 665 VAC Pri 1536 Va 60 Hz . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 212 947 . . . . Plate, Mtg Toroid XFMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 39 . . . . . . L2 . . . . . . 218 018 . . Inductor, Pre-Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 40 . . . . . . . . . . . . . . . 218 566 . . Gasket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 41 . . . . . CT1 . . . . . 196 231 . . XMFR, Current Sensing 200/1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 42 . . . . . C15 . . . . . 196 143 . . Capacitor, Polyp Met Film 16. Uf 400 VAC 10% . . . . . . . . . . . . . . . . . . . . 1
. . . 43 . . . . . . . . . . . . . . . 219 472 . . Bracket, Mtg Capacitor Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 44 . . . . . RT2 . . . . . 199 798 . . Thermistor, NTC 30K Ohm @ 25 Deg C 18in Lead . . . . . . . . . . . . . . . . . 1
. . . 45 . . . . . PC2 . . . . . 229 987 . . Circuit Card Assy, Interconnect W/Label & Clips (Includes) . . . . . . . . . . 1
. . . 46 . . . . . . . . . . . . . . . 219 335 . . . . Label, Warning Electric Shock Can Kill Ce Wordless . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 223 343 . . . . Clip, Wire Stdf .40−.50 Bndl .156Hole .031−.078Thk . . . . . . . . . . . . . . 2
. . . 47 . . . . . . . . . . . . . . . 153 403 . . Bushing, Snap-In Nyl .750 Id X 1.000 Mtg Hole Cent . . . . . . . . . . . . . . . . 3
. . . 48 . . . . . RM1 . . . . . 205 751 . . Module, Power Resistor W/Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 49 . . . . . . . . . . . . . . . 217 625 . . Kit, Input/Pre-Regulator And Inverter Module (Includes) . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOD 1, SKiip 83 HEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MOD 2, SKiip 83 EC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 50 . . . . . . . . . . . . . . . 212 206 . . Windtunnel, Rh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 51 . . . . . . . . . . . . . . . 196 330 . . Heat Sink, Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 52 . . . . . . . . . . . . . . +175 132 . . Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 53 . . . . . . . . . . . . . . . 229 325 . . Foot, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 54 . . . . . . . . . . . . . . . 176 736 . . Screw, Mtg Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 55 . . . . . . . . . . . . . . . 212 073 . . Label, Warning Exploding Parts Can CE Wordless . . . . . . . . . . . . . . . . . . 1
. . . 56 . . . . . . . . . . . . . . . 212 074 . . Bus Bar, Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 57 . . . . . HD1 . . . . . 182 918 . . Transducer, Current 400A Module Supply V +/− 15V . . . . . . . . . . . . . . . . 1
. . . 58 . . . . . PC3 . . . . . 229 985 . . Circuit Card Assy, Front Panel & Display W/Program . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC50 . . . . 210 233 . . Rcpt, W/Pins (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG21 . . . . 212 088 . . Plug, W/Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC21 . . . . 167 640 . . Housing Plug+Pins (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 59 . . . . . . S1 . . . . . 231 191 . . Switch, Tgl 3Pst 50A 600VAC Scr Term Wide Tgl . . . . . . . . . . . . . . . . . . 1
. . . 60 . . . . . . . . . . . . . . . 176 226 . . Insulator, Switch Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 61 . . . . . FM1 . . . . . 196 313 . . Fan, Muffin 115V 50/60Hz 3000 RPM 6.378 Mtg Holes . . . . . . . . . . . . . . 1
. . . . . . . . . . PLG16 . . . . 131 054 . . Housing Plug+Pins (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . RC16 . . . . 135 635 . . Housing Plug+Pins (Service Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 62 . . . . . . . . . . . . . . . 208 967 . . Rcpt Assy, Tw Lk Insul Fem (Dinse Type) 50/70 Series (Includes) . . . . 2
. . . . . . . . . . . . . . . . . . . . . 208 968 . . . . Rcpt, Tw Lk Insul W/O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 185 712 . . . . Insulator, Bulkhead Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 185 713 . . . . Insulator, Bulkhead Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 185 714 . . . . Washer, Tooth 22mmid X 31.5mmod 1.310-1mmt Intern . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 185 717 . . . . Nut, M20-1.5 1.00Hex .19H Brs Locking . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 185 718 . . . . O-Ring, 0.989 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . 186 228 . . . . O-Ring, 0.739 Id X 0.070 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 63 . . . . . . . . . . . . . . . 212 070 . . Panel, Front Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 64 . . . . C5,6,7 . . . . 233 668 . . Capacitor Assy, W/Plug & Leads (Voltage Feedback) . . . . . . . . . . . . . . . 1
. . . 65 . . . . . . . . . . . . . . . 216 112 . . Fastener, Panel Receptacle Quick Access . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 66 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate (Order by Model and Serial Number) . . . . . . . . . . . . . . . . . . . 1
. . . 67 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Connection (Order by Model and Serial Number) . . . . . . . . 1
. . . 68 . . . . . . . . . . . . . . . . . . . . . . . . . . Nameplate, Power (Order by Model and Serial Number) . . . . . . . . . . . . . 1
. . . 69 . . . . . . . . . . . . . . . 174 991 . . Knob, Pointer 1.250 Dia X .250 Id W/Spring Clip−.21 . . . . . . . . . . . . . . . 2
OM-233 865 Page 26

Item Dia. Part
Figure 8.1. Parts Assembly (Continued)
... 70 . . . . . . . . . . . . . . . 174 992 . . Knob, Pointer .840 Dia X .250 Id W/Spring Clip−.21 . . . . . . . . . . . . . . . . 1
... 71 . . . . . . . . . . . . . . . 218 041 . . Door, W/Quick Access Ball Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 72 . . . . . . . . . . . . . . . 175 138 . . Box, Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 73 .......................... Label (Order by Model and Serial Number) . . . . . . . . . . . . . . . . . . . . . . . . 1
... 74 . . . . . . . . . . . . . . +212 207 . . Windtunnel, Lh . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 75 . . . . . . . . . . . . . . . 211 503 . . Insulator, Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 76 . . . . . C8 . . . . . 219 191 . . Capacitor, Polyp Film .001 Uf 2000V W/Terms . . . . . . . . . . . . . . . . . . . . . 1
... 77 . . . . . . L6 . . . . . . 131 447 . . Core, Toroidal 1.332 Id X 1.932 Od X .625 Thk . . . . . . . . . . . . . . . . . . . . . 1
... 78 . . . . L5,L7 . . . . 199 122 . . Core, Toroidal .750 Id X 1.450 Od X .544 Thk . . . . . . . . . . . . . . . . . . . . . . 2
... 79 . . . . . . . . . . . . . . . 083 147 . . Grommet, Scr No 8/10 Panel Hole .312 Sq .500 High . . . . . . . . . . . . . . . 2
... 80 . . . . . . . . . . . . . . . 219 471 . . Bracket, Mtg Filter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 81 . . . . . . . . . . . . . . . 219 473 . . Bracket, Mtg CE Filter Ground Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 82 . . . . . PC4 . . . . . 229 989 . . Circuit Card Assy, Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
... 83 . . . . . . . . . . . . . . . 227 746 . . Gasket, Inductor Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-233 865 Page 27

Notes
Work like a Pro!

Pros weld and cut
safely. Read the
safety rules at
the beginning
of this manual.

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
229895
MATERIAL THICKNESS GAUGE

Effective January 1, 2011
(Equipment with a serial number preface of MB or newer)
This limited warranty supersedes all previous Miller warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the terms and conditions 6. 90 Days — Parts

below, ITW Welding Products Italy warrants to its original retail
purchaser that new Miller equipment sold after the effective date * Accessory (Kits)
of this limited warranty is free of defects in material and * Canvas Covers
workmanship at the time it is shipped by Miller. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER * Induction Heating Coils and Blankets
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE * MIG Guns
WARRANTIES OF MERCHANTABILITY AND FITNESS. * Remote Controls
Within the warranty periods listed below, Miller will repair or * Replacement Parts (No Labor)
replace any warranted parts or components that fail due to such
defects in material or workmanship. Miller must be notified in * Spoolmate Spoolguns
writing within thirty (30) days of such defect or failure, at which
time Miller will provide instructions on the warranty claim Miller’s True Blue® Limited Warranty shall not apply to:
procedures to be followed.
1. Consumable components; such as contact tips,
Miller shall honor warranty claims on warranted equipment listed cutting nozzles, contactors, brushes, switches, slip
below in the event of such a failure within the warranty time rings, relays or parts that fail due to normal wear.
periods. All warranty time periods start on the date the
equipment was delivered to the original retail purchaser or one 2. Items furnished by Miller, but manufactured by others, such
year after the equipment is shipped to a European distributor or as engines or trade accessories. These items are covered
eighteen months after the equipment is shipped to an by the manufacturer’s warranty, if any.
International distributor.
1. 5 Years Parts — 3 Years Labor 3. Equipment that has been modified by any party other than
Miller, or equipment that has been improperly installed,
* Original main power rectifiers only to include SCRs, improperly operated or misused based upon industry
diodes, and discrete rectifier modules standards, or equipment which has not had reasonable and
2. 3 Years — Parts and Labor necessary maintenance, or equipment which has been
used for operation outside of the specifications for the
* Engine Driven Welding Generators equipment.
(NOTE: Engines are warranted separately by the
engine manufacturer.) MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND
* HF Units USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS
* Inverter Power Sources (Unless Otherwise Stated) TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
* Process Controllers
* 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 replacement; or, where authorized in writing by Miller in
appropriate cases, (3) the reasonable cost of repair or
* Auto-Darkening Helmet Lenses (No Labor) replacement at an authorized Miller service station; or (4)
* Migmatic 171 payment of or credit for the purchase price (less reasonable
depreciation based upon actual use) upon return of the goods at
4. 1 Year — Parts and Labor Unless Specified
customer’s risk and expense. Miller’s option of repair or
* Automatic Motion Devices replacement will be F.O.B., Factory at ITW Welding Products
* Field Options Group Europe or F.O.B. at a Miller authorized service facility as
(NOTE: Field options are covered under True Blue® determined by Miller. Therefore no compensation or
for the remaining warranty period of the product they reimbursement for transportation costs of any kind will be
are installed in, or for a minimum of one year — allowed.
whichever is greater.)
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES
* Induction Heating Power Sources, Coolers, and PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE
Electronic Controls/Recorders REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR
* Motor Driven Guns (w/exception of Spoolmate DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
Spoolguns) CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF
* Positioners and Controllers PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY
OTHER LEGAL THEORY.
* Powered Air Purifying Respirator (PAPR) Blower
Unit (No Labor) ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND
* Racks ANY IMPLIED WARRANTY, GUARANTY OR
* Running Gear and Trailers REPRESENTATION AS TO PERFORMANCE, AND ANY
* Subarc Wire Drive Assemblies REMEDY FOR BREACH OF CONTRACT TORT OR ANY
OTHER LEGAL THEORY WHICH, BUT FOR THIS
* Water Coolant Systems (Hydramate 1 and 2) PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION
* Water Coolant Systems (USA Models, OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,
Non-Integrated) INCLUDING ANY IMPLIED WARRANTY OF
* Work Stations/Weld Tables (No Labor) MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT
5. 6 Months — Parts FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED
* Batteries BY MILLER.
milan_warr 2011−01

Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date (Date which equipment was delivered to original customer.)
Distributor
Address
Country Zip/Postal Code
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.

Contact your Distributor for: Welding Supplies and Consumables
Options and Accessories
Service and Repair
Replacement Parts
Owner’s Manuals
ITW Welding Products Italy S.r.l.

Via Privata Iseo, 6/E
20098 San Giuliano
Milanese, Italy
Contact the Delivering Carrier to: File a claim for loss or damage during Phone: 39 (0) 2982901
shipment. Fax: 39 (0) 298290-203
email: miller@itw−welding.it
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2011 Miller Electric Mfg. Co. 2011−01

XMT 350 CC/CV Auto-Line: OM-233 865J Processes

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OM-233 865J 2011-04

Arc Welding Power Source

XMT 350 CC/CV

Visit our website at

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Miller Electric manufactures a full line of

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

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for European Community (CE marked) products.

Product Stock Number

• 2006/95/EC Low Voltage

• 2004/108/EC Electromagnetic Compatibility

December 13th, 2010

Massimigliano Lavarini Date of Declaration

ELECTRONIC ENGINEER R&D TECH. SUPPORT

956 142 832

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1-1. Symbol Usage

DANGER! − Indicates a hazardous situation which, if . Indicates special instructions.

1-2. Arc Welding Hazards

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Arc rays from the welding process produce intense

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FIRE OR EXPLOSION hazard. MOVING PARTS can injure.

D Use lifting eye to lift unit only, NOT running

OVERUSE can cause OVERHEATING

D Put on grounded wrist strap BEFORE handling

OM-233 865 Page 3

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1-5. Principal Safety Standards

1-6. EMF Information

OM-233 865 Page 4

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2-1. Manufacturer’s Warning Label Definitions

Warning! Watch Out! There are

+ + + 4.1 Wear hat and safety glasses.

+ 5 Become trained and read the

OM-233 865 Page 5

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1 Warning! Watch Out! There

1 Warning! Watch Out! There

OM-233 865 Page 6

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Do not discard product (where ap-

2-3. Symbols And Definitions

Output Circuit Breaker Remote On

Gas Tungsten Arc

Direct Current Protective Earth

Constant Current Constant Voltage Foot Control Line Connection

Three Phase Static

I1max Rated Maximum

OM-233 865 Page 7

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

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

B. Information On Electromagnetic Compatibility (EMC)

3-2. Serial Number And Rating Label Location

*See Section 3-5 for Duty Cycle Rating.